JLG Boom Lift 800AJ Parts Catalog 31222377

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JLG Boom Lift 800AJ Parts Catalog 31222377
Size: 68.77 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 800AJ Boom Lift
Part Number: 31222377
Publication Date: 2025
Number of Pages: 976 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - FIXED​

FIGURE 1-2. AXLE INSTALLATION - OSCILLATING​

FIGURE 1-3. AXLE INSTALLATION - OSCILLATING WITH TOW PACKAGE​

FIGURE 1-4. STEER INSTALLATION - 2WS​

FIGURE 1-5. STEER INSTALLATION - 2WS WITH TOW PACKAGE​

FIGURE 1-6. STEER INSTALLATION - 4WS​

FIGURE 1-7. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 2WD​

FIGURE 1-8. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD/2WS​

FIGURE 1-9. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD/4WS​

FIGURE 1-10. HUB ASSEMBELY - 2WD FRONT​

FIGURE 1-11. DRIVE HUB/BRAKE ASSEMBLY​

FIGURE 1-12. DRIVE MOTOR ASSEMBLY - 2WD​

FIGURE 1-13. DRIVE MOTOR ASSEMBLY - 4WD​

FIGURE 1-14. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED TIRE​

FIGURE 1-15. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED NON-MARKING TIRE​

FIGURE 1-16. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED SAND TIRE​

FIGURE 1-17. LP TANK BRACKETS INSTALLATIONS​

FIGURE 1-18. FRAME SHIELDS INSTALLATION - 2WS​

FIGURE 1-19. FRAME SHIELDS INSTALLATION - 4WS​

FIGURE 1-20. TOW PACKAGE INSTALLATION - 2WS (ENGLISH LANGUAGE DECALS)​

FIGURE 1-21. TOW PACKAGE INSTALLATION - 2WS (CE & UK CA SPECS)​

FIGURE 1-22. TOW BAR ASSEMBLY​

SECTION 2 - TURNTABLE

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

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

FIGURE 2-3. CONTROL VALVE ASSEMBLY - 2WS MACHINES​

FIGURE 2-4. CONTROL VALVE ASSEMBLY - 4WS MACHINES​

FIGURE 2-5. SWING DRIVE INSTALLATION​

FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY​

FIGURE 2-7. TURNTABLE BEARING INSTALLATION​

FIGURE 2-8. TURNTABLE LOCK INSTALLATION​

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

FIGURE 2-10. ROTARY COUPLING INSTALLATION - 4WS MACHINES​

FIGURE 2-11. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITHOUT SIGHT GLASS) (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-12. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITHOUT SIGHT GLASS) (JIANGYING 4IIN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-13. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITH SIGHT GLASS) (HELGESEN 6IIN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-14. TANK INSTALLATION - DIESEL MACHINE (FUEL TANK WITH SIGHT GLASS) (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-15. TANK INSTALLATION - GAS ENGINES (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-16. TANK INSTALLATION - GAS ENGINES (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-17. HYDRAULIC TANK ASSEMBLY (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-18. HYDRAULIC TANK ASSEMBLY (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK - 25 GAL CAPACITY)​

FIGURE 2-19. AUXILIARY POWER INSTALLATION - WITHOUT BATTERY DISCONNECT​

FIGURE 2-20. AUXILIARY POWER INSTALLATION - WITH BATTERY DISCONNECT​

FIGURE 2-21. AUXILIARY POWER PUMP/MOTOR ASSEMBLY​

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

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

FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (CE & UK CA LRC SPECS)​

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 AND WITH TOWER STOW (CE & UK CA LRC SPECS)​

FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH MECHANICAL HOUR METER (ANSI SPECS)​

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 AND TOWER STOW - WITH MECHANICAL HOUR METER (ANSI SPECS)​

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) (CE & UK CA SPECS)​

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) AND WITH TOWER STOW (CE & UK CA SPECS)​

