JLG Boom Lift 800S HC3 860SJ HC3 Parts Catalog 31220671

Hyundai · Jun 21, 2026

JLG Boom Lift 800S HC3 860SJ HC3 Parts Catalog 31220671
Size: 83.89 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 800S HC3, 860SJ HC3 Boom Lift
Part Number: 31220671
Publication Date: 2025
Number of Pages: 1130 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - FIXED (WITHOUT TOW PACKAGE)

FIGURE 1-2. AXLE INSTALLATION - OSCILLATING (WITHOUT TOW PACKAGE) (MACHINES WITH SN STARTING WITH 03)

FIGURE 1-3. AXLE INSTALLATION - OSCILLATING (WITHOUT TOW PACKAGE) (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. STEERING INSTALLATION - WITHOUT TOW PACKAGE (MACHINES WITH SN STARTING WITH 03)

FIGURE 1-7. STEERING INSTALLATION - WITHOUT TOW PACKAGE (MACHINES WITH SN STARTING WITH B3)

FIGURE 1-8. STEERING INSTALLATION - WITH TOW PACKAGE (MACHINES WITH SN STARTING WITH 03)

FIGURE 1-9. STEERING INSTALLATION - WITH TOW PACKAGE (MACHINES WITH SN STARTING WITH B3)

FIGURE 1-10. WHEEL DRIVE AND FRAME VALVES INSTALLATION – 2WD

FIGURE 1-11. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD (SN STARTING WITH 03)

FIGURE 1-12. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 4WD (SN STARTING WITH B3)

FIGURE 1-13. HUB ASSEMBLY - NON-DRIVE

FIGURE 1-14. DRIVE HUB/BRAKE ASSEMBLY

FIGURE 1-15. DRIVE MOTOR ASSEMBLY - 2WD

FIGURE 1-16. DRIVE MOTOR ASSEMBLY - 4WD (SN STARTING WITH 03)

FIGURE 1-17. DRIVE MOTOR ASSEMBLY - 4WD (SN STARTING WITH B3)

FIGURE 1-18. TIRE & WHEEL INSTALLATION - 15-625 NHS FOAM-FILLED

FIGURE 1-19. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED TIRE

FIGURE 1-20. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED NON-MARKING TIRE

FIGURE 1-21. TIRE AND WHEEL INSTALLATION 18-22.5 NHS FOAM-FILLED NON-MARKING TIRE

FIGURE 1-22. LP TANK BRACKETS INSTALLATIONS

FIGURE 1-23. TOW PACKAGE INSTALLATION (ENGLISH DECALS)

FIGURE 1-24. TOW PACKAGE INSTALLATION (FRENCH/ENGLISH DECALS)

FIGURE 1-25. TOW BAR ASSEMBLY

FIGURE 1-26. FRAME SHIELDS INSTALLATION

SECTION 2 - TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATION (800S HC3)

FIGURE 2-2. CONTROL VALVES INSTALLATION (860SJ HC3)

FIGURE 2-3. MAIN CONTROL VALVE ASSEMBLY

FIGURE 2-4. SWING DRIVE INSTALLATION

FIGURE 2-5. SWING MOTOR/HUB ASSEMBLY

FIGURE 2-6. TURNTABLE BEARING INSTALLATION

FIGURE 2-7. REMOTE BEARING LUBE INSTALLATION

FIGURE 2-8. TURNTABLE LOCK INSTALLATION

FIGURE 2-9. ROTARY COUPLING INSTALLATION

FIGURE 2-10. TANK INSTALLATION - GAS ENGINES (HELGESEN 25 GAL HYDRAULIC TANK WITH 6IN DIA BREATHER)

FIGURE 2-11. TANK INSTALLATION - DIESEL ENGINES (HELGESEN 25 GAL HYDRAULIC TANK WITH 6IN BREATHER)

FIGURE 2-12. TANK INSTALLATION - DIESEL ENGINES (JIANGYING 25 GAL HYDRAULIC TANK WITH 4IN DIA BREATHER)

FIGURE 2-13. HYDRAULIC TANK ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-14. HYDRAULIC TANK ASSEMBLY (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-15. AUXILIARY PUMP WITH BATTERY WITHOUT BATTERY DISCONNECT SWITCH INSTALLATION (SN STARTING WITH 03)

FIGURE 2-16. AUXILIARY PUMP WITH BATTERY WITHOUT BATTERY DISCONNECT SWITCH INSTALLATION (SN STARTING WITH B3)

FIGURE 2-17. AUXILIARY PUMP WITH BATTERY WITH BATTERY DISCONNECT SWITCH INSTALLATION (SN STARTING WITH 03)

FIGURE 2-18. AUXILIARY PUMP WITH BATTERY WITH BATTERY DISCONNECT SWITCH INSTALLATION (SN STARTING WITH B3)

FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 - WITH DIGITAL DISPLAY (ANSI EXPORT (LRC) SPECS) (800S HC3)

FIGURE 2-20. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (800S HC3) (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 2-21. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (800S HC3) (SN 0300298220 to Present, Including 0300295807)

FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (RUSSIA AND UK CA (LRC) SPECS) (800S HC3) (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (RUSSIA AND UK CA (LRC) SPECS) (800S HC3) (SN 0300298220 to Present, Including 0300295807)

FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH DIGITAL DISPLAY (ANSI, ANSI EXPORT (HRC), CSA AND JAPANESE SPECS) (800S HC3)

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT (HRC), CSA AND JAPANESE SPECS) (800S HC3) (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT (HRC), CSA AND JAPANESE SPECS) (800S HC3) (SN 0300298220 to Present, Including 0300295807)

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) (CE & UK CA SPECS) (800S HC3) (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) (CE & UK CA SPECS) (800S HC3) (SN 0300298220 to Present, Including 0300295807)

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY - WITH FORD DF 2.5L - WITH DIGITAL DISPLAY (ANSI, ANSI EXPORT AND CSA SPECS) (800S HC3)

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY - WITH FORD DF 2.5L - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, AUSTRAILIAN AND CSA SPECS) (800S HC3) (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 2-31. GROUND CONTROL BOX ASSEMBLY - WITH FORD DF 2.5L - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, AUSTRAILIAN AND CSA SPECS) (800S HC3) (SN 0300298220 to Present, Including 0300295807)

FIGURE 2-32. GROUND CONTROL BOX ASSEMBLY WITH DEUTZ D2011 - WITH DIGITAL DISPLAY (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (860SJ HC3)

FIGURE 2-33. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (860SJ HC3) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 2-34. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (860SJ HC3) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 2-35. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (CE, RUSSIA & UK CA SPECS) (860SJ HC3) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 2-36. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (CE, RUSSIA & UK CA SPECS) (860SJ HC3) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 2-37. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (HIGH TEMP MARKETS) (ANSI EXPORT (LRC), UK CA (LRC) & AUSTRALIAN SPECS) (860SJ HC3) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 2-38. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ D2011 (HIGH TEMP MARKETS) (ANSI EXPORT (LRC), UK CA (LRC) & AUSTRALIAN SPECS) (860SJ HC3) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 2-39. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH DIGITAL DISPLAY (ANSI, ANSI EXPORT (HRC), CSA, RUSSIA, JAPANESE AND CHINA SPECS) (860SJ HC3)

FIGURE 2-40. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT (HRC), CSA, RUSSIA, JAPANESE AND CHINA SPECS) (860SJ HC3) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 2-41. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT (HRC), CSA, RUSSIA, JAPANESE AND CHINA SPECS) (860SJ HC3) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 2-42. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) (CE & UK CA SPECS) (860SJ HC3) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 2-43. GROUND CONTROL BOX ASSEMBLY - WITH DEUTZ TD2.9L4 (STAGE V) (CE & UK CA SPECS) (860SJ HC3) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 2-44. GROUND CONTROL BOX ASSEMBLY - WITH FORD DF 2.5L - WITH DIGITAL DISPLAY (ANSI, ANSI EXPORT, AUSTRALIAN AND CSA SPECS) (860SJ HC3)

FIGURE 2-45. GROUND CONTROL BOX ASSEMBLY - WITH FORD DF 2.5L - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, AUSTRALIAN AND CSA SPECS) (860SJ HC3) (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 2-46. GROUND CONTROL BOX ASSEMBLY - WITH FORD DF 2.5L - WITH MECHANICAL HOUR METER (ANSI, ANSI EXPORT, AUSTRALIAN AND CSA SPECS) (860SJ HC3) (SN 0300298220 to Present, Including 0300295807)

FIGURE 2-47. LIGHT PANEL INSTALLATION (MACHINES WITH SN STARTING WITH 03) (CE & UK CA SPEC MACHINES WITH SN STARTING WITH B3)

FIGURE 2-48. LIGHT PANEL INSTALLATION (ALL SPEC EXCEPT CE & UK CA SPEC MACHINES WITH SN STARTING WITH B3)

FIGURE 2-49. ALARM INSTALLATION

FIGURE 2-50. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ D2011 ENGINES)

FIGURE 2-51. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-52. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-53. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 (STAGE V) ENGINES) (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-54. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 (STAGE V) ENGINES) (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-55. EXHAUST STACK INSTALLATION - STEEL HOOD WITH HOSTILE ENVIRONMENT MACHINES (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-56. EXHAUST STACK INSTALLATION - STEEL HOOD WITH HOSTILE ENVIRONMENT MACHINES (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-57. EXHAUST STACK INSTALLATION - STEEL HOOD (FORD DF 2.5L ENGINES)

FIGURE 2-58. HOODS INSTALLATION - ABS (DEUTZ D2011 ENGINES)

FIGURE 2-59. HOODS INSTALLATION - STEEL (DEUTZ D2011 ENGINES)

FIGURE 2-60. HOODS INSTALLATION - ABS (DEUTZ TD2.9L4 (STAGE V) ENGINES) (CE & UK CA SPECS)

FIGURE 2-61. HOODS INSTALLATION – STEEL (DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES) (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-62. HOODS INSTALLATION - STEEL (DEUTZ TD2.9L4 (STAGE V) ENGINES) (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-63. HOODS INSTALLATION - STEEL (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-64. HOODS INSTALLATION – STEEL WITH HOSTILE ENVIRONMENT MACHINES (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-65. HOODS INSTALLATION – STEEL WITH HOSTILE ENVIRONMENT MACHINES (DEUTZ TD2.9L4 ENGINES) (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-66. HOODS INSTALLATION – STEEL (FORD DF 2.5L ENGINES)

FIGURE 2-67. HOOD ASSEMBLY - ENGINE SIDE REAR (DEUTZ TD2.9L4 ENGINES)

FIGURE 2-68. HOOD ASSEMBLY - ENGINE SIDE REAR (DEUTZ TD2.9L4 (STAGE V) ENGINES)

FIGURE 2-69. HOOD ASSEMBLY - TANK SIDE REAR (DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES)

FIGURE 2-70. LIFTING PLATE INSTALLATION

FIGURE 2-71. SKYAIR AIR COMPRESSOR INSTALLATION (DEUTZ D2011 AND FORD DF 2.5L ENGINES)

FIGURE 2-72. SKYAIR AIR COMPRESSOR INSTALLATION (DEUTZ TD2.9L4 ENGINES)

FIGURE 2-73. AIR COMPRESSOR ASSEMBLY

FIGURE 2-74. STROBE LIGHT INSTALLATION (AMBER) (ALL SPECS EXCEPT CHINA SPEC) (WITHOUT CLEARSKY BEACON) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 2-75. STROBE LIGHT INSTALLATION (AMBER) (ALL SPECS EXCEPT CHINA SPEC) (WITHOUT CLEARSKY BEACON) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 2-76. STROBE LIGHT INSTALLATION (AMBER) (CHINA SPEC) (WITHOUT CLEARSKY BEACON)

FIGURE 2-77. STROBE LIGHT INSTALLATION (BLUE) (WITHOUT CLEARSKY BEACON)

FIGURE 2-78. STROBE LIGHT INSTALLATION (RED) (WITHOUT CLEARSKY BEACON)

FIGURE 2-79. WHITE NOISE ALARM INSTALLATION - AMBIENT

FIGURE 2-80. WHITE NOISE ALARM INSTALLATION - CONSTANT

FIGURE 2-81. WHITE NOISE ALARM HARNESS

SECTION 3 - ENGINE

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

FIGURE 3-2. DEUTZ D2011 ENGINE INSTALLATION - (WITH ARCTIC PACKAGE) (WITH 25 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-3. DEUTZ D2011 ENGINE INSTALLATION - (WITH ARCTIC PACKAGE) (WITH 47.8 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-4. DEUTZ D2011 ENGINE INSTALLATION (HIGH TEMP MARKETS)

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

FIGURE 3-6. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY - (WITH ARCTIC PACKAGE) (WITH 25 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-7. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY - (WITH ARCTIC PACKAGE) (WITH 47.8 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-8. DEUTZ D2011 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-9. DEUTZ D2011 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-10. DEUTZ D2011 ENGINE COMPONENTS

FIGURE 3-11. DEUTZ TD2.9L4 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)

FIGURE 3-12. DEUTZ TD2.9L4 ENGINE INSTALLATION - (WITH ARCTIC PACKAGE) (WITH 25 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-13. DEUTZ TD2.9L4 (STAGE V) ENGINE INSTALLATION

FIGURE 3-14. DEUTZ TD2.9L4 ENGINE INSTALLATION - (WITH ARCTIC PACKAGE) (WITH 47.8 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-15. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA III ENGINES)

FIGURE 3-16. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA IV ENGINES)

FIGURE 3-17. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-18. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY - (WITH ARCTIC PACKAGE) (WITH 25 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-19. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY - (WITH ARCTIC PACKAGE) (WITH 47.8 GAL CAPACITY HYDRAULIC TANK)

FIGURE 3-20. DEUTZ TD2.9L4 (STAGE V) ENGINE AND PUMP SUB-ASSEMBLY

FIGURE 3-21. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA III ENGINES)

FIGURE 3-22. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA IV ENGINES)

FIGURE 3-23. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-24. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-25. DEUTZ TD2.9L4 ENGINE ASSEMBLY (STAGE V)

FIGURE 3-26. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA III ENGINES)

FIGURE 3-27. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA IV ENGINES) (Prior to SN B300017278)

FIGURE 3-28. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA IV ENGINES) (SN B300017278 to Present)

FIGURE 3-29. DEUTZ TD2.9L4 ENGINE COMPONENTS

FIGURE 3-30. DEUTZ TD2.9L4 ENGINE COMPONENTS (STAGE V)

FIGURE 3-31. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA III ENGINES)

FIGURE 3-32. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA IV ENGINES)

FIGURE 3-33. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES)

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

FIGURE 3-35. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES) (CHINA III & CHINA IV ENGINES) (Prior to SN B300017849)

FIGURE 3-36. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES) (CHINA III & CHINA IV ENGINES) (SN B300017849 to Present)

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

FIGURE 3-38. FORD ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)

FIGURE 3-39. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-40. FORD ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-41. FORD ENGINE PREP ASSEMBLY

FIGURE 3-42. FORD ENGINE BRACKETS AND EXHAUST MANIFOLD INSTALLATION

FIGURE 3-43. FORD ENGINE DRIVE BELT INSTALLATION (MACHINES WITHOUT GENERATOR)

FIGURE 3-44. FORD ENGINE COMPONENTS

FIGURE 3-45. PUMP COUPING KIT (DEUTZ ENGINES)

FIGURE 3-46. HYDROSTATIC PUMP ASSEMBLY

FIGURE 3-47. VARIABLE PUMP ASSEMBLY (ALL ENGINES EXCEPT DEUTZ TD2.9L4 (STAGE V))

FIGURE 3-48. VARIABLE PUMP ASSEMBLY (DEUTZ TD 2.9L4 (STAGE V) & CHINA IV ENGINES)

FIGURE 3-49. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-50. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-51. EXHAUST PIPE INSTALLATION - FORD DF 2.5L ENGINES

FIGURE 3-52. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES

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

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

FIGURE 3-55. FUEL FILTER ASSEMBLY (DEUTZ TD2.9L4 ENGINES)

FIGURE 3-56. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITHOUT GENERATORS)

FIGURE 3-57. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)

FIGURE 3-58. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ TD2.9L4 AND DEUTZ 2.9L4 (STAGE V) ENGINES WITH ABS HOODS

FIGURE 3-59. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ TD2.9L4 AND DEUTZ 2.9L4 (STAGE V) ENGINES WITH STEEL HOODS

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

FIGURE 3-61. ENGINE TRAY JACK INSTALLATION - FORD ENGINES

FIGURE 3-62. QUICKFIT OIL DRAIN VALVE (DEUTZ ENGINES)

FIGURE 3-63. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-64. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-65. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-66. 2500W/110V/60HZ GENERATOR INSTALLATION - FORD ENGINES

FIGURE 3-67. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-68. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-69. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-70. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-71. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-72. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-73. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-74. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 3-75. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION – FORD DF 2.5L ENGINES

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION (800S HC3) (Prior to SN 0300297258)

FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION (800S HC3) (SN 0300297258 to Present)

FIGURE 4-3. BOOM AND CYLINDERS INSTALLATION (MACHINES WITH SN STARTING WITH 03) (860SJ HC3)

FIGURE 4-4. BOOM AND CYLINDERS INSTALLATION (MACHINES WITH SN STARTING WITH B3) (860SJ HC3)

FIGURE 4-5. MAIN BOOM ASSEMBLY (800S HC3) (Prior to SN 0300296333, Excluding 0300295806)

FIGURE 4-6. MAIN BOOM ASSEMBLY (800S HC3) (SN 0300296333 to Present, Including 0300295806)

FIGURE 4-7. MAIN BOOM ASSEMBLY (MACHINES WITH SN STARTING WITH 03) (860SJ HC3)

FIGURE 4-8. MAIN BOOM ASSEMBLY (MACHINES WITH SN STARTING WITH B3) (860SJ HC3)

FIGURE 4-9. JIB ASSEMBLY (860SJ HC3)

FIGURE 4-10. ROTATOR ASSEMBLY (860SJ HC3)

FIGURE 4-11. PLATFORM SUPPORT INSTALLATION

FIGURE 4-12. CONTROL VALVE INSTALLATION (800S HC3)

FIGURE 4-13. CONTROL VALVE INSTALLATION (860SJ HC3)

FIGURE 4-14. PLATFORM VALVE ASSEMBLY (800S HC3)

FIGURE 4-15. PLATFORM VALVE ASSEMBLY (860SJ HC3)

FIGURE 4-16. POWER TRACK INSTALLATION - MAIN BOOM (800S HC3)

FIGURE 4-17. POWER TRACK INSTALLATION - MAIN BOOM (860SJ HC3)

FIGURE 4-18. POWER TRACK SUPPORT BRACKET INSTALLATION

FIGURE 4-19. LIMIT SWITCHES AND COVERS INSTALLATION (800S HC3)

FIGURE 4-20. LIMIT SWITCHES AND COVERS INSTALLATION (860SJ HC3)

FIGURE 4-21. SENSOR ASSEMBLY - LOWER

SECTION 5 - PLATFORM

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

FIGURE 5-2. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 4FT (76CM X 1.22M) (SAE MATERIAL)

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

FIGURE 5-4. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 5FT (76CM X 1.52M) (SAE MATERIAL)

FIGURE 5-5. PLATFORM ASSEMBLY WITH DROP BAR - 30IN X 5FT (76CM X 1.52M) (METRIC MATERIAL)

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

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

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

FIGURE 5-9. PLATFORM ASSEMBLY WITH DROP BAR - 36IN X 8FT (91.5CM X 2.44M) (METRIC MATERIAL)

FIGURE 5-10. PLATFORM ASSEMBLY WITH SWING GATE - 30IN X 4FT (76CM X 1.22M) (SAE MATERIAL)

FIGURE 5-11. PLATFORM ASSEMBLY WITH SWING GATE - 30IN X 4FT (76CM X 1.22M) (METRIC MATERIAL)

FIGURE 5-12. PLATFORM ASSEMBLY WITH SWING GATE - 30IN X 5FT (76CM X 1.52M) (SAE MATERIAL)

FIGURE 5-13. PLATFORM ASSEMBLY WITH SWING GATE - 30IN X 5FT (76CM X 1.52M) (METRIC MATERIAL)

FIGURE 5-14. PLATFORM ASSEMBLY WITH SWING GATE - 36IN X 6FT (91.5CM X 1.83M) (SAE MATERIAL)

FIGURE 5-15. PLATFORM ASSEMBLY WITH SWING GATE - 36IN X 6FT (91.5CM X 1.83M) (METRIC MATERIAL)

FIGURE 5-16. PLATFORM ASSEMBLY WITH SWING GATE - 36IN X 8FT (91.5CM X 2.44M) (SAE MATERIAL)

FIGURE 5-17. PLATFORM ASSEMBLY WITH SWING GATE - 36IN X 8FT (91.5CM X 2.44M) (METRIC MATERIAL)

FIGURE 5-18. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-19. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-20. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-21. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-22. PLATFORM ASSEMBLY WITH FALL ARREST (6FT)

FIGURE 5-23. PLATFORM ASSEMBLY WITH FALL ARREST (8FT)

FIGURE 5-24. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION

FIGURE 5-25. PLATFORM CONSOLE ASSEMBLY

FIGURE 5-26. FOOTSWITCH ASSEMBLY

FIGURE 5-27. CONTROLLER ASSEMBLY - LIFT/SWING

FIGURE 5-28. CONTROLLER ASSEMBLY- DRIVE/STEER

FIGURE 5-29. LIGHT PANEL INSTALLATION (MACHINES WITH SN STARTING WITH 03) (CE & UK CA SPEC MACHINES WITH SN STARTING WITH B3)

FIGURE 5-30. LIGHT PANEL INSTALLATION (ALL SPEC EXCEPT CE & UK CA SPEC MACHINES WITH SN STARTING WITH B3)

FIGURE 5-31. JIB SWITCH INSTALLATION (860SJ HC3)

FIGURE 5-32. SKYEYE INSTALLATION

FIGURE 5-33. SKYGUARD BAR INSTALLATION

FIGURE 5-34. SKYLINE INSTALLATION

FIGURE 5-35. STORAGE TRAY INSTALLATION - CENTER

FIGURE 5-36. SKYCUTTER INSTALLATION

FIGURE 5-37. SKYGLAZIER INSTALLATION (UNIVERSAL LANGUAGE) (ANSI, ANSI EXPORT, CSA, AND AUSTRALIAN SPECS)

FIGURE 5-38. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)

FIGURE 5-39. PLASMA CUTTER ASSEMBLY

FIGURE 5-40. SKYWELDER INSTALLATION (50HZ)

FIGURE 5-41. SKYWELDER INSTALLATION (60HZ)

FIGURE 5-42. WELDER ASSEMBLY

FIGURE 5-43. SKYWELDER PREP PACKAGE (60HZ)

FIGURE 5-44. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M PLATFORM

FIGURE 5-45. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM

FIGURE 5-46. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM

FIGURE 5-47. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM

FIGURE 5-48. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)

FIGURE 5-49. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.82M PLATFORM)

FIGURE 5-50. FALL ARREST INSTALLATION (BOLT-ON) (8FT/2.4M PLATFORM)

FIGURE 5-51. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.82M TRI-ENTRY PLATFORM)

FIGURE 5-52. 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 (860SJ HC3)

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB (800S HC3) (Prior to SN 0300297258)

FIGURE 6-5. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (800S HC3) (SN 0300297258 to Present)

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - JIB (860SJ HC3)

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - JIB (860SJ HC3)

FIGURE 6-8. LIFT CYLINDER ASSEMBLY - JIB (860SJ HC3)

FIGURE 6-9. LIFT CYLINDER ASSEMBLY - MAIN BOOM (800S HC3) (Prior to SN 0300297258)

FIGURE 6-10. LIFT CYLINDER ASSEMBLY - MAIN BOOM (800S HC3) (SN 0300297258 to Present)

FIGURE 6-11. LIFT CYLINDER ASSEMBLY - MAIN BOOM (860SJ HC3)

FIGURE 6-12. STEER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 6-13. STEER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)

FIGURE 6-14. TELESCOPE CYLINDER ASSEMBLY (800S HC3) (Prior to SN 0300296333, Excluding 0300295806)

FIGURE 6-15. TELESCOPE CYLINDER ASSEMBLY (800S HC3) (SN 0300296333 to Present, Including 0300295806)

FIGURE 6-16. TELESCOPE CYLINDER ASSEMBLY (860SJ HC3)

SECTION 7 - HYDRAULIC

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

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

FIGURE 7-3. HYDRAULIC DIAGRAM - DRIVE (4WD WITH ARCTIC PACKAGE)

FIGURE 7-4. HYDRAULIC DIAGRAM - DRIVE (4WD WITH TOW BAR PACKAGE)

FIGURE 7-5. HYDRAULIC DIAGRAM - DRIVE (4WD WITH ARCTIC & TOW BAR PACKAGE)

FIGURE 7-6. HYDRAULIC DIAGRAM - STANDARD (WITHOUT TOW BAR PACKAGE) (SN STARTING WITH 03) (800S HC3)

FIGURE 7-7. HYDRAULIC DIAGRAM - STANDARD (WITHOUT TOW BAR PACKAGE) (SN STARTING WITH 03) (860SJ HC3)

FIGURE 7-8. HYDRAULIC DIAGRAM - STANDARD (WITHOUT TOW BAR PACKAGE) (SN STARTING WITH B3) (860SJ HC3)

FIGURE 7-9. HYDRAULIC DIAGRAM - STANDARD (WITH TOW BAR PACKAGE) (SN STARTING WITH 03) (800S HC3)

FIGURE 7-10. HYDRAULIC DIAGRAM - STANDARD (WITH TOW BAR PACKAGE) (SN STARTING WITH 03) (860SJ HC3)

FIGURE 7-11. HYDRAULIC DIAGRAM - STANDARD (WITH TOW BAR PACKAGE) (SN STARTING WITH B3) (860SJ HC3)

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V GFI RECEPTACLE (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 220V (ANSI, CSA & JAPANESE SPECS)

FIGURE 8-3. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR) (ANSI EXPORT, AUSTRALIAN, CE & UK CA SPECS)

FIGURE 8-4. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT GENERATOR) (CHINA SPECS)

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (RUSSIAN, CE, & UK CA SPECS)

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITH 2500W GENERATOR (RUSSIAN, CE & UK CA SPECS)

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (RUSSIAN, CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

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

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITH 2500W GENERATOR (RUSSIAN, CE & UK CA SPECS)

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

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

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITH 2500W GENERATOR (RUSSIAN, CE & UK CA SPECS)

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (RUSSIAN, CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (RUSSIAN, CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITH 2500W GENERATOR (RUSSIAN, CE & UK CA SPECS)

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (RUSSIAN, CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (RUSSIAN, CE & UK CA SPECS) (MACHINES WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-18. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITH 2500W GENERATOR (RUSSIAN, CE & UK CA SPECS)

FIGURE 8-19. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (RUSSIAN, CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)

FIGURE 8-20. AC BOX AT PLATFORM INSTALLATION - 220V (2X4 BOX & COVER ONLY - LOCALLY SUPPLIED RECEPTACLE) (4000W GENERATOR)

FIGURE 8-21. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI, ANSI EXPORT AND CSA SPECS WITH 4000W SKYPOWER GENERATOR)

FIGURE 8-22. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI AND CSA SPECS WITH 7500W SKYPOWER GENERATOR)

FIGURE 8-23. AC CABLE WITH 16 AMP BREAKER INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR) (CE & UK CA SPECS)

FIGURE 8-24. AC CABLE WITH 10 AMP BREAKER INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR) (CE & UK CA SPECS)

FIGURE 8-25. ANALYZER CABLE HARNESS

FIGURE 8-26. BATTERY DISCONNECT SWITCH INSTALLATION

FIGURE 8-27. BEACON CONTROL HARNESS (BLUE AND RED STROBE LIGHTS)

FIGURE 8-28. BOOM CABLES INSTALLATION - WITHOUT ARCTIC PACKAGE (ALL SPECS) (860SJ HC3)

FIGURE 8-29. BOOM CABLES INSTALLATION - WITH ARCTIC PACKAGE (ANSI, ANSI EXPORT AND CSA SPECS) (860SJ HC3)

FIGURE 8-30. BOOM CABLES INSTALLATION - WITH 4000W GENERATOR AND WITHOUT ARCTIC PACKAGE (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS) (860SJ HC3)

FIGURE 8-31. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR AND WITHOUT ARCTIC PACKAGE (ALL SPECS) (860SJ HC3)

FIGURE 8-32. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR AND WITH ARCTIC PACKAGE (ANSI, ANSI EXPOERT AND CSA SPECS) (860SJ HC3)

FIGURE 8-33. BOOM CABLES INSTALLATION - WITHOUT AC CABLES (RUSSIAN AND CHINA SPECS) (860SJ HC3)

FIGURE 8-34. BOOM HARNESS (MAIN BOOM) (WITHOUT ARCTIC PACKAGE) (860SJ HC3)

FIGURE 8-35. BOOM HARNESS (MAIN BOOM) (WITH ARCTIC PACKAGE) (860SJ HC3)

FIGURE 8-36. BOOM HARNESS (MAIN BOOM) (WITH ARCTIC PACKAGE) (800S HC3)

FIGURE 8-37. BOOM CABLE (MAIN BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-38. BOOM CABLE (TOWER BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-39. BOOM CABLE (TOWER BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-40. BOOM CABLES INSTALLATION - WITHOUT ARCTIC PACKAGE (ALL SPECS EXCEPT AUSTRALIAN SPECS) (800S HC3)

FIGURE 8-41. BOOM CABLES INSTALLATION - WITH ARCTIC PACKAGE (ANSI, ANSI EXPORT AND CSA SPECS) (800S HC3)

FIGURE 8-42. BOOM CABLES INSTALLATION - WITH 4000W GENERATOR AND WITHOUT ARCTIC PACKAGE (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS) (800S HC3)

FIGURE 8-43. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR AND WITHOUT ARCTIC PACKAGE (ANSI, ANSI EXPORT, CSA, RUSSIA AND JAPANESE SPECS) (800S HC3)

FIGURE 8-44. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR AND WITH ARCTIC PACKAGE (ANSI, ANSI EXPORT AND CSA SPECS) (800S HC3)

FIGURE 8-45. BOOM CABLES INSTALLATION - WITHOUT ARCTIC PACKAGE (ALL SPECS EXCEPT CHINEASE SPECS) (860SJ HC3)

FIGURE 8-46. BOOM CABLES INSTALLATION - WITH ARCTIC PACKAGE (ANSI, ANSI EXPORT AND CSA SPECS) (860SJ HC3)

FIGURE 8-47. BOOM CABLES INSTALLATION - WITH 4000W GENERATOR AND WITHOUT ARCTIC PACKAGE (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS) (860SJ HC3)

FIGURE 8-48. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR AND WITHOUT ARCTIC PACKAGE (ALL SPECS) (860SJ HC3)

FIGURE 8-49. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR AND WITH ARCTIC PACKAGE (ANSI, ANSI EXPOERT AND CSA SPECS) (860SJ HC3)

FIGURE 8-50. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (CE & UK CA SPECS WITHOUT 7500W GENERATOR)

FIGURE 8-51. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (WITH 4000W/50HZ GENERATOR)

FIGURE 8-52. BREAKER BOX KIT - 10 AMP (CE & UK CA SPECS WITHOUT 7500W GENERATOR)

FIGURE 8-53. CLEARSKY 3-WIRE TELEMATICS INSTALLATION (ALL SPECS EXCEPT UL & CHINA SPECS)

FIGURE 8-54. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (ANSI EXPORT, RUSSIAN, CE & UK CA SPECS)

FIGURE 8-55. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (AUSTRALIAN SPECS)

FIGURE 8-56. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (ANSI & CSA SPECS)

FIGURE 8-57. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (CHINA SPECS)

FIGURE 8-58. CLEARSKY CS550 BEACON INSTALLATION

FIGURE 8-59. CLEARSKY HARNESS - 3-WIRE TELEMATICS

FIGURE 8-60. CLEARSKY HARNESS - CANBUS TELEMATICS

FIGURE 8-61. ENGINE HARNESS - DEUTZ D2011 ENGINES (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 8-62. ENGINE HARNESS - DEUTZ D2011 ENGINES (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 8-63. ENGINE HARNESS - DEUTZ D2011 ENGINES (CE, CHINA & UK CA SPECS) (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 8-64. ENGINE HARNESS - DEUTZ D2011 ENGINES (CE, CHINA & UK CA SPECS) (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

FIGURE 8-65. ENGINE HARNESS - DEUTZ TD2.9L4 AND DEUTZ 2.9L4 (STAGE V) ENGINES (Prior to SN B300017904, Prior to SN 0300298220, Excluding 0300295807)

FIGURE 8-66. ENGINE HARNESS - DEUTZ TD2.9L4 AND DEUTZ 2.9L4 (STAGE V) ENGINES (SN B00017904 to Present, SN 0300298220 to Present, Including 0300295807)

FIGURE 8-67. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-68. ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V & CHINA IV) ENGINES (Prior to SN B300017278)

FIGURE 8-69. ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V & CHINA IV) ENGINES (SN STARTING WITH 03 & B300017278 TO PRESENT)

FIGURE 8-70. ENGINE HARNESS - FORD DF 2.5L ENGINES (Prior to SN 0300298220, Excluding 0300295807)

FIGURE 8-71. ENGINE HARNESS - FORD DF 2.5L ENGINES (SN 0300298220 to Present, Including 0300295807)

FIGURE 8-72. FUEL PUMP HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-73. FUEL HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE

FIGURE 8-74. GENERATOR TO ENGINE HARNESS - 2500W (FORD ENGINES)

FIGURE 8-75. GENERATOR TO ENGINE HARNESS - 4000W/50HZ (DEUTZ D2011 ENGINES)

FIGURE 8-76. GENERATOR TO ENGINE HARNESS - 4000W/60HZ (DEUTZ ENGINES)

FIGURE 8-77. GENERATOR TO ENGINE HARNESS - 4000W/50HZ (DEUTZ TD2.9L4 ENGINES)

FIGURE 8-78. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ENGINES)

FIGURE 8-79. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (DEUTZ TD2.9L4 T4F ENGINES)

FIGURE 8-80. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES)

FIGURE 8-81. GENERATOR TO REAR OF BOOM HARNESS - 110V

FIGURE 8-82. GENERATOR TO REAR OF BOOM HARNESS - 220V

FIGURE 8-83. GROUND CONTROL BOX HARNESS (Prior to SN B300017904, Prior to SN 0300298220, Excluding 0300295807)

FIGURE 8-84. GROUND CONTROL BOX HARNESS (SN B00017904 to Present, SN 0300298220 to Present, Including 0300295807)

FIGURE 8-85. HOLDING VALVE/LIFT DUMP HARNESS ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 8-86. HOLDING VALVE/LIFT DUMP HARNESS ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 8-87. PLATFORM CONSOLE BOX HARNESS

FIGURE 8-88. RECEPTACLE BOX KIT - 110V IEC YELLOW WITHOUT 2500W GENERATOR (CE & UK CA SPECS)

FIGURE 8-89. RECEPTACLE BOX KIT - 110V IEC YELLOW WITH 2500W GENERATOR (CE & UK CA SPECS)

FIGURE 8-90. RECEPTACLE BOX KIT - 220V IEC BLUE WITHOUT 2500W GENERATOR (CE & UK CA SPECS)

FIGURE 8-91. RECEPTACLE BOX KIT - 220V IEC BLUE WITH 2500W GENERATOR (CE & UK CA SPECS)

FIGURE 8-92. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE & UK CA SPEC) (WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-93. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE & UK CA SPEC) (WITH 2500W GENERATOR)

FIGURE 8-94. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 BOX (CE & UK CA SPEC) (WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-95. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 BOX (CE & UK CA SPEC) (WITH 2500W GENERATOR)

FIGURE 8-96. RECEPTACLE BOX KIT - 220V AFSINT107 KEYED GROUND (CE & UK CA SPECS) (WITH 2500W GENERATOR OR NO GENERATOR OPTION)

FIGURE 8-97. RECEPTACLE BOX KIT - 220V AFSINT107 KEYED GROUND (CE & UK CA SPECS) (WITH 2500W GENERATOR)

FIGURE 8-98. SKYEYE INTERMEDIATE HARNESS

FIGURE 8-99. SKYEYE RECEIVER HARNESS

FIGURE 8-100. SKYEYE EMITTER HARNESS

FIGURE 8-101. SKYLINE HARNESS

FIGURE 8-102. SKYGUARD INERFACE HARNESS

FIGURE 8-103. TILT SENSOR HARNESS

FIGURE 8-104. VALVE HARNESS (Prior to SN 0300298220, Prior to SN B300017904, Excluding 0300295807)

FIGURE 8-105. VALVE HARNESS (SN 0300298220 to Present, SN B300017904 to Present, Including 0300295807)

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION (ANSI SPECS) (800S HC3)

FIGURE 9-2. DECAL INSTALLATION (ANSI SPECS) (860SJ HC3)

FIGURE 9-3. DECAL INSTALLATION (AUSTRALIAN SPECS) (860SJ HC3)

FIGURE 9-4. DECAL INSTALLATION (BRAZILIAN SPECS) (800S HC3)

FIGURE 9-5. DECAL INSTALLATION (BRAZILIAN SPECS) (860SJ HC3)

FIGURE 9-6. DECAL INSTALLATION (CE & UK CA SPECS) (860SJ HC3)

FIGURE 9-7. DECAL INSTALLATION (CHINESE SPECS) (800S HC3)

FIGURE 9-8. DECAL INSTALLATION (CHINESE SPECS) (860SJ HC3)

FIGURE 9-9. DECAL INSTALLATION (CSA SPECS) (800S HC3)

FIGURE 9-10. DECAL INSTALLATION (CSA SPECS) (860SJ HC3)

FIGURE 9-11. DECAL INSTALLATION (JAPANESE SPECS) (800S HC3)

FIGURE 9-12. DECAL INSTALLATION (JAPANESE SPECS) (860SJ HC3)

FIGURE 9-13. DECAL INSTALLATION (KOREAN SPECS) (800S HC3)

FIGURE 9-14. DECAL INSTALLATION (KOREAN SPECS) (860SJ HC3)

FIGURE 9-15. DECAL INSTALLATION (LATIN AMERICAN SPECS) (800S HC3)

FIGURE 9-16. DECAL INSTALLATION (LATIN AMERICAN SPECS) (860SJ HC3)

FIGURE 9-17. DECAL INSTALLATION - OPTIONS

FIGURE 9-18. SKYCUTTER DECAL INSTALLATION (ANSI, ANSI EXPORT & CSA SPECS)

FIGURE 9-19. SKYCUTTER DECAL INSTALLATION (JAPANESE SPECS)

FIGURE 9-20. SKYWELDER DECAL INSTALLATION - 50HZ

FIGURE 9-21. SKYWELDER DECAL INSTALLATION - 60HZ

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS

PART NUMBER INDEX

JLG Boom Lift 800S HC3 860SJ HC3 Parts Catalog 31220671

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