JLG Boom Lift H800AJ Parts Manual 31222489

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JLG Boom Lift H800AJ Parts Manual 31222489
Size: 34.10 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG H800AJ Boom Lift
Part Number: 31222489
Publication Date: 2024
Number of Pages: 498 Pages

Contents:
SECTION 1 - FRAME

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

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

FIGURE 1-3. STEER INSTALLATION - WITHOUT TOW PACKAGE​

FIGURE 1-4. STEER INSTALLATION - WITH TOW PACKAGE​

FIGURE 1-5. WHEEL DRIVE AND FRAME VALVES INSTALLATION​

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY​

FIGURE 1-7. DRIVE MOTOR ASSEMBLY​

FIGURE 1-8. TIRE & WHEEL INSTALLATION - 15-625 NHS FOAM-FILLED​

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

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 18-625 NHS FOAM-FILLED NON-MARKING​

FIGURE 1-11. FRAME SHIELDS INSTALLATION​

FIGURE 1-12. TOW PACKAGE INSTALLATION (OPTIONAL) (ANSI, SPECS)​

FIGURE 1-13. TOW BAR ASSEMBLY​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVES INSTALLATION​

FIGURE 2-2. MAIN VALVE ASSEMBLY​

FIGURE 2-3. BRAKE/2 SPEED VALVE ASSEMBLY​

FIGURE 2-4. SWING DRIVE INSTALLATION​

FIGURE 2-5. SWING MOTOR/HUB ASSEMBLY​

FIGURE 2-6. TURNTABLE BEARING AND LUBE INSTALLATION​

FIGURE 2-7. TURNTABLE LOCK INSTALLATION​

FIGURE 2-8. ROTARY COUPLING INSTALLATION​

FIGURE 2-9. TANKS INSTALLATION​

FIGURE 2-10. HYDRAULIC TANK ASSEMBLY​

FIGURE 2-11. FUEL TANK ASSEMBLY​

FIGURE 2-12. OIL COOLER INSTALLATION​

FIGURE 2-13. BATTERY BOXES INSTALLATION​

FIGURE 2-14. BATTERY CHARGERS INSTALLATION (FACTORY SUPPLIED 220V PLUG)​

FIGURE 2-15. BATTERY CHARGERS INSTALLATION (CUSTOMER SUPPLIED PLUG)​

FIGURE 2-16. ELECTRICAL SYSTEM INSTALLATION​

FIGURE 2-17. IMG CONTROL BOX ASSEMBLY​

FIGURE 2-18. ELECTRICAL ASSEMBLY - 12V FUSE BOX​

FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY​

FIGURE 2-20. LIGHT PANEL INSTALLATION - GROUND CONTROL​

FIGURE 2-21. GROUND CONTROL PANEL DECAL INSTALLATION (WITHOUT MSSO & WITHOUT TOWER STOW)​

FIGURE 2-22. GROUND CONTROL PANEL DECAL INSTALLATION (WITHOUT MSSO & WITH TOWER STOW)​

FIGURE 2-23. GROUND CONTROL PANEL DECAL INSTALLATION (WITH MSSO & WITHOUT TOWER STOW)​

FIGURE 2-24. GROUND CONTROL PANEL DECAL INSTALLATION (WITH MSSO & WITH TOWER STOW)​

FIGURE 2-25. ALARM INSTALLATION​

FIGURE 2-26. WHITE NOISE ALARM INSTALLATION - ADJUSTABLE AMBIENT​

FIGURE 2-27. WHITE NOISE MOTION ALARM INSTALLATION - AMBIENT​

FIGURE 2-28. STROBE LIGHT INSTALLATION - AMBER​

FIGURE 2-29. STROBE LIGHT INSTALLATION - BLUE​

FIGURE 2-30. STROBE LIGHT INSTALLATION - RED (OPTIONAL)​

FIGURE 2-31. HEAT SHIELD AND ACCESS PANELS INSTALLATION​

FIGURE 2-32. HOODS INSTALLATION​

FIGURE 2-33. HOOD ASSEMBLY - TANK SIDE​

FIGURE 2-34. HOOD ASSEMBLY - ENGINE SIDE​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION (KUBOTA ENGINE)​

FIGURE 3-2. ENGINE AND PUMPS SUB-ASSEMBLY​

FIGURE 3-3. ENGINE AND TRAY ASSEMBLY​

FIGURE 3-4. ENGINE AND GENERATOR ASSEMBLY​

FIGURE 3-5. ENGINE AND CLUTCH ASSEMBLY​

FIGURE 3-6. ENGINE FAN MOUNTING ASSEMBLY (H800AJ)​

FIGURE 3-7. KUBOTA ENGINE COMPONENTS​

FIGURE 3-8. GENERATOR ASSEMBLY​

FIGURE 3-9. VARIABLE PUMP ASSEMBLY​

FIGURE 3-10. HYDROSTATIC PUMP ASSEMBLY​

FIGURE 3-11. FUEL/WATER SEPARATOR ASSEMBLY​

FIGURE 3-12. ENGINE HOOD BAFFLES INSTALLATION​

FIGURE 3-13. TRAY JACK INSTALLATION​

FIGURE 3-14. 4000W GENERATOR INSTALLATION - 220V/50HZ (OPTIONAL)​

FIGURE 3-15. 7500W SKYPOWER GENERATOR INSTALLATION - 220V/50HZ (OPTIONAL)​

FIGURE 3-16. 7500W SKYPOWER GENERATOR INSTALLATION - 110V/60HZ (OPTIONAL)​

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. POWER TRACK INSTALLATION - MAIN BOOM​

FIGURE 4-7. POWER TRACK INSTALLATION - TOWER BOOM​

FIGURE 4-8. BOOM VALVES INSTALLATION​

FIGURE 4-9. BOOM VALVE ASSEMBLY​

FIGURE 4-10. BOOM VALVE AND LIMIT SWITCHES INSTALLATION (WITHOUT TOWER STOW)​

FIGURE 4-11. BOOM VALVE AND LIMIT SWITCHES INSTALLATION (WITH TOWER STOW)​

FIGURE 4-12. TILT SENSOR INSTALLATION​

FIGURE 4-13. TRANSPORT POSITION SWITCH INSTALLATION (CE & UK CA SPECS)​

FIGURE 4-14. PLATFORM SUPPORT INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) WITH SWING GATE​

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

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) WITH SWING GATE​

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

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

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

FIGURE 5-7. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (ANSI, ANSI EXPORT, CHINA & CSA SPECS)​

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

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

FIGURE 5-10. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST​

FIGURE 5-11. TRAY ASSEMBLY​

FIGURE 5-12. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION (WITHOUT TOWER STOW)​

FIGURE 5-13. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION (WITH TOWER STOW)​

FIGURE 5-14. PLATFORM CONSOLE BOX ASSEMBLY (WITHOUT TOWER STOW)​

FIGURE 5-15. PLATFORM CONSOLE BOX ASSEMBLY (WITH TOWER STOW)​

FIGURE 5-16. LIGHT PANEL INSTALLATION​

FIGURE 5-17. JIB SWITCH INSTALLATION​

FIGURE 5-18. FOOTSWITCH ASSEMBLY​

FIGURE 5-19. SOFT TOUCH INSTALLATION - 6FT (1.83M) PLATFORM (OPTIONAL)​

FIGURE 5-20. SOFT TOUCH INSTALLATION - 6FT (1.83M) FALL ARREST PLATFORM (OPTIONAL)​

FIGURE 5-21. SOFT TOUCH INSTALLATION - 8FT (2.4M) PLATFORM (OPTIONAL)​

FIGURE 5-22. SOFT TOUCH INSTALLATION - 8FT (2.4M) FALL ARREST PLATFORM (OPTIONAL)​

FIGURE 5-23. SKYEYE INSTALLATION​

FIGURE 5-24. SKYGUARD BAR INSTALLATION​

FIGURE 5-25. SKYLINE INSTALLATION​

FIGURE 5-26. SKYGLAZIER INSTALLATION (ANSI, ANSI EXPORT, AUSTRALIAN & CSA SPECS)​

FIGURE 5-27. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-28. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-29. SKYWELDER PREP PACKAGE (60HZ)​

FIGURE 5-30. WELDER ASSEMBLY​

FIGURE 5-31. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 4FT (76CM X 1.22M) PLATFORM​

FIGURE 5-32. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.2CM X 1.82M) PLATFORM​

FIGURE 5-33. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 6FT (76CM X 1.83M) PLATFORM​

FIGURE 5-34. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 8FT (91.5CM X 2.4M) PLATFORM​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSMBLY​

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

FIGURE 6-3. LEVEL (SLAVE) 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. AXLE LOCKOUT HYDRAULIC DIAGRAM​

FIGURE 7-2. DRIVE HYDRAULIC DIAGRAM​

FIGURE 7-3. STANDARD HYDRAULIC DIAGRAM​

FIGURE 7-4. TOW HYDRAULIC DIAGRAM​

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 - 110V IEC YELLOW (CE & UK CA SPECS) (MACHINES WITHOUT 4000W GENERATOR)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V (ANSI, CSA & JAPANESE SPECS)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPECS) (MACHINES WITHOUT 4000W GENERATOR)​

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 POST GROUND (CE & UK CA SPECS) (MACHINES WITHOUT 4000W GENERATOR)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 POST GROUND (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 SIDE GROUND (CE & UK CA SPECS) (MACHINES WITHOUT 4000W GENERATOR)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 SIDE GROUND (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE & UK CA SPECS) (MACHINES WITHOUT 4000W GENERATOR)​

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE & UK CA SPECS) (MACHINES WITH 4000W GENERATOR)​

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - BOX WITH COVER (ANSI EXPORT, AUSTRALIAN, CHINA & JAPANESE SPECS)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 240V RECEPTACLE (WITH 4000W GENERATOR) (ALL SPECS EXCEPT ANSI & CSA SPECS)​

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 240V RECEPTACLE (WITH 7500W SKYPOWER GENERATOR) (ANSI & CSA SPECS)​

FIGURE 8-16. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT ANSI & CSA SPECS)​

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

FIGURE 8-18. AC BREAKER BOX INSTALLATION - WITH 2 BREAKERS (CE & UK CA SPECS WITH 4000W GENERATOR)​

FIGURE 8-19. AC BREAKER BOX INSTALLATION - WITH 2 BREAKERS (BRAZIL SPECS)​

FIGURE 8-20. AC BREAKER BOX INSTALLATION - WITH 3 BREAKERS (CE & UK CA SPECS WITH 4000W GENERATOR)​

FIGURE 8-21. BATTERY CABLES INSTALLATION​

FIGURE 8-22. BATTERY STACK HARNESS (LH)​

FIGURE 8-23. BATTERY STACK HARNESS (RH)​

FIGURE 8-24. BOOM VALVE HARNESS​

FIGURE 8-25. BOOM CABLES INSTALLATION (MACHINES WITHOUT GENERATOR)​

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

FIGURE 8-27. BOOM CABLES INSTALLATION (CE & UK CA SPECS WITH 4000W GENERATOR)​

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

FIGURE 8-29. BOOM CABLE - MAIN BOOM​

FIGURE 8-30. BOOM CABLE - TOWER BOOM​

FIGURE 8-31. BREAKER BOX KIT - WITH 2 BREAKERS (CE & UK CA SPECS WITHOUT 4000W GENERATOR & BRAZIL SPECS)​

FIGURE 8-32. BREAKER BOX KIT - WITH 2 BREAKERS (CE & UK CA SPECS WITH 4000W GENERATOR) (H800AJ)​

FIGURE 8-33. BREAKER BOX KIT - WITH 3 BREAKERS (CE & UK CA SPECS WITH 4000W GENERATOR)​

FIGURE 8-34. CLEARSKY INSTALLATION - 3 WIRE GT1030​

FIGURE 8-35. CLEARSKY INSTALLATION - CANBUS (ANSI SPECS)​

FIGURE 8-36. CLEARSKY INSTALLATION - CANBUS (AUSTRALIAN SPECS)​

FIGURE 8-37. CLEARSKY INSTALLATION - CANBUS (CE SPECS)​

FIGURE 8-38. CLEARSKY INSTALLATION - CANBUS (CHINA SPECS)​

FIGURE 8-39. CLEARSKY TELEMATCIS HARNESS (3-WIRE)​

FIGURE 8-40. CLEARSKY TELEMATCIS HARNESS (CANBUS)​

FIGURE 8-41. CHARGER HARNESS​

FIGURE 8-42. CONTROL HARNESS​

FIGURE 8-43. ELECTRICAL SYSTEM INSTALLATION​

FIGURE 8-44. ENGINE HARNESS - KUBOTA​

FIGURE 8-45. ENGINE TRAY HARNESS​

FIGURE 8-46. GENERATOR HARNESS - 4000W​

FIGURE 8-47. GENERATOR HARNESS - 7500W SKYPOWER​

FIGURE 8-48. GENERATOR HARNESS - 4000W AND 7500W SKYPOWER​

FIGURE 8-49. GROUND CONTROL BOX HARNESS​

FIGURE 8-50. H-BRIDGE/CLUTCH HARNESS​

FIGURE 8-51. HYBRID 84V HARNESS​

FIGURE 8-52. HOURMETER JUMPER HARNESS​

FIGURE 8-53. MAIN VALVE HARNESS​

FIGURE 8-54. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-55. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPEC)​

FIGURE 8-56. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPEC)​

FIGURE 8-57. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE & UK CA SPEC)​

FIGURE 8-58. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE & UK CA SPEC)​

FIGURE 8-59. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE & UK CA SPEC)​

FIGURE 8-60. RESOLVER/CONVERTER/INVERTER HARNESS​

FIGURE 8-61. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-62. SKYEYE RECEIVER HARNESS​

FIGURE 8-63. SKYEYE EMITTER HARNESS​

FIGURE 8-64. SKYGUARD INTERFACE HARNESS​

FIGURE 8-65. SKYLINE HARNESS​

FIGURE 8-66. STROBE LIGHT CONTROL HARNESS (BLUE & RED LIGHTS)​

FIGURE 8-67. TURNTABLE HARNESS​

FIGURE 8-68. TURNTABLE/FUSE PANEL HARNESS​

FIGURE 8-69. USB RECEPTACLE INSTALLATION​

FIGURE 8-70. WHITE NOISE ALARM HARNESS​

SECTION 9 - DECALS

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

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

FIGURE 9-3. DECAL INSTALLATION - BRAZIL SPECS (ENGLISH/PORTUGUESE LANGUAGES)​

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

FIGURE 9-5. DECAL INSTALLATION - CHINA SPECS (ENGLISH/CHINESE LANGUAGES)​

FIGURE 9-6. DECAL INSTALLATION - CSA SPECS (ENGLISH/FRENCH LANGUAGES)​

FIGURE 9-7. DECAL INSTALLATION - JAPANESE SPECS (ENGLISH/JAPANESE LANGUAGES)​

FIGURE 9-8. DECAL INSTALLATION - KOREAN SPECS (ENGLISH/KOREAN LANGUAGES)​

FIGURE 9-9. DECAL INSTALLATION - LATIN AMERICAN SPECS (ENGLISH/SPANISH LANGUAGES)​

FIGURE 9-10. DECALS INSTALLATION - OPTIONS​

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

FIGURE 9-12. DECAL INSTALLATION - SKYWELDER - 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