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY - WITH FORD ENGINES - WITH MECHANICAL HOUR METER​

FIGURE 2-31. GROUND CONTROL BOX ASSEMBLY - WITH FORD ENGINES AND TOWER STOW - WITH MECHANICAL HOUR METER​

FIGURE 2-32. LIGHT PANEL INSTALLATION​

FIGURE 2-33. ALARM INSTALLATION​

FIGURE 2-34. WHITE NOISE ALARM INSTALLATION - ADJUSTABLE AMBIENT​

FIGURE 2-35. WHITE NOISE MOTION ALARM INSTALLATION - AMBIENT​

FIGURE 2-36. STROBE LIGHT INSTALLATION (AMBER) (WITHOUT CLEARSKY BEACON)​

FIGURE 2-37. STROBE LIGHT INSTALLATION (BLUE) (WITHOUT CLEARSKY BEACON)​

FIGURE 2-38. STROBE LIGHT INSTALLATION (RED) (WITHOUT CLEARSKY BEACON)​

FIGURE 2-39. SKYAIR AIR COMPRESSOR INSTALLATION (ANSI EXPORT AND CHINA SPECS)​

FIGURE 2-40. SKYAIR AIR COMPRESSOR INSTALLATION (ANSI AND CSA SPECS)​

FIGURE 2-41. AIR COMPRESSOR ASSEMBLY​

FIGURE 2-42. HOODS INSTALLATION - ABS (DEUTZ D2011 ENGINES)​

FIGURE 2-43. HOODS INSTALLATION - ABS (DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES)​

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

FIGURE 2-45. HOODS INSTALLATION - STEEL (DEUTZ D2011 ENGINES)​

FIGURE 2-46. HOODS INSTALLATION - STEEL (DEUTZ TD2.9L4 ENGINES)​

FIGURE 2-47. HOODS INSTALLATION - STEEL (FORD ENGINES)​

FIGURE 2-48. EXHAUST COVER AND HEAT SHIELDS INSTALLATION - STEEL HOODS (DEUTZ D2011 ENGINES)​

FIGURE 2-49. EXHAUST COVER AND HEAT SHIELDS INSTALLATION - STEEL HOODS (DEUTZ TD2.9L4 ENGINES)​

FIGURE 2-50. EXHAUST COVER INSTALLATION - STEEL HOODS (FORD ENGINES)​

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 AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-4. DEUTZ TD2.9L4 ENGINE AND 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 (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-9. DEUTZ TD2.9L4 ENGINE INSTALLATION (WITH ARCTIC PACKAGE)​

FIGURE 3-10. DEUTZ TD2.9L4 ENGINE INSTALLATION (STAGE V)​

FIGURE 3-11. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA III)​

FIGURE 3-12. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA IV)​

FIGURE 3-13. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-14. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-15. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (STAGE V)​

FIGURE 3-16. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA III)​

FIGURE 3-17. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA IV)​

FIGURE 3-18. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-19. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-20. DEUTZ TD2.9L4 ENGINE ASSEMBLY (STAGE V)​

FIGURE 3-21. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA III)​

FIGURE 3-22. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA IV)​

FIGURE 3-23. DEUTZ TD2.9L4 ENGINE COMPONENTS​

FIGURE 3-24. DEUTZ TD2.9L4 ENGINE COMPONENTS (STAGE V)​

FIGURE 3-25. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA III)​

FIGURE 3-26. DEUTZ ENGINE COMPONENTS - CHINA IV​

FIGURE 3-27. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH ARCTIC PACKAGE​

FIGURE 3-28. DEUTZ D2.9L4 - EMR5 ENGINE AND PUMP SUB-ASSEMBLY WITH ARCTIC PACKAGE​

FIGURE 3-29. ENGINE ASSEMBLY - DEUTZ D2.9L4 EMR5 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-30. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITHOUT ARCTIC PACKAGE​

FIGURE 3-31. DEUTZ D2.9L4 - EMR5 ENGINE AND PUMP SUB-ASSEMBLY WITHOUT ARCTIC PACKAGE​

FIGURE 3-32. ENGINE ASSEMBLY - DEUTZ D2.9L4 EMR5 ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-33. ENGINE COMPONENTS - DEUTZ D2.9L4 EMR5 ENGINE​

FIGURE 3-34. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES)​

FIGURE 3-35. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 (STAGE V) ENGINES)​

FIGURE 3-36. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES) (CHINA III)​

FIGURE 3-37. BREATHER HEATER INST (DEUTZ TD2.9L4 ENGINES)​

FIGURE 3-38. PUMP COUPLING KIT (DEUTZ ENGINES)​

FIGURE 3-39. FORD ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-40. FORD ENGINE INSTALLATION (WITH ARCTIC PACKAGE)​

FIGURE 3-41. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-42. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-43. FORD ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-44. FORD ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-45. FORD ENGINE DRIVE BELT INSTALLATION (MACHINES WITHOUT GENERATOR)​

FIGURE 3-46. FORD ENGINE COMPONENTS​

FIGURE 3-47. FORD ENGINE PREP ASSEMBLY​

FIGURE 3-48. FORD ENGINE BRACKETS AND EXHAUST MANIFOLD INSTALLATION​

FIGURE 3-49. HYDROSTATIC PUMP ASSEMBLY​

FIGURE 3-50. VARIABLE PUMP ASSEMBLY - DANFOSS​

FIGURE 3-51. VARIABLE PUMP ASSEMBLY - HENGLI​

FIGURE 3-52. HYDROSTATIC PUMP ASSEMBLY​

FIGURE 3-53. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES​

FIGURE 3-54. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 (STAGE V) ENGINES​

FIGURE 3-55. EXHAUST PIPE INSTALLATION - FORD ENGINES​

FIGURE 3-56. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-57. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-58. SPARK ARRESTOR MUFFLER INSTALLATION - FORD ENGINES​

FIGURE 3-59. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-60. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-61. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITHOUT GENERATORS)​

FIGURE 3-62. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)​

FIGURE 3-63. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ TD2.9L4 ENGINES, DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES WITH ABS HOODS​

FIGURE 3-64. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ TD2.9L4 ENGINES WITH STEEL HOODS​

FIGURE 3-65. ENGINE TRAY JACK INSTALLATION - DEUTZ ENGINES​

FIGURE 3-66. ENGINE TRAY JACK INSTALLATION - FORD ENGINES​

FIGURE 3-67. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-68. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-69. 2500W/110V/60HZ GENERATOR INSTALLATION - FORD ENGINES​

FIGURE 3-70. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-71. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-72. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES, DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES​

FIGURE 3-73. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-74. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-75. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-76. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES, DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES​

FIGURE 3-77. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-78. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-79. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD ENGINES​

FIGURE 3-80. QUICKFIT OIL VALVE​

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDER INSTALLATION - WITHOUT ARCTIC PACKAGE​

FIGURE 4-2. BOOM AND CYLINDER INSTALLATION - WITH ARCTIC PACKAGE​

FIGURE 4-3. BOOM ASSEMBLY - MAIN (WITHOUT ARCTIC PACKAGE)​

FIGURE 4-4. BOOM ASSEMBLY - MAIN (WITH ARCTIC PACKAGE)​

FIGURE 4-5. TOWER BOOM ASSEMBLY​

FIGURE 4-6. JIB ASSEMBLY (Prior to SN 0300307186)​

FIGURE 4-7. JIB ASSEMBLY (SN 0300307186 to Present)​

FIGURE 4-8. ROTATOR ASSEMBLY​

FIGURE 4-9. SUPPORT, PLATFORM INSTALLATION​

FIGURE 4-10. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION​

FIGURE 4-11. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION WITH TOWER STOW​

FIGURE 4-12. CONTROL VALVES INSTALLATION - WITH 2WS​

FIGURE 4-13. CONTROL VALVES INSTALLATION - WITH 4WS​

FIGURE 4-14. BOOM VALVE ASSEMBLY​

FIGURE 4-15. CONTROL VALVE ASSEMBLY​

FIGURE 4-16. POWER TRACK INSTALLATION - MAIN BOOM​

FIGURE 4-17. POWER TRACK INSTALLATION - TOWER BOOM WITHOUT ARCTIC PACKAGE​

FIGURE 4-18. POWER TRACK INSTALLATION - TOWER BOOM WITH ARCTIC PACKAGE​

FIGURE 4-19. TRANSPORT POSITION SWITCH INSTALLATION​

FIGURE 4-20. UPRIGHT TILT SENSOR 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​

FIGURE 5-19. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH WITH TOWER STOW​

FIGURE 5-20. FOOTSWITCH ASSEMBLY​

FIGURE 5-21. JIB SWITCH INSTALLATION - 800AJ​

FIGURE 5-22. LIGHT PANEL INSTALLATION​

FIGURE 5-23. STEER SWITCH INSTALLATION - 4WS​

FIGURE 5-24. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 4FT (76CM X 1.22M) PLATFORM​

FIGURE 5-25. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.2CM X 1.82M) PLATFORM​

FIGURE 5-26. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 6FT (76CM X 1.83M) PLATFORM​

FIGURE 5-27. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 8FT (91.5CM X 2.4M) PLATFORM​

FIGURE 5-28. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.5CM X 1.82M) TRI-ENTRY PLATFORM)​

FIGURE 5-29. SKYCUTTER INSTALLATION​

FIGURE 5-30. PLASMA CUTTER ASSEMBLY​

FIGURE 5-31. SKYEYE INSTALLATION​

FIGURE 5-32. SKYGLAZIER INSTALLATION (ENGLISH LANGUAGE DECALS)​

FIGURE 5-33. SKYGLAZIER INSTALLATION (SPANISH LANGUAGE DECALS)​

FIGURE 5-34. SKYGLAZIER INSTALLATION (PORTUGUESE LANGUAGE DECALS)​

FIGURE 5-35. SKYGUARD BAR INSTALLATION​

FIGURE 5-36. SKYLINE INSTALLATION​

FIGURE 5-37. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-38. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-39. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)​

FIGURE 5-40. WELDER ASSEMBLY​

FIGURE 5-41. SKYWELDER PREP PACKAGE (60HZ)​

FIGURE 5-42. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M PLATFORM​

FIGURE 5-43. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM​

FIGURE 5-44. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM​

FIGURE 5-45. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM​

FIGURE 5-46. STORAGE TRAY INSTALLATION - CENTER​

FIGURE 5-47. USB CHARGER INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY​

FIGURE 6-2. LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB​

FIGURE 6-3. LEVEL CYLINDER ASSEMBLY - UPRIGHT​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB (Prior to SN 0300307186)​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB (SN 0300307186 to Present)​

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - MAIN BOOM​

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - TOWER BOOM​

FIGURE 6-8. MASTER CYLINDER ASSEMBLY​

FIGURE 6-9. STEER CYLINDER ASSEMBLY​

FIGURE 6-10. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (WITHOUT ARCTIC PACKAGE)​

FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (WITH ARCTIC PACKAGE)​

FIGURE 6-12. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM​

SECTION 7 - HYDRAULIC

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

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

FIGURE 7-3. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS WITH TOW PACKAGE)​

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

FIGURE 7-5. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE/WITH ARCTIC PACKAGE)​

FIGURE 7-6. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE/WITHOUT ARCTIC PACKAGE)​

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

FIGURE 7-8. HYDRAULIC DIAGRAM - DRIVE (4WD/4WS WITHOUT TOW PACKAGE/WITHOUT ARCTIC PACKAGE)​

FIGURE 7-9. HYDRAULIC DIAGRAM - DRIVE (4WD/4WS WITHOUT TOW PACKAGE/WITH ARCTIC PACKAGE)​

FIGURE 7-10. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS WITHOUT TOW PACKAGE) (ALL SPECS EXCEPT CE & UK CA)​

FIGURE 7-11. HYDRAULIC DIAGRAM - DRIVE (4WD/4WS WITHOUT TOW PACKAGE) (ALL SPECS)​

FIGURE 7-12. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS WITH TOW PACKAGE) (ANSI SPEC ONLY)​

FIGURE 7-13. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE) (CE & UK CA SPECS ONLY)​

FIGURE 7-14. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE AND ARCTIC PACKAGE) (ANSI SPEC ONLY)​

FIGURE 7-15. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE AND WITHOUT ARCTIC PACKAGE) (ALL SPECS)​

FIGURE 7-16. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE AND WITH ARCTIC PACKAGE) (CSA AND ANSI SPECS)​

FIGURE 7-17. HYDRAULIC DIAGRAM - DRIVE (4WD/4WS WITHOUT TOW PACKAGE AND WITH ARCTIC PACKAGE) (CSA AND ANSI SPECS)​

FIGURE 7-18. HYDRAULIC DIAGRAM - STANDARD 800AJ​

SECTION 8 - ELECTRICAL

FIGURE 8-1. 800AJ 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, CHINA, CSA & JAPANESE SPECS)​

FIGURE 8-5. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT ANSI & 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 (ANSI, ANSI EXPORT AND CSA SPECS WITH 4000W SKYPOWER GENERATOR)​

FIGURE 8-19. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI AND CSA SPECS WITH 7500W SKYPOWER GENERATOR)​

FIGURE 8-20. BEACON CONTROL HARNESS (BLUE AND RED STROBE LIGHTS)​

FIGURE 8-21. BATTERY DISCONNECT SWITCH INSTALLATION​

FIGURE 8-22. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR OR NO GENERATOR OPTION (ANSI & CSA SPECS)​

FIGURE 8-23. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR OR NO GENERATOR OPTION (CE & UK CA SPECS)​

FIGURE 8-24. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR OR NO GENERATOR OPTION (ANSI EXPORT, AUSTRALIAN, CHINA & JAPANESE SPECS)​

FIGURE 8-25. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR OR NO GENERATOR OPTION & ARCTIC PACKAGE (ANSI, ANSI EXPORT, CHINA & CSA SPECS)​

FIGURE 8-26. BOOM CABLES INSTALLATION - WITH 4000W GENERATOR (ALL SPECS)​

FIGURE 8-27. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR (ALL SPECS EXCEPT CE & UK CA SPECS)​

FIGURE 8-28. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR (CE & UK CA SPECS)​

FIGURE 8-29. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR & ARCTIC PACKAGE (ANIT, ANSI EXPORT, CHINA & CSA SPECS)​

FIGURE 8-30. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR AND COMMUNICATION CABLES (ANSI SPECS)​

FIGURE 8-31. BOOM CABLE - MAIN BOOM (WITH ARCTIC PACKAGE)​

FIGURE 8-32. BOOM CABLE - MAIN BOOM​

FIGURE 8-33. BOOM CABLE - TOWER BOOM WITHOUT ARCTIC PACKAGE​

FIGURE 8-34. BOOM CABLE - TOWER BOOM WITH ARCTIC PACKAGE​

FIGURE 8-35. BOOM VALVE HARNESS​

FIGURE 8-36. BREAKER BOX INSTALLATION (BRAZIL SPECS)​

FIGURE 8-37. BREAKER BOX INSTALLATION (CE & UK CA SPECS WITHOUT 4000W GENERATOR)​

FIGURE 8-38. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (BRAZIL SPECS, CE & UK CA SPECS WITHOUT 4000W GENERATOR)​

FIGURE 8-39. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (CE & UK CA SPECS WITH 4000W GENERATOR)​

FIGURE 8-40. CLEARSKY 3-WIRE TELEMATICS INSTALLATION​

FIGURE 8-41. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (AUSTRALIAN SPECS)​

FIGURE 8-42. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (CE SPECS)​

FIGURE 8-43. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (ANSI SPECS)​

FIGURE 8-44. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (CHINA SPECS)​

FIGURE 8-45. CLEARSKY HARNESS - 3-WIRE TELEMATICS​

FIGURE 8-46. CLEARSKY HARNESS - CANBUS TELEMATICS​

FIGURE 8-47. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-48. CBS HARNESS​

FIGURE 8-49. ECU POWER JUMPER HARNESS​

FIGURE 8-50. ENGINE HARNESS - DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (CHINA III) ENGINES​

FIGURE 8-51. ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V & CHINA IV) ENGINES​

FIGURE 8-52. ENGINE HARNESS - FORD ENGINES​

FIGURE 8-53. FUEL PUMP HARNESS - DEUTZ TD2.9L4 ENGINES​

FIGURE 8-54. FUEL HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE​

FIGURE 8-55. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-56. GENERATOR HARNESS - 7500W SKYPOWER GENERATOR​

FIGURE 8-57. GENERATOR TO ENGINE HARNESS - 2500W (FORD ENGINES)​

FIGURE 8-58. GENERATOR TO ENGINE HARNESS - 4000W (DEUTZ D2011 ENGINES)​

FIGURE 8-59. GENERATOR TO ENGINE HARNESS - 4000W (DEUTZ TD2.9L4 ENGINES)​

FIGURE 8-60. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ENGINES)​

FIGURE 8-61. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES)​

FIGURE 8-62. GENERATOR HARNESS - 7500W SKYPOWER (DEUTZ TD2.9L4 T4F ENGINES)​

FIGURE 8-63. GENERATOR TO REAR OF BOOM HARNESS - 110V​

FIGURE 8-64. GENERATOR TO REAR OF BOOM HARNESS - 220V​

FIGURE 8-65. GROUND CONTROL BOX HARNESS​

FIGURE 8-66. GROUND CONTROL ENGINE HARNESS - DEUTZ D2011 ENGINES​

FIGURE 8-67. GROUND CONTROL ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE​

FIGURE 8-68. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-69. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPECS)​

FIGURE 8-70. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPECS)​

FIGURE 8-71. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE & UK CA SPECS)​

FIGURE 8-72. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 BOX (CE & UK CA SPECS)​

FIGURE 8-73. RECEPTACLE BOX KIT - 220V AFSINT107 KEYED GROUND (CE & UK CA SPECS)​

FIGURE 8-74. RECEPTACLE/BREAKER BOX ASSEMBLY - 240V (7500W SKYPOWER GENERATORS) (ANSI, ANSI EXPORT AND CSA SPECS)​

FIGURE 8-75. SKYEYE EMITTER HARNESS​

FIGURE 8-76. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-77. SKYEYE RECEIVER HARNESS​

FIGURE 8-78. SKYLINE HARNESS​

FIGURE 8-79. SKYGUARD INTERFACE HARNESS​

FIGURE 8-80. STROBE LIGHT JUMPER HARNESS​

FIGURE 8-81. VALVE HARNESS​

FIGURE 8-82. WHITE NOISE ALARM HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI SPECS (800AJ)​

FIGURE 9-2. DECAL INSTALLATION - AUSTRALIAN SPECS (800AJ)​

FIGURE 9-3. DECAL INSTALLATION - BRAZILIAN SPECS (800AJ)​

FIGURE 9-4. DECAL INSTALLATION - CE & UK CA SPECS (800AJ)​

FIGURE 9-5. DECAL INSTALLATION - CHINESE SPECS (800AJ)​

FIGURE 9-6. DECAL INSTALLATION - CSA SPECS (800AJ)​

FIGURE 9-7. DECAL INSTALLATION - JAPANESE SPECS (800AJ)​

FIGURE 9-8. DECAL INSTALLATION - KOREAN SPECS (800AJ)​

FIGURE 9-9. DECAL INSTALLATION - LATIN AMERICAN SPECS (800AJ)​

FIGURE 9-10. DECAL INSTALLATION - OPTIONS​

FIGURE 9-11. SKYCUTTER DECAL INSTALLATION​

FIGURE 9-12. SKYWELDER DECAL INSTALLATION - 50HZ​

FIGURE 9-13. SKYWELDER DECAL INSTALLATION - 60HZ​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX