JLG Boom Lift 800AJ HC3 Parts Catalog 31223064

Hyundai · Jun 21, 2026

JLG Boom Lift 800AJ HC3 Parts Catalog 31223064
Size: 65.33 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 800AJ HC3 Boom Lift
Part Number: 31223064
Publication Date: 2025
Number of Pages: 908 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - OSCILLATING

FIGURE 1-2. AXLE INSTALLATION - OSCILLATING WITH TOW PACKAGE

FIGURE 1-3. STEER INSTALLATION - 2WS

FIGURE 1-4. STEER INSTALLATION - 2WS WITH TOW PACKAGE

FIGURE 1-5. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD/2WS

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY

FIGURE 1-7. DRIVE MOTOR ASSEMBLY - 4WD

FIGURE 1-8. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED TIRE

FIGURE 1-9. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED NON-MARKING TIRE

FIGURE 1-10. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED SAND TIRE

FIGURE 1-11. LP TANK BRACKETS INSTALLATIONS

FIGURE 1-12. FRAME SHIELDS INSTALLATION - 2WS

FIGURE 1-13. TOW PACKAGE INSTALLATION - 2WS (ENGLISH LANGUAGE DECALS)

FIGURE 1-14. TOW PACKAGE INSTALLATION - 2WS (CE & UK CA SPECS)

FIGURE 1-15. TOW BAR ASSEMBLY

SECTION 2 - TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATION - WITH 2WS

FIGURE 2-2. CONTROL VALVE ASSEMBLY - 2WS MACHINES

FIGURE 2-3. SWING DRIVE INSTALLATION (Prior to SN 0300315218)

FIGURE 2-4. SWING DRIVE INSTALLATION (SN 0300315218 to Present)

FIGURE 2-5. SWING MOTOR/HUB ASSEMBLY (Prior to SN 0300315218)

FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300315218 to Present)

FIGURE 2-7. TURNTABLE BEARING INSTALLATION

FIGURE 2-8. TURNTABLE LOCK INSTALLATION

FIGURE 2-9. ROTARY COUPLING INSTALLATION - 2WS MACHINES

FIGURE 2-10. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITHOUT SIGHT GLASS) (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-11. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITHOUT SIGHT GLASS) (JIANGYING 4IIN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-12. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITH SIGHT GLASS) (HELGESEN 6IIN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-13. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITH SIGHT GLASS) (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-14. TANK INSTALLATION - GAS ENGINES (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-15. TANK INSTALLATION - GAS ENGINES (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-16. HYDRAULIC TANK ASSEMBLY (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-17. HYDRAULIC TANK ASSEMBLY (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)

FIGURE 2-18. AUXILIARY POWER INSTALLATION - WITHOUT BATTERY DISCONNECT

FIGURE 2-19. AUXILIARY POWER INSTALLATION - WITH BATTERY DISCONNECT

FIGURE 2-20. AUXILIARY POWER PUMP/MOTOR ASSEMBLY

FIGURE 2-21. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES - WITH MECHANICAL HOUR METER (ANSI EXPORT LRC AND AUSTRALIAN SPECS) (Prior to SN 0300315790)

FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES - WITH MECHANICAL HOUR METER (ANSI EXPORT LRC AND AUSTRALIAN SPECS) (SN 0300315790 to Present)

FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 AND TOWER STOW - WITH MECHANICAL HOUR METER (ANSI EXPORT LRC AND AUSTRALIAN SPECS) (Prior to SN 0300315790)

FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 AND TOWER STOW - WITH MECHANICAL HOUR METER (ANSI EXPORT LRC AND AUSTRALIAN SPECS) (SN 0300315790 to Present)

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES (CE & UK CA SPECS) (Prior to SN 0300315790)

FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES (CE & UK CA SPECS) (SN 0300315790 to Present)

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES - WITH FORD ENGINES - WITH MECHANICAL HOUR METER (Prior to SN 0300315790)

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES - WITH FORD ENGINES - WITH MECHANICAL HOUR METER (SN 0300315790 to Present)

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES AND WITH TOWER STOW (CE & UK CA LRC SPECS) (Prior to SN 0300315790)

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 ENGINES AND WITH TOWER STOW (CE & UK CA LRC SPECS) (SN 0300315790 to Present)

FIGURE 2-31. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 ENGINES - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, CSA, CHINA & JAPANESE SPECS) (Prior to SN 0300315790)

FIGURE 2-32. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 ENGINES - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, CSA, CHINA & JAPANESE SPECS) (SN 0300315790 to Present)

FIGURE 2-33. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 AND TOWER STOW - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, CSA, CHINA & JAPANESE SPECS) (Prior to SN 0300315790)

FIGURE 2-34. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 AND TOWER STOW - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, CSA, CHINA & JAPANESE SPECS) (SN 0300315790 to Present)

FIGURE 2-35. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) ENGINES (CE & UK CA SPECS) (Prior to SN 0300315790)

FIGURE 2-36. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) ENGINES (CE & UK CA SPECS) (SN 0300315790 to Present)

FIGURE 2-37. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) ENGINES AND WITH TOWER STOW (CE & UK CA SPECS) (Prior to SN 0300315790)

FIGURE 2-38. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) ENGINES AND WITH TOWER STOW (CE & UK CA SPECS) (SN 0300315790 to Present)

FIGURE 2-39. GROUND CONTROL BOX ASSEMBLY - WITH FORD ENGINES AND TOWER STOW - WITH MECHANICAL HOUR METER (Prior to SN 0300315790)

FIGURE 2-40. GROUND CONTROL BOX ASSEMBLY - WITH FORD ENGINES AND TOWER STOW - WITH MECHANICAL HOUR METER (SN 0300315790 to Present)

FIGURE 2-41. LIGHT PANEL INSTALLATION

FIGURE 2-42. ALARM INSTALLATION

FIGURE 2-43. HOODS INSTALLATION - ABS (DEUTZ D2011 ENGINES)

FIGURE 2-44. HOODS INSTALLATION - ABS (DEUTZ TD2.9L4 ENGINES)

FIGURE 2-45. HOODS INSTALLATION - ABS (DEUTZ TD2.9L4 (STAGE V) ENGINES)

FIGURE 2-46. HOODS INSTALLATION - STEEL (DEUTZ D2011 ENGINES)

FIGURE 2-47. HOODS INSTALLATION - STEEL (DEUTZ TD2.9L4 ENGINES)

FIGURE 2-48. HOODS INSTALLATION - STEEL (FORD ENGINES)

FIGURE 2-49. EXHAUST COVER AND HEAT SHIELDS INSTALLATION - STEEL HOODS (DEUTZ D2011 ENGINES)

FIGURE 2-50. EXHAUST COVER AND HEAT SHIELDS INSTALLATION - STEEL HOODS (DEUTZ TD2.9L4 ENGINES)

FIGURE 2-51. EXHAUST COVER INSTALLATION - STEEL HOODS (FORD ENGINES)

FIGURE 2-52. SKYAIR AIR COMPRESSOR INSTALLATION

FIGURE 2-53. SKYAIR AIR COMPRESSOR INSTALLATION

FIGURE 2-54. AIR COMPRESSOR ASSEMBLY

FIGURE 2-55. WHITE NOISE ALARM INSTALLATION - ADJUSTABLE AMBIENT

FIGURE 2-56. WHITE NOISE MOTION ALARM INSTALLATION - AMBIENT

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ D2011 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)

FIGURE 3-2. DEUTZ D2011 ENGINE INSTALLATION (WITH ARCTIC PACKAGE)

FIGURE 3-3. DEUTZ D2011 ENGINE/PUMP SUB ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-4. DEUTZ TD2.9L4 ENGINE/PUMP SUB ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-5. DEUTZ D2011 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-6. DEUTZ D2011 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-7. DEUTZ D2011 ENGINE COMPONENTS

FIGURE 3-8. DEUTZ TD2.9L4 ENGINE INSTALLATION (STAGE V)

FIGURE 3-9. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA III)

FIGURE 3-10. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA IV)

FIGURE 3-11. DEUTZ ENGINE COMPONENTS - CHINA IV

FIGURE 3-12. DEUTZ TD2.9L4 ENGINE/PUMP SUB ASSEMBLY (CHINA III)

FIGURE 3-13. DEUTZ TD2.9L4 ENGINE/PUMP SUB ASSEMBLY (CHINA IV)

FIGURE 3-14. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA IV)

FIGURE 3-15. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA IV)

FIGURE 3-16. DEUTZ TD2.9L4 ENGINE ASSEMBLY (STAGE V)

FIGURE 3-17. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA III SPECS)

FIGURE 3-18. DEUTZ TD2.9L4 ENGINE/PUMP SUB ASSEMBLY (STAGE V)

FIGURE 3-19. DEUTZ TD2.9L4 ENGINE COMPONENTS (STAGE V)

FIGURE 3-20. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA III SPECS)

FIGURE 3-21. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH ARCTIC PACKAGE

FIGURE 3-22. DEUTZ D2.9L4 - EMR5 ENGINE AND PUMP SUB-ASSEMBLY WITH ARCTIC PACKAGE

FIGURE 3-23. ENGINE ASSEMBLY - DEUTZ D2.9L4 EMR5 ENGINE (WITH ARCTIC PACKAGE)

FIGURE 3-24. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITHOUT ARCTIC PACKAGE

FIGURE 3-25. DEUTZ D2.9L4 - EMR5 ENGINE AND PUMP SUB-ASSEMBLY WITHOUT ARCTIC PACKAGE

FIGURE 3-26. ENGINE ASSEMBLY - DEUTZ D2.9L4 EMR5 ENGINE (WITHOUT ARCTIC PACKAGE)

FIGURE 3-27. ENGINE COMPONENTS - DEUTZ D2.9L4 EMR5 ENGINE

FIGURE 3-28. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES)

FIGURE 3-29. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 (STAGE V) ENGINES)

FIGURE 3-30. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES) (CHINA III ENGINES)

FIGURE 3-31. BREATHER HEATER INST (DEUTZ TD2.9L4 ENGINES)

FIGURE 3-32. FORD ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)

FIGURE 3-33. FORD ENGINE INSTALLATION (WITH ARCTIC PACKAGE)

FIGURE 3-34. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-35. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-36. FORD ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-37. FORD ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-38. FORD ENGINE PREP ASSEMBLY

FIGURE 3-39. FORD ENGINE BRACKETS AND EXHAUST MANIFOLD INSTALLATION

FIGURE 3-40. FORD ENGINE DRIVE BELT INSTALLATION (MACHINES WITHOUT GENERATOR)

FIGURE 3-41. FORD ENGINE COMPONENTS

FIGURE 3-42. PUMP COUPING KIT (DEUTZ ENGINES)

FIGURE 3-43. HYDROSTATIC PUMP ASSEMBLY

FIGURE 3-44. VARIABLE PUMP ASSEMBLY

FIGURE 3-45. VARIABLE PUMP ASSEMBLY - HENGLI

FIGURE 3-46. HYDROSTATIC PUMP ASSEMBLY

FIGURE 3-47. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-48. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-49. EXHAUST PIPE INSTALLATION - FORD ENGINES

FIGURE 3-50. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-51. SPARK ARRESTOR INSTALLATION (WITH STEEL HOODS) (SN 0300314169 to Present)

FIGURE 3-52. SPARK ARRESTOR INSTALLATION (WITH PLASTIC HOODS) (SN 0300314169 to Present)

FIGURE 3-53. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-54. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-55. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITHOUT GENERATORS)

FIGURE 3-56. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)

FIGURE 3-57. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES WITH ABS HOODS

FIGURE 3-58. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ TD2.9L4 ENGINES WITH STEEL HOODS

FIGURE 3-59. ENGINE TRAY JACK INSTALLATION - DEUTZ ENGINES

FIGURE 3-60. ENGINE TRAY JACK INSTALLATION - FORD ENGINES

FIGURE 3-61. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-62. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-63. 2500W/110V/60HZ GENERATOR INSTALLATION - FORD ENGINES

FIGURE 3-64. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-65. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-66. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-67. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-68. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-69. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-70. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-71. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-72. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-73. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD ENGINES

FIGURE 3-74. QUICKFIT OIL VALVE (DEUTZ ENGINES)

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDER INSTALLATION

FIGURE 4-2. MAIN BOOM ASSEMBLY

FIGURE 4-3. TOWER BOOM ASSEMBLY

FIGURE 4-4. JIB ASSEMBLY

FIGURE 4-5. ROTATOR ASSEMBLY

FIGURE 4-6. SUPPORT, PLATFORM INSTALLATION

FIGURE 4-7. POWER TRACK INSTALLATION - MAIN BOOM

FIGURE 4-8. POWER TRACK INSTALLATION - TOWER BOOM

FIGURE 4-9. CONTROL VALVES INSTALLATION - WITH 2WS

FIGURE 4-10. CONTROL VALVE ASSEMBLY

FIGURE 4-11. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION

FIGURE 4-12. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION WITH TOWER STOW

FIGURE 4-13. TRANSPORT POSITION SWITCH INSTALLATION

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 3FT (76CM X 1M)

FIGURE 5-2. PLATFORM ASSEMBLY WITH GATE - 30IN X 4FT (76CM X 1.22M)

FIGURE 5-3. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 4FT (76CM X 1.22M)

FIGURE 5-4. PLATFORM ASSEMBLY WITH GATE - 30IN X 6FT (76CM X 1.83M)

FIGURE 5-5. PLATFORM ASSEMBLY WITH GATE- 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-6. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 6FT (76CM X 1.83M)

FIGURE 5-7. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-8. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-9. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-10. PLATFORM ASSEMBLY WITH FALL ARREST (6FT)

FIGURE 5-11. PLATFORM ASSEMBLY WITH GATE - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-12. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-13. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-14. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-15. PLATFORM ASSEMBLY WITH FALL ARREST (8FT)

FIGURE 5-16. CONSOLE AND FOOT SWITCH INSTALLATION

FIGURE 5-17. CONSOLE AND FOOT SWITCH INSTALLATION WITH TOWER STOW

FIGURE 5-18. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITHOUT TOWER STOW) (Prior to SN 0300316691)

FIGURE 5-19. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITHOUT TOWER STOW) (SN 0300316691 to Present)

FIGURE 5-20. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITH TOWER STOW) (Prior to SN 0300316691)

FIGURE 5-21. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITH TOWER STOW) (SN 0300316691 to Present)

FIGURE 5-22. LIGHT PANEL INSTALLATION

FIGURE 5-23. FOOTSWITCH ASSEMBLY

FIGURE 5-24. JIB SWITCH INSTALLATION

FIGURE 5-25. SKYEYE INSTALLATION

FIGURE 5-26. SKYGUARD BAR INSTALLATION

FIGURE 5-27. SKYLINE INSTALLATION

FIGURE 5-28. STORAGE TRAY INSTALLATION - CENTER

FIGURE 5-29. MANUAL STORAGE BOX INSTALLATION

FIGURE 5-30. SKYCUTTER INSTALLATION

FIGURE 5-31. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)

FIGURE 5-32. PLASMA CUTTER ASSEMBLY

FIGURE 5-33. SKYWELDER INSTALLATION (50HZ)

FIGURE 5-34. SKYWELDER INSTALLATION (60HZ)

FIGURE 5-35. WELDER ASSEMBLY

FIGURE 5-36. SKYWELDER PREP PACKAGE (60HZ)

FIGURE 5-37. SKYGLAZIER INSTALLATION (ALL SPECS EXCEPT CHINA AND JAPANESES SPECS)

FIGURE 5-38. SKYGLAZIER INSTALLATION (ENGLISH LANGUAGE DECALS)

FIGURE 5-39. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M PLATFORM

FIGURE 5-40. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM

FIGURE 5-41. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM

FIGURE 5-42. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM

FIGURE 5-43. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 4FT (76CM X 1.22M) PLATFORM

FIGURE 5-44. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.2CM X 1.82M) PLATFORM

FIGURE 5-45. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 6FT (76CM X 1.83M) PLATFORM

FIGURE 5-46. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 8FT (91.5CM X 2.4M) PLATFORM

FIGURE 5-47. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.5CM X 1.82M) TRI-ENTRY PLATFORM)

FIGURE 5-48. USB CHARGER INSTALLATION

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY

FIGURE 6-2. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE

FIGURE 6-3. LEVEL CYLINDER ASSEMBLY - UPRIGHT

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MAIN BOOM

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - TOWER BOOM

FIGURE 6-7. MASTER CYLINDER ASSEMBLY

FIGURE 6-8. STEER CYLINDER ASSEMBLY

FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM

FIGURE 6-10. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM - AXLE (OSCILLATING)

FIGURE 7-2. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE/WITHOUT ARCTIC PACKAGE)

FIGURE 7-3. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE/WITH ARCTIC PACKAGE)

FIGURE 7-4. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE/WITHOUT ARCTIC PACKAGE)

FIGURE 7-5. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE/WITH ARCTIC PACKAGE)

FIGURE 7-6. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE)(CE & UK CA SPECS ONLY)

FIGURE 7-7. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE AND ARCTIC PACKAGE)(ANSI SPEC ONLY)

FIGURE 7-8. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE AND WITHOUT ARCTIC PACKAGE)(ALL SPECS)

FIGURE 7-9. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE AND WITH ARCTIC PACKAGE)(CSA AND ANSI SPECS)

FIGURE 7-10. HYDRAULIC DIAGRAM - STANDARD

SECTION 8 - ELECTRICAL

FIGURE 8-1. ELECTRICAL LAYOUT

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V GFI RECEPTACLE (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 220V (ANSI, CSA & JAPANESE SPECS)

FIGURE 8-4. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITH 4000W/60HZ GENERATOR) (ANSI, ANSI EXPORT, CSA & JAPANESE SPECS)

FIGURE 8-5. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT ANSI, JAPANESE & CSA SPECS)

FIGURE 8-6. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITH 7500W SKYPOWER GENERATOR)

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V (2X4 BOX & COVER ONLY - LOCALLY SUPPLIED RECEPTACLE) (4000W GENERATOR)

FIGURE 8-18. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ALL SPECS EXCEPT CE, UK CA, AUSTRALIAN & CHINESE SPECS WITH 4000W SKYPOWER GENERATOR)

FIGURE 8-19. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ALL SPECS EXCEPT CE, UK CA, AUSTRALIAN & CHINESE SPECS WITH 7500W SKYPOWER GENERATOR)

FIGURE 8-20. BATTERY DISCONNECT

FIGURE 8-21. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR

FIGURE 8-22. BOOM CABLES INSTALLATION - WITH 4000W GENERATOR (50HZ)

FIGURE 8-23. BOOM CABLES INSTALLATION - WITH 4000W GENERATOR (60HZ)

FIGURE 8-24. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR

FIGURE 8-25. BOOM CABLE - MAIN BOOM

FIGURE 8-26. BOOM CABLE (TOWER BOOM)

FIGURE 8-27. BOOM VALVE HARNESS

FIGURE 8-28. BREAKER BOX INSTALLATION (BRAZIL SPECS)

FIGURE 8-29. BREAKER BOX INSTALLATION (CE & UK CA SPECS WITHOUT 4000W GENERATOR)

FIGURE 8-30. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (BRAZIL, CE & UK CA SPECS WITHOUT 4000W GENERATOR)

FIGURE 8-31. BREAKER BOX KIT - WITH 3 BREAKERS (CE & UK CA SPECS WITH 4000W GENERATOR)

FIGURE 8-32. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (CE & UK CA SPECS WITH 4000W GENERATOR)

FIGURE 8-33. CLEARSKY CS550 BEACON INSTALLATION

FIGURE 8-34. ECU POWER JUMPER HARNESS

FIGURE 8-35. ENGINE HARNESS - DEUTZ D2011 ENGINES

FIGURE 8-36. GROUND CONTROL ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE

FIGURE 8-37. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES

FIGURE 8-38. ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 8-39. ENGINE HARNESS - FORD ENGINES

FIGURE 8-40. FUEL PUMP HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-41. FUEL HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE

FIGURE 8-42. GENERATOR HARNESS - 4000W GENERATOR

FIGURE 8-43. GENERATOR HARNESS - 7500W SKYPOWER GENERATOR

FIGURE 8-44. GENERATOR TO ENGINE HARNESS - 2500W (FORD ENGINES)

FIGURE 8-45. GENERATOR TO ENGINE HARNESS - 4000W (DEUTZ D2011 ENGINES)

FIGURE 8-46. GENERATOR TO ENGINE HARNESS - 4000W (DEUTZ TD2.9L4 ENGINES)

FIGURE 8-47. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ENGINES)

FIGURE 8-48. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES)

FIGURE 8-49. GENERATOR HARNESS - 7500W SKYPOWER (DEUTZ TD2.9L4 T4F ENGINES)

FIGURE 8-50. GENERATOR TO REAR OF BOOM HARNESS - 110V

FIGURE 8-51. GENERATOR TO REAR OF BOOM HARNESS - 220V

FIGURE 8-52. GROUND CONTROL BOX HARNESS (Prior to SN 0300315790)

FIGURE 8-53. GROUND CONTROL BOX HARNESS (SN 0300315790 to Present)

FIGURE 8-54. MID BOOM PROXIMITY SENSOR HARNESS

FIGURE 8-55. PLATFORM CONSOLE BOX HARNESS (Prior to SN 0300316691)

FIGURE 8-56. PLATFORM CONSOLE BOX HARNESS (SN 0300316691 to Present)

FIGURE 8-57. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPECS)

FIGURE 8-58. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPECS)

FIGURE 8-59. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE & UK CA SPEC)

FIGURE 8-60. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 BOX (CE & UK CA SPEC)

FIGURE 8-61. RECEPTACLE BOX KIT - 220V AFSINT107 KEYED GROUND (CE & UK CA SPECS)

FIGURE 8-62. SKYEYE EMITTER HARNESS

FIGURE 8-63. SKYEYE INTERMEDIATE HARNESS

FIGURE 8-64. SKYEYE RECEIVER HARNESS

FIGURE 8-65. SKYLINE HARNESS

FIGURE 8-66. SKYGUARD INTERFACE HARNESS

FIGURE 8-67. TOWER STOW HARNESS

FIGURE 8-68. VALVE HARNESS

FIGURE 8-69. WHITE NOISE ALARM HARNESS

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION (ANSI SPECS)

FIGURE 9-2. DECAL INSTALLATION (AUSTRALIAN SPECS)

FIGURE 9-3. DECAL INSTALLATION (BRAZILIAN SPECS)

FIGURE 9-4. DECAL INSTALLATION (CE & UK CA SPECS)

FIGURE 9-5. DECAL INSTALLATION (CHINA SPECS)

FIGURE 9-6. DECAL INSTALLATION (CSA SPECS)

FIGURE 9-7. DECAL INSTALLATION (JAPANESE SPECS)

FIGURE 9-8. DECAL INSTALLATION (KOREAN SPECS)

FIGURE 9-9. DECAL INSTALLATION (LATIN AMERICAN SPECS)

FIGURE 9-10. DECAL INSTALLATION - OPTIONS

FIGURE 9-11. SKYCUTTER DECAL INSTALLATION

FIGURE 9-12. SKYWELDER DECAL INSTALLATION - 50HZ

FIGURE 9-13. DECAL INSTALLATION - SKYWELDER (60HZ)

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORES/KITS

PART NUMBER INDEX

JLG Boom Lift 800AJ HC3 Parts Catalog 31223064

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