JLG Boom Lift 800AJ Parts Manual 3122562000

[Hyundai]

Download this document, you need 2725 Gallons

JLG Boom Lift 800AJ Parts Manual 3122562000
Size: 58.50 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG 800AJ Boom Lift
Part Number: 3122562000
Publication Date: 2025
Number of Pages: 828 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - FIXED​

FIGURE 1-2. AXLE INSTALLATION - OSCILLATING (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-3. AXLE INSTALLATION - OSCILLATING (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-4. AXLE INSTALLATION - OSCILLATING WITH TOW PACKAGE (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-5. AXLE INSTALLATION - OSCILLATING WITH TOW PACKAGE (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-6. STEER INSTALLATION - 2WS (WITHOUT TOW PACKAGE)​

FIGURE 1-7. STEER INSTALLATION - 2WS (WITH TOW PACKAGE)​

FIGURE 1-8. STEER INSTALLATION - 4WS​

FIGURE 1-9. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 2WD​

FIGURE 1-10. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD/2WS​

FIGURE 1-11. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD/4WS​

FIGURE 1-12. HUB ASSEMBELY - 2WD FRONT​

FIGURE 1-13. DRIVE HUB/BRAKE ASSEMBLY​

FIGURE 1-14. DRIVE MOTOR ASSEMBLY - 2WD​

FIGURE 1-15. DRIVE MOTOR ASSEMBLY - 4WD​

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

FIGURE 1-17. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED NON-MARKING TIRE​

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

FIGURE 1-19. LP TANK BRACKETS INSTALLATIONS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-20. FRAME SHIELDS INSTALLATION - 2WS​

FIGURE 1-21. FRAME SHIELDS INSTALLATION - 4WS​

FIGURE 1-22. TOW PACKAGE INSTALLATION (ANSI & ANSI EXPORT SPECS)​

FIGURE 1-23. TOW PACKAGE INSTALLATION (CE & UK CA SPECS)​

FIGURE 1-24. TOW BAR ASSEMBLY​

SECTION 2 - TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATION - WITH 2WS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-2. CONTROL VALVES INSTALLATION - WITH 2WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-3. CONTROL VALVES INSTALLATION - WITH 4WS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-4. CONTROL VALVES INSTALLATION - WITH 4WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-5. CONTROL VALVE ASSEMBLY - 2WS MACHINES​

FIGURE 2-6. CONTROL VALVE ASSEMBLY - 4WS MACHINES​

FIGURE 2-7. SWING DRIVE INSTALLATION​

FIGURE 2-8. SWING MOTOR/HUB ASSEMBLY​

FIGURE 2-9. TURNTABLE BEARING INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-10. TURNTABLE BEARING INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-11. TURNTABLE LOCK INSTALLATION​

FIGURE 2-12. ROTARY COUPLING INSTALLATION - 2WS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-13. ROTARY COUPLING INSTALLATION - 2WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-14. ROTARY COUPLING INSTALLATION - 4WS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-15. ROTARY COUPLING INSTALLATION - 4WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-16. ROTARY COUPLING ASSEMBLY - 2WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-17. ROTARY COUPLING ASSEMBLY - 4WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-18. TANK INSTALLATION - DIESEL ENGINES (PLASTIC FUEL TANK) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-19. TANK INSTALLATION - DIESEL ENGINES (PLASTIC FUEL TANK) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-20. TANK INSTALLATION - DIESEL ENGINES (STEEL FUEL TANK) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-21. TANK INSTALLATION - DIESEL ENGINES (STEEL FUEL TANK) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-22. TANK INSTALLATION - GAS ENGINES​

FIGURE 2-23. HYDRAULIC TANK ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-24. HYDRAULIC TANK ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-25. AUXILIARY POWER INSTALLATION - WITHOUT BATTERY DISCONNECT​

FIGURE 2-26. AUXILIARY POWER INSTALLATION - WITH BATTERY DISCONNECT​

FIGURE 2-27. AUXILIARY POWER PUMP/MOTOR ASSEMBLY​

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (CHINA IV), TD2.9L4 (UN R96) & TD2.9L4 EMR5 ENGINES (WITHOUT TOWER STOW)​

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (CHINA IV), TD2.9L4 (UN R96) & TD2.9L4 EMR5 ENGINES (WITH TOWER STOW)​

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) ENGINES (WITHOUT TOWER STOW)​

FIGURE 2-31. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) ENGINES (WITH TOWER STOW)​

FIGURE 2-32. GROUND CONTROL BOX ASSEMBLY - WITH FORD ENGINES​

FIGURE 2-33. GROUND CONTROL BOX ASSEMBLY - WITH FORD ENGINES (TOWER STOW)​

FIGURE 2-34. LIGHT PANEL INSTALLATION​

FIGURE 2-35. ALARM INSTALLATION​

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

FIGURE 2-37. EXHAUST COVER INSTALLATION - STEEL HOODS (FORD ENGINES)​

FIGURE 2-38. EXHAUST COVER AND HEAT SHIELDS INSTALLATION - STEEL HOODS (DEUTZ ENGINES)​

FIGURE 2-39. HOODS INSTALLATION - ABS (DEUTZ TD2.9L4 (STAGE V) ENGINES)​

FIGURE 2-40. HOODS INSTALLATION - ABS (DEUTZ TD2.9L4 (UN R96) & TD2.9L4 EMR5 ENGINES)​

FIGURE 2-41. HOODS INSTALLATION - STEEL (DEUTZ ENGINES)​

FIGURE 2-42. HOODS INSTALLATION - STEEL (FORD ENGINES)​

FIGURE 2-43. SKYAIR AIR COMPRESSOR INSTALLATION (ANSI AND CSA SPECS)​

FIGURE 2-44. SKYAIR AIR COMPRESSOR INSTALLATION (ANSI EXPORT SPECS)​

FIGURE 2-45. AIR COMPRESSOR ASSEMBLY​

FIGURE 2-46. WHITE NOISE MOTION ALARM INSTALLATION​

FIGURE 2-47. WHITE NOISE MOTION ALARM INSTALLATION (ADJUSTABLE AMBIENT)​

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ TD2.9L4 (CHINA IV) ENGINE INSTALLATION​

FIGURE 3-2. DEUTZ TD2.9L4 (CHINA IV) ENGINE AND PUMP SUB-ASSEMBLY​

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

FIGURE 3-4. DEUTZ TD2.9L4 (CHINA IV) ENGINE COMPONENTS​

FIGURE 3-5. DEUTZ TD2.9L4 (STAGE V) ENGINE INSTALLATION​

FIGURE 3-6. DEUTZ TD2.9L4 (STAGE V) ENGINE AND PUMP SUB-ASSEMBLY​

FIGURE 3-7. DEUTZ TD2.9L4 (STAGE V) ENGINE ASSEMBLY​

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

FIGURE 3-9. DEUTZ TD2.9L4 (UN R96) ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE (PLASTIC HOODS)​

FIGURE 3-10. DEUTZ TD2.9L4 (UN R96) ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE (WITH STEEL HOODS)​

FIGURE 3-11. DEUTZ TD2.9L4 (UN R96) ENGINE AND PUMP SUB-ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-12. DEUTZ TD2.9L4 (UN R96) ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-13. DEUTZ TD2.9L4 (UN R96) ENGINE INSTALLATION - WITH ARCTIC PACKAGE (PLASTIC HOODS)​

FIGURE 3-14. DEUTZ TD2.9L4 (UN R96) ENGINE INSTALLATION - WITH ARCTIC PACKAGE (STEEL HOODS)​

FIGURE 3-15. DEUTZ TD2.9L4 (UN R96) ENGINE AND PUMP SUB-ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-16. DEUTZ TD2.9L4 (UN R96) ENGINE ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-17. DEUTZ TD2.9L4 (UN R96) ENGINE COMPONENTS​

FIGURE 3-18. DEUTZ TD2.9L4 EMR5 ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE​

FIGURE 3-19. DEUTZ TD2.9L4 EMR5 ENGINE AND PUMP SUB-ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-20. DEUTZ TD2.9L4 EMR5 ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-21. DEUTZ TD2.9L4 EMR5 ENGINE INSTALLATION - WITH ARCTIC PACKAGE​

FIGURE 3-22. DEUTZ TD2.9L4 EMR5 ENGINE AND PUMP SUB-ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-23. DEUTZ TD2.9L4 EMR5 ENGINE ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-24. DEUTZ TD2.9L4 EMR5 ENGINE COMPONENTS​

FIGURE 3-25. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 (STAGE V) & TD2.9L4 EMR5 ENGINES)​

FIGURE 3-26. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 (CHINA IV) & TD2.9L4 (UN R96) ENGINES)​

FIGURE 3-27. BREATHER HEATER INSTALLATION (DEUTZ TD2.9L4 (UN R96) & TD2.9L4 EMR5 ENGINES)​

FIGURE 3-28. PUMP COUPLING KIT (DEUTZ ENGINES)​

FIGURE 3-29. FORD ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE​

FIGURE 3-30. FORD ENGINE AND PUMP SUB-ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-31. FORD ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-32. FORD ENGINE INSTALLATION - WITH ARCTIC PACKAGE​

FIGURE 3-33. FORD ENGINE AND PUMP SUB-ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-34. FORD ENGINE ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-35. FORD ENGINE PREP ASSEMBLY​

FIGURE 3-36. FORD ENGINE BRACKETS AND EXHAUST MANIFOLD INSTALLATION​

FIGURE 3-37. FORD ENGINE COMPONENTS​

FIGURE 3-38. FORD ENGINE DRIVE BELT INSTALLATION (MACHINES WITHOUT GENERATOR)​

FIGURE 3-39. HYDROSTATIC PUMP ASSEMBLY (DEUTZ TD2.9L4 (CHINA IV), TD2.9L4 (STAGE V) & TD2.9L4 EMR5 ENGINES)​

FIGURE 3-40. HYDROSTATIC PUMP ASSEMBLY (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 3-41. VARIABLE PUMP ASSEMBLY (DEUTZ TD2.9L4 (CHINA IV), TD2.9L4 (STAGE V) & TD2.9L4 EMR5 ENGINES)​

FIGURE 3-42. VARIABLE PUMP ASSEMBLY (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 3-43. ENGINE HOOD BAFFLE INSTALLATION - WITH ABS HOODS​

FIGURE 3-44. ENGINE HOOD BAFFLE INSTALLATION - WITH STEEL HOODS​

FIGURE 3-45. ENGINE TRAY JACK INSTALLATION - DEUTZ ENGINES​

FIGURE 3-46. ENGINE TRAY JACK INSTALLATION - FORD ENGINES​

FIGURE 3-47. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 (STAGE V) ENGINES​

FIGURE 3-48. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 EMR5 ENGINES​

FIGURE 3-49. EXHAUST PIPE INSTALLATION - FORD ENGINES​

FIGURE 3-50. FUEL-WATER SEPARATOR INSTALLATION​

FIGURE 3-51. QUICKFIT OIL VALVE - DEUTZ ENGINES​

FIGURE 3-52. SPARK ARRESTOR INSTALLATION (WITH ABS HOODS)​

FIGURE 3-53. SPARK ARRESTOR INSTALLATION (WITH STEEL HOODS)​

FIGURE 3-54. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ ENGINES​

FIGURE 3-55. 2500W/110V/60HZ GENERATOR INSTALLATION - FORD ENGINES​

FIGURE 3-56. 2500W/120V/60HZ GENERATOR INSTALLATION​

FIGURE 3-57. 2500W/220V/50HZ GENERATOR INSTALLATION​

FIGURE 3-58. 4000W/50HZ GENERATOR INSTALLATION​

FIGURE 3-59. 4000W/60HZ GENERATOR INSTALLATION​

FIGURE 3-60. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION​

FIGURE 3-61. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ ENGINES​

FIGURE 3-62. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD ENGINES​

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDER INSTALLATION - WITHOUT ARCTIC PACKAGE (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-2. BOOM AND CYLINDER INSTALLATION - WITHOUT ARCTIC PACKAGE (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-3. BOOM AND CYLINDER INSTALLATION - WITH ARCTIC PACKAGE (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-4. BOOM AND CYLINDER INSTALLATION - WITH ARCTIC PACKAGE (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-5. BOOM ASSEMBLY - MAIN (WITHOUT ARCTIC PACKAGE)​

FIGURE 4-6. BOOM ASSEMBLY - MAIN (WITH ARCTIC PACKAGE)​

FIGURE 4-7. TOWER BOOM ASSEMBLY​

FIGURE 4-8. JIB ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-9. JIB ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-10. PLATFORM ROTATOR ASSEMBLY​

FIGURE 4-11. RAPID REPLACEABLE PLATFORM SUPPORT (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-12. RAPID REPLACEABLE PLATFORM INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-13. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION (WITHOUT TOWER STOW)​

FIGURE 4-14. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION (WITH TOWER STOW)​

FIGURE 4-15. CONTROL VALVES INSTALLATION - WITH 2WS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-16. CONTROL VALVES INSTALLATION - WITH 2WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-17. CONTROL VALVES INSTALLATION - WITH 4WS (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-18. CONTROL VALVES INSTALLATION - WITH 2WS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-19. BOOM VALVE ASSEMBLY​

FIGURE 4-20. POWER TRACK INSTALLATION - MAIN BOOM​

FIGURE 4-21. POWER TRACK INSTALLATION - TOWER BOOM​

FIGURE 4-22. TRANSPORT POSITION SWITCH INSTALLATION​

FIGURE 4-23. UPRIGHT TILT SENSOR INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. RAPID REPLACEABLE PLATFORM - 30IN X 4FT (76.2CM X 1.22M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-2. RAPID REPLACEABLE PLATFORM - 30IN X 4FT (76.2CM X 1.22M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-3. RAPID REPLACEABLE PLATFORM - 30IN X 6FT (76.2CM X 1.83M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-4. RAPID REPLACEABLE PLATFORM - 30IN X 6FT (76.2CM X 1.83M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-5. RAPID REPLACEABLE PLATFORM - 36IN X 6FT (91.5CM X 1.83M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-6. RAPID REPLACEABLE PLATFORM - 36IN X 6FT (91.5CM X 1.83M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-7. RAPID REPLACEABLE PLATFORM - 36IN X 8FT (91.5CM X 2.44M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-8. RAPID REPLACEABLE PLATFORM - 36IN X 8FT (91.5CM X 2.44M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-9. TRADITIONAL PLATFORM - 36IN X 6FT (91.5CM X 1.83M) (WITH FALL ARREST) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-10. TRADITIONAL PLATFORM - 36IN X 6FT (91.5CM X 1.83M) (WITH FALL ARREST) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-11. TRADITIONAL PLATFORM - 36IN X 8FT (91.5CM X 2.44M) (WITH FALL ARREST) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-12. TRADITIONAL PLATFORM - 36IN X 8FT (91.5CM X 2.44M) (WITH FALL ARREST) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-13. TRADITIONAL PLATFORM - 36IN X 8FT (91.5CM X 2.44M) (WITH 1 GATE / 2 DROP BARS) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-14. TRADITIONAL PLATFORM - 36IN X 8FT (91.5CM X 2.44M) (WITH 1 GATE / 2 DROP BARS) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-15. CONSOLE AND FOOT SWITCH INSTALLATION (WITHOUT TOWER STOW)​

FIGURE 5-16. CONSOLE BOX AND FOOTSWITCH ASSEMBLY (WITHOUT TOWER STOW)​

FIGURE 5-17. CONSOLE AND FOOTSWITCH INSTALLATION (WITH TOWER STOW)​

FIGURE 5-18. CONSOLE BOX AND FOOTSWITCH ASSEMBLY (WITH TOWER STOW)​

FIGURE 5-19. SWING GATE INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-20. SWING GATE INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-21. DROP BAR INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-22. DROP BAR INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-23. FOOTSWITCH ASSEMBLY​

FIGURE 5-24. JIB SWITCH INSTALLATION​

FIGURE 5-25. LIGHT PANEL INSTALLATION​

FIGURE 5-26. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 4FT (76CM X 1.22M) PLATFORM​

FIGURE 5-27. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 6FT (76CM X 1.83M) PLATFORM​

FIGURE 5-28. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.2CM X 1.82M) PLATFORM​

FIGURE 5-29. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 8FT (91.5CM X 2.4M) PLATFORM​

FIGURE 5-30. MANUAL STORAGE BOX INSTALLATION​

FIGURE 5-31. PLATFORM BEACON 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. SKYLINE INSTALLATION​

FIGURE 5-36. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-37. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-38. WELDER ASSEMBLY​

FIGURE 5-39. SKYWELDER PREP PACKAGE (60HZ)​

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

FIGURE 5-41. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM​

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

FIGURE 5-43. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM​

FIGURE 5-44. STEER SWITCH INSTALLATION - 4WS​

FIGURE 5-45. STORAGE TRAY INSTALLATION - CENTER​

FIGURE 5-46. USB CHARGER INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-2. AXLE LOCKOUT CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-3. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE​

FIGURE 6-4. LEVEL CYLINDER ASSEMBLY - UPRIGHT​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB​

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) (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 7-3. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS WITHOUT TOW PACKAGE) (DEUTZ TD2.9L4 (CHINA IV) & TD2.9L4 EMR5 ENGINES)​

FIGURE 7-4. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS WITH TOW PACKAGE) (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 7-5. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS WITH TOW PACKAGE) (DEUTZ TD2.9L4 EMR5 ENGINES)​

FIGURE 7-6. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE) (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 7-7. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITHOUT TOW PACKAGE) (DEUTZ TD2.9L4 (CHINA IV), TD2.9L4 (STAGE V) & TD2.9L4 EMR5 ENGINES)​

FIGURE 7-8. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE) (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 7-9. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS WITH TOW PACKAGE) (DEUTZ TD2.9L4 (STAGE V) & TD2.9L4 EMR5 ENGINES)​

FIGURE 7-10. HYDRAULIC DIAGRAM - DRIVE (4WD/4WS) (DEUTZ TD2.9L4 (UN R96) & FORD ENGINES)​

FIGURE 7-11. HYDRAULIC DIAGRAM - DRIVE (4WD/4WS) (DEUTZ TD2.9L4 (CHINA IV), TD2.9L4 (STAGE V) & TD2.9L4 EMR5 ENGINES)​

FIGURE 7-12. HYDRAULIC DIAGRAM - STANDARD​

SECTION 8 - ELECTRICAL

FIGURE 8-1. ELECTRICAL LAYOUT​

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V GFI RECEPTACLE​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (WITHOUT GENERATOR)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (WITH 4000W/50HZ GENERATOR)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V​

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 240V (2X4 BOX & COVER ONLY - LOCALLY SUPPLIED RECEPTACLE)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 240V AFSNIT 107 KEYED GROUND (WITHOUT GENERATOR)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 240V AFSNIT 107 KEYED GROUND (WITH 4000W/50HZ GENERATOR)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 240V IEC BLUE (WITHOUT GENERATOR)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 240V IEC BLUE (MACHINES WITH 4000W/50HZ GENERATOR)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 240V CEE7 POST GROUND (WITHOUT GENERATOR)​

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 240V CEE7 POST GROUND (WITH 4000W/50HZ GENERATOR)​

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 240V CEE7 SIDE GROUND (WITHOUT GENERATOR)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 240V CEE7 SIDE GROUND (WITH 4000W/50HZ GENERATOR)​

FIGURE 8-15. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT GENERATOR)​

FIGURE 8-16. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITH 4000W/60HZ GENERATOR)​

FIGURE 8-17. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITH 7500W SKYPOWER GENERATOR)​

FIGURE 8-18. AC RECEPTACLE/BREAKER BOX INSTALLATION - 240V GFCI (WITH 4000W GENERATOR)​

FIGURE 8-19. AC RECEPTACLE/BREAKER BOX INSTALLATION - 240V GFCI (WITH 7500W SKYPOWER GENERATOR)​

FIGURE 8-20. BATTERY DISCONNECT SWITCH INSTALLATION​

FIGURE 8-21. BOOM CABLES INSTALLATION - NO GENERATOR OPTION (WITHOUT ARCTIC PACKAGE) (ANSI & CSA SPECS)​

FIGURE 8-22. BOOM CABLES INSTALLATION - NO GENERATOR OPTION (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, CE, AUSTRALIAN, JAPANESE & UKCA SPECS)​

FIGURE 8-23. BOOM CABLES INSTALLATION - NO GENERATOR OPTION (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CHINA & JAPANESE SPECS)​

FIGURE 8-24. BOOM CABLES INSTALLATION - NO GENERATOR OPTION (WITH ARCTIC PACKAGE)​

FIGURE 8-25. BOOM CABLES INSTALLATION - WITH 4000W/60HZ GENERATOR​

FIGURE 8-26. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR (WITHOUT ARCTIC PACKAGE OR DAVID CLARK COMUNICATION SYSTEM)​

FIGURE 8-27. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR (WITH ARCTIC PACKAGE)​

FIGURE 8-28. BOOM CABLES INSTALLATION - WITH 7500W SKYPOWER GENERATOR (WITH DAVID CLARK COMMUNICATION SYSTEM)​

FIGURE 8-29. BOOM CABLE - MAIN BOOM (WITHOUT ARCTIC PACKAGE)​

FIGURE 8-30. BOOM CABLE - MAIN BOOM (WITH ARCTIC PACKAGE)​

FIGURE 8-31. BOOM CABLE - TOWER BOOM (WITHOUT ARCTIC PACKAGE)​

FIGURE 8-32. BOOM CABLE - TOWER BOOM (WITH ARCTIC PACKAGE)​

FIGURE 8-33. BOOM VALVE HARNESS​

FIGURE 8-34. BREAKER BOX INSTALLATION (ANSI EXPORT SPECS)​

FIGURE 8-35. BREAKER BOX INSTALLATION (CE & UK CA SPECS)​

FIGURE 8-36. BREAKER BOX KIT (WITHOUT 4000W/50HZ GENERATOR)​

FIGURE 8-37. BREAKER BOX KIT (WITH 4000W/50HZ GENERATOR)​

FIGURE 8-38. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-39. CSB HARNESS​

FIGURE 8-40. ECU POWER JUMPER HARNESS​

FIGURE 8-41. ENGINE HARNESS - DEUTZ ENGINES​

FIGURE 8-42. FUEL FILTER HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE​

FIGURE 8-43. FUEL PUMP HARNESS - DEUTZ ENGINES​

FIGURE 8-44. GENERATOR HARNESS - 2500W/110V/60HZ GENERATOR (FORD ENGINES)​

FIGURE 8-45. GENERATOR HARNESS - 4000W GENERATORS​

FIGURE 8-46. GENERATOR HARNESS - 7500W SKYPOWER GENERATORS​

FIGURE 8-47. GENERATOR CONTROL BOX TO ENGINE HARNESS - 4000W GENERATORS​

FIGURE 8-48. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (DEUTZ ENGINES)​

FIGURE 8-49. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD ENGINES)​

FIGURE 8-50. GENERATOR TO REAR OF BOOM HARNESS - 2500W/110V & 2500W/120V GENERATORS​

FIGURE 8-51. GENERATOR TO REAR OF BOOM HARNESS - 2500W/220V GENERATORS​

FIGURE 8-52. GROUND CONTROL BOX HARNESS​

FIGURE 8-53. GROUND CONTROL ENGINE HARNESS - DEUTZ ENGINES​

FIGURE 8-54. GROUND CONTROL ENGINE HARNESS - FORD ENGINES​

FIGURE 8-55. PLATFORM BEACON HARNESS​

FIGURE 8-56. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-57. SKYLINE HARNESS​

FIGURE 8-58. STROBE LIGHT JUMPER HARNESS​

FIGURE 8-59. USB HARNESS​

FIGURE 8-60. VALVE HARNESS​

FIGURE 8-61. WHITE NOISE ALARM HARNESS​

FIGURE 8-62. WORK LIGHTS HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI SPEC)​

FIGURE 9-2. DECAL INSTALLATION - ENGLISH LANGUAGE (AUSTRALIAN SPEC)​

FIGURE 9-3. DECAL INSTALLATION - ENGLISH LANGUAGE (CE & UK CA SPECS)​

FIGURE 9-4. DECAL INSTALLATION - CHINESE/ENGLISH LANGUAGES​

FIGURE 9-5. DECAL INSTALLATION - FRENCH/ENGLISH LANGUAGES​

FIGURE 9-6. DECAL INSTALLATION - JAPANESE/ENGLISH LANGUAGES​

FIGURE 9-7. DECAL INSTALLATION - KOREAN/ENGLISH LANGUAGES​

FIGURE 9-8. DECAL INSTALLATION - PORTUGUESE/ENGLISH LANGUAGES​

FIGURE 9-9. DECAL INSTALLATION - SPANISH/ENGLISH LANGUAGES​

FIGURE 9-10. DECAL INSTALLATION - OPTIONS​

FIGURE 9-11. SKYWELDER DECAL INSTALLATION - 50HZ​

FIGURE 9-12. 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