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JLG H800AJ Boom Lift Parts Manual

486 pages · Publication 31215044

$69.75
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Models
H800AJ
Manual type
Parts Manual
Pages
486
Publication
31215044
Condition
Brand new
JLG H800AJ Boom Lift Parts Manual, publication 31215044

What's inside

From the manual's own table of contents: 107 sections, 205 entries. See sample pages (PDF, 643 KB)

General61 topics
  • 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)
  • FIGURE 2-22. GROUND CONTROL PANEL DECAL INSTALLATION (WITH MSSO)
  • FIGURE 2-23. ALARM INSTALLATION
  • FIGURE 2-24. WHITE NOISE ALARM INSTALLATION - ADJUSTABLE AMBIENT
  • FIGURE 2-25. WHITE NOISE MOTION ALARM INSTALLATION - AMBIENT
  • FIGURE 2-26. STROBE LIGHT INSTALLATION - AMBER (OPTIONAL)
  • FIGURE 2-27. STROBE LIGHT INSTALLATION - BