JLG 800AJ Boom Lift Parts Manual 31219943 PDF

JLG 800AJ Boom Lift Parts Manual 31219943 PDF

Size: 64.76 MB
Language: English
Make: JLG
Machine: Boom Lift
Document: Parts Manual
Model: JLG 800AJ
Part Number: 31219943
Publication Date: 2024
Page: 916 Pages

Detail 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)
  FIGURE 2-12. TANK INSTALLATION – DIESEL MACHINE (FUEL TANK WITHOUT SIGHT GLASS) (JIANGYING 4IIN DIA BREATHER HYDRAULIC TANK)
  FIGURE 2-13. TANK INSTALLATION – DIESEL MACHINE (FUEL TANK WITH SIGHT GLASS) (HELGESEN 6IIN DIA BREATHER HYDRAULIC TANK)
  FIGURE 2-14. TANK INSTALLATION – DIESEL MACHINE (FUEL TANK WITH SIGHT GLASS) (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK)
  FIGURE 2-15. TANK INSTALLATION – GAS ENGINES (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK)
  FIGURE 2-16. TANK INSTALLATION – GAS ENGINES (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK)
  FIGURE 2-17. HYDRAULIC TANK ASSEMBLY (HELGESEN 6IN DIA BREATHER HYDRAULIC TANK)
  FIGURE 2-18. HYDRAULIC TANK ASSEMBLY (JIANGYING 4IN DIA BREATHER HYDRAULIC TANK)
  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 DIGITAL DISPLAY (ANSI EXPORT LRC AND AUSTRALIAN SPECS)
  FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ D2011 ENGINES – WITH MECHANICAL HOUR METER (ANSI EXPORT LRC AND AUSTRALIAN SPECS)
  FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ D2011 AND TOWER STOW – WITH DIGITAL DISPLAY (ANSI EXPORT LRC AND AUSTRALIAN SPECS)
  FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ D2011 AND TOWER STOW – WITH MECHANICAL HOUR METER (ANSI EXPORT LRC AND AUSTRALIAN SPECS)
  FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ D2011 (CE & UK CA LRC SPECS)
  FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ D2011 AND WITH TOWER STOW (CE & UK CA LRC SPECS)
  FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ TD2.9L4 – WITH DIGITAL DISPLAY (ANSI SPECS)
  FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ TD2.9L4 – WITH MECHANICAL HOUR METER (ANSI SPECS)
  FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ TD2.9L4 AND TOWER STOW – WITH DIGITAL DISPLAY (ANSI SPECS)
  FIGURE 2-31. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ TD2.9L4 AND TOWER STOW – WITH MECHANICAL HOUR METER (ANSI SPECS)
  FIGURE 2-32. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ TD2.9L4 (STAGE V) (CE & UK CA SPECS)
  FIGURE 2-33. GROUND CONTROL BOX ASSEMBLY – WITH DEUTZ TD2.9L4 (STAGE V) AND WITH TOWER STOW (CE & UK CA SPECS)
  FIGURE 2-34. GROUND CONTROL BOX ASSEMBLY – WITH FORD ENGINES – WITH DIGITAL DISPLAY
  FIGURE 2-35. GROUND CONTROL BOX ASSEMBLY – WITH FORD ENGINES – WITH MECHANICAL HOUR METER
  FIGURE 2-36. GROUND CONTROL BOX ASSEMBLY – WITH FORD ENGINES AND TOWER STOW – WITH DIGITAL DISPLAY
  FIGURE 2-37. GROUND CONTROL BOX ASSEMBLY – WITH FORD ENGINES AND TOWER STOW – WITH MECHANICAL HOUR METER
  FIGURE 2-38. LIGHT PANEL INSTALLATION
  FIGURE 2-39. ALARM INSTALLATION
  FIGURE 2-40. WHITE NOISE ALARM INSTALLATION – ADJUSTABLE AMBIENT
  FIGURE 2-41. WHITE NOISE MOTION ALARM INSTALLATION – AMBIENT
  FIGURE 2-42. STROBE LIGHT INSTALLATION (AMBER)
  FIGURE 2-43. STROBE LIGHT INSTALLATION (BLUE)
  FIGURE 2-44. STROBE LIGHT INSTALLATION (RED)
  FIGURE 2-45. SKYAIR AIR COMPRESSOR INSTALLATION (ANSI EXPORT AND CHINA SPECS)
  FIGURE 2-46. SKYAIR AIR COMPRESSOR INSTALLATION (ANSI AND CSA SPECS)
  FIGURE 2-47. AIR COMPRESSOR ASSEMBLY
  FIGURE 2-48. HOODS INSTALLATION – ABS (DEUTZ D2011 ENGINES)
  FIGURE 2-49. HOODS INSTALLATION – ABS (DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES)
  FIGURE 2-50. HOODS INSTALLATION – ABS (DEUTZ TD2.9L4 (STAGE V) ENGINES)
  FIGURE 2-51. HOODS INSTALLATION – STEEL (DEUTZ D2011 ENGINES)
  FIGURE 2-52. HOODS INSTALLATION – STEEL (DEUTZ TD2.9L4 ENGINES)
  FIGURE 2-53. HOODS INSTALLATION – STEEL (FORD ENGINES)
  FIGURE 2-54. EXHAUST COVER AND HEAT SHIELDS INSTALLATION – STEEL HOODS (DEUTZ D2011 ENGINES)
  FIGURE 2-55. EXHAUST COVER AND HEAT SHIELDS INSTALLATION – STEEL HOODS (DEUTZ TD2.9L4 ENGINES)
  FIGURE 2-56. 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 D2011 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 SPECS)
  FIGURE 3-12. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA IV SPECS)
  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 SPECS)
  FIGURE 3-17. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA IV SPECS) (WITH DANFOSS PUMP)
  FIGURE 3-18. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA IV SPECS) (WITH HENGLI PUMP)
  FIGURE 3-19. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)
  FIGURE 3-20. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)
  FIGURE 3-21. DEUTZ TD2.9L4 ENGINE ASSEMBLY (STAGE V)
  FIGURE 3-22. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA III SPECS)
  FIGURE 3-23. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA IV SPECS)
  FIGURE 3-24. DEUTZ TD2.9L4 ENGINE COMPONENTS
  FIGURE 3-25. DEUTZ TD2.9L4 ENGINE COMPONENTS (STAGE V)
  FIGURE 3-26. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA III SPECS)
  FIGURE 3-27. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA IV SPECS)
  FIGURE 3-28. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES)
  FIGURE 3-29. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 (STAGE V) ENGINES)
  FIGURE 3-30. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES) (CHINA III SPECS)
  FIGURE 3-31. BREATHER HEATER INST (DEUTZ TD2.9L4 ENGINES)
  FIGURE 3-32. PUMP COUPLING KIT (DEUTZ ENGINES)
  FIGURE 3-33. FORD ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)
  FIGURE 3-34. FORD ENGINE INSTALLATION (WITH ARCTIC PACKAGE)
  FIGURE 3-35. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)
  FIGURE 3-36. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)
  FIGURE 3-37. FORD ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)
  FIGURE 3-38. FORD ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)
  FIGURE 3-39. FORD ENGINE DRIVE BELT INSTALLATION (MACHINES WITHOUT GENERATOR)
  FIGURE 3-40. FORD ENGINE COMPONENTS
  FIGURE 3-41. FORD ENGINE PREP ASSEMBLY
  FIGURE 3-42. FORD ENGINE BRACKETS AND EXHAUST MANIFOLD INSTALLATION
  FIGURE 3-43. HYDROSTATIC PUMP ASSEMBLY
  FIGURE 3-44. VARIABLE PUMP ASSEMBLY – DANFOSS
  FIGURE 3-45. VARIABLE PUMP ASSEMBLY – HENGLI
  FIGURE 3-46. EXHAUST PIPE INSTALLATION – DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES
  FIGURE 3-47. EXHAUST PIPE INSTALLATION – DEUTZ TD2.9L4 (STAGE V) ENGINES
  FIGURE 3-48. EXHAUST PIPE INSTALLATION – FORD ENGINES
  FIGURE 3-49. SPARK ARRESTOR MUFFLER INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-50. SPARK ARRESTOR MUFFLER INSTALLATION – DEUTZ TD2.9L4 ENGINES
  FIGURE 3-51. SPARK ARRESTOR MUFFLER INSTALLATION – FORD ENGINES
  FIGURE 3-52. FUEL-WATER SEPARATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-53. FUEL-WATER SEPARATOR INSTALLATION – DEUTZ TD2.9L4 ENGINES
  FIGURE 3-54. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITHOUT GENERATORS)
  FIGURE 3-55. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)
  FIGURE 3-56. 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 3-57. ENGINE HOOD BAFFLE INSTALLATION – DEUTZ TD2.9L4 ENGINES WITH STEEL HOODS
  FIGURE 3-58. ENGINE TRAY JACK INSTALLATION – DEUTZ ENGINES
  FIGURE 3-59. ENGINE TRAY JACK INSTALLATION – FORD ENGINES
  FIGURE 3-60. 2500W/110V/60HZ GENERATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-61. 2500W/110V/60HZ GENERATOR INSTALLATION – DEUTZ TD2.9L4 ENGINES
  FIGURE 3-62. 2500W/110V/60HZ GENERATOR INSTALLATION – FORD ENGINES
  FIGURE 3-63. 2500W/220V/50HZ GENERATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-64. 4000W/50HZ GENERATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-65. 4000W/50HZ GENERATOR INSTALLATION – DEUTZ TD2.9L4 ENGINES, DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES AND DEUTZ TD2.9L4 (STAGE V) ENGINES
  FIGURE 3-66. 4000W/60HZ GENERATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-67. 4000W/60HZ GENERATOR INSTALLATION – DEUTZ TD2.9L4 ENGINES
  FIGURE 3-68. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-69. 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 3-70. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION – DEUTZ D2011 ENGINES
  FIGURE 3-71. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION – DEUTZ TD2.9L4 ENGINES
  FIGURE 3-72. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION – FORD ENGINES

SECTION 4 – BOOM

• FIGURE 4-1. BOOM INSTALLATION – WITHOUT ARCTIC PACKAGE (Prior to SN 0300288879, SN 0300288881 through 0300289013, SN 0300289020 through 0300289215, SN 0300289220 through 0300291403)
  FIGURE 4-2. BOOM AND CYLINDER INSTALLATION – WITHOUT ARCTIC PACKAGE (SN 0300289014 through 0300289019, SN 0300289216 through 0300289219, SN 0300291404 to Present, Including 0300288880)
  FIGURE 4-3. BOOM INSTALLATION – WITH ARCTIC PACKAGE (Prior to SN 0300288879, SN 0300288881 through 0300289013, SN 0300289020 through 0300289215, SN 0300289220 through 0300291403)
  FIGURE 4-4. BOOM AND CYLINDER INSTALLATION – WITH ARCTIC PACKAGE (SN 0300289014 through 0300289019, SN 0300289216 through 0300289219, SN 0300291404 to Present, Including 0300288880)
  FIGURE 4-5. BOOM ASSEMBLY – MAIN (WITHOUT ARCTIC PACKAGE)
  FIGURE 4-6. BOOM ASSEMBLY – MAIN (WITH ARCTIC PACKAGE)
  FIGURE 4-7. TOWER BOOM ASSEMBLY (Prior to SN 0300288872)
  FIGURE 4-8. TOWER BOOM ASSEMBLY (SN 0300288872 to Present)
  FIGURE 4-9. JIB ASSEMBLY
  FIGURE 4-10. ROTATOR ASSEMBLY
  FIGURE 4-11. SUPPORT, PLATFORM INSTALLATION
  FIGURE 4-12. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION
  FIGURE 4-13. BOOM VALVES AND PROXIMITY SWITCHES INSTALLATION WITH TOWER STOW
  FIGURE 4-14. CONTROL VALVES INSTALLATION – WITH 2WS
  FIGURE 4-15. CONTROL VALVES INSTALLATION – WITH 4WS
  FIGURE 4-16. BOOM VALVE ASSEMBLY
  FIGURE 4-17. CONTROL VALVE ASSEMBLY
  FIGURE 4-18. POWER TRACK INSTALLATION – MAIN BOOM
  FIGURE 4-19. POWER TRACK INSTALLATION – TOWER BOOM WITHOUT ARCTIC PACKAGE
  FIGURE 4-20. POWER TRACK INSTALLATION – TOWER BOOM WITH ARCTIC PACKAGE
  FIGURE 4-21. TRANSPORT POSITION SWITCH INSTALLATION
  FIGURE 4-22. 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. CONTROLLER ASSEMBLY- DRIVE/STEER
  FIGURE 5-21. CONTROLLER ASSEMBLY – LIFT/SWING
  FIGURE 5-22. FOOTSWITCH ASSEMBLY
  FIGURE 5-23. JIB SWITCH INSTALLATION – 800AJ
  FIGURE 5-24. LIGHT PANEL INSTALLATION
  FIGURE 5-25. STEER SWITCH INSTALLATION – 4WS
  FIGURE 5-26. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 4FT (76CM X 1.22M) PLATFORM
  FIGURE 5-27. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.2CM X 1.82M) PLATFORM
  FIGURE 5-28. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 6FT (76CM X 1.83M) PLATFORM
  FIGURE 5-29. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 8FT (91.5CM X 2.4M) PLATFORM
  FIGURE 5-30. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.5CM X 1.82M) TRI-ENTRY PLATFORM)
  FIGURE 5-31. SKYCUTTER INSTALLATION
  FIGURE 5-32. PLASMA CUTTER ASSEMBLY
  FIGURE 5-33. SKYEYE INSTALLATION
  FIGURE 5-34. SKYGLAZIER INSTALLATION (ENGLISH LANGUAGE DECALS)
  FIGURE 5-35. SKYGLAZIER INSTALLATION (SPANISH LANGUAGE DECALS)
  FIGURE 5-36. SKYGLAZIER INSTALLATION (PORTUGUESE LANGUAGE DECALS)
  FIGURE 5-37. SKYGUARD BAR INSTALLATION
  FIGURE 5-38. SKYLINE INSTALLATION
  FIGURE 5-39. SKYWELDER INSTALLATION (50HZ)
  FIGURE 5-40. SKYWELDER INSTALLATION (60HZ)
  FIGURE 5-41. SKYWELDER/SKYCUTTER COMBO 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. STORAGE TRAY INSTALLATION – CENTER
  FIGURE 5-49. USB CHARGER INSTALLATION

SECTION 6 – CYLINDER

• FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY
  FIGURE 6-2. LEVEL CYLINDER ASSEMBLY – PLATFORM SLAVE (800AJ) (Prior to SN 0300288879, SN 0300288881 through 0300289013, SN 0300289020 through 0300289215, SN 0300289220 through 0300291403)
  FIGURE 6-3. LEVEL (SLAVE) CYLINDER ASSEMBLY – JIB (SN 0300289014 through 0300289019, SN 0300289216 through 0300289219, SN 0300291404 to Present, Including 0300288880)
  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 (800AJ) (Prior to SN 0300288879, SN 0300288881 through 0300289013, SN 0300289020 through 0300289215, SN 0300289220 through 0300291403)
  FIGURE 6-9. MASTER CYLINDER ASSEMBLY (SN 0300289014 through 0300289019, SN 0300289216 through 0300289219, SN 0300291404 to Present, Including 0300288880)
  FIGURE 6-10. STEER CYLINDER ASSEMBLY
  FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY – MAIN BOOM
  FIGURE 6-12. TELESCOPE CYLINDER ASSEMBLY – TOWER BOOM (Prior to SN 0300288872)
  FIGURE 6-13. TELESCOPE CYLINDER ASSEMBLY – TOWER BOOM (SN 0300288872 to Present)

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 – 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. ENGINE HARNESS – DEUTZ D2011 ENGINES
  FIGURE 8-41. ENGINE HARNESS – DEUTZ TD2.9L4 ENGINES
  FIGURE 8-42. ENGINE HARNESS – DEUTZ TD2.9L4 ENGINES AND DEUTZ TD2.9L4 (STAGE V PRE-BUY) ENGINES
  FIGURE 8-43. ENGINE HARNESS – DEUTZ TD2.9L4 (STAGE V) ENGINES
  FIGURE 8-44. ENGINE HARNESS – FORD ENGINES
  FIGURE 8-45. FUEL PUMP HARNESS – DEUTZ TD2.9L4 ENGINES
  FIGURE 8-46. FUEL HARNESS – DEUTZ TD2.9L4 (STAGE V) ENGINE
  FIGURE 8-47. GENERATOR HARNESS – 4000W GENERATOR
  FIGURE 8-48. GENERATOR HARNESS – 7500W SKYPOWER GENERATOR
  FIGURE 8-49. GENERATOR TO ENGINE HARNESS – 2500W (FORD ENGINES)
  FIGURE 8-50. GENERATOR TO ENGINE HARNESS – 4000W (DEUTZ D2011 ENGINES)
  FIGURE 8-51. GENERATOR TO ENGINE HARNESS – 4000W (DEUTZ TD2.9L4 ENGINES)
  FIGURE 8-52. GENERATOR TO ENGINE HARNESS – 7500W SKYPOWER GENERATOR (DEUTZ D2011 ENGINES)
  FIGURE 8-53. GENERATOR TO ENGINE HARNESS – 7500W SKYPOWER (FORD DF 2.5L ENGINES)
  FIGURE 8-54. GENERATOR HARNESS – 7500W SKYPOWER (DEUTZ TD2.9L4 T4F ENGINES)
  FIGURE 8-55. GENERATOR TO REAR OF BOOM HARNESS – 110V
  FIGURE 8-56. GENERATOR TO REAR OF BOOM HARNESS – 220V
  FIGURE 8-57. GROUND CONTROL BOX HARNESS
  FIGURE 8-58. PLATFORM CONSOLE BOX HARNESS
  FIGURE 8-59. RECEPTACLE BOX KIT – 110V IEC YELLOW (CE & UK CA SPECS)
  FIGURE 8-60. RECEPTACLE BOX KIT – 220V IEC BLUE (CE & UK CA SPECS)
  FIGURE 8-61. RECEPTACLE BOX KIT – 220V CEE7 POST GROUND 2X4 BOX (CE & UK CA SPECS)
  FIGURE 8-62. RECEPTACLE BOX KIT – 220V CEE7 SIDE GROUND 2X4 BOX (CE & UK CA SPECS)
  FIGURE 8-63. RECEPTACLE BOX KIT – 220V AFSINT107 KEYED GROUND (CE & UK CA SPECS)
  FIGURE 8-64. RECEPTACLE/BREAKER BOX ASSEMBLY – 240V (7500W SKYPOWER GENERATORS) (ANSI, ANSI EXPORT AND CSA SPECS)
  FIGURE 8-65. SKYEYE EMITTER HARNESS
  FIGURE 8-66. SKYEYE INTERMEDIATE HARNESS
  FIGURE 8-67. SKYEYE RECEIVER HARNESS
  FIGURE 8-68. SKYLINE HARNESS
  FIGURE 8-69. SKYGUARD INTERFACE HARNESS
  FIGURE 8-70. VALVE HARNESS
  FIGURE 8-71. 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/ACCESSORIES/KITS

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

PART NUMBER INDEX

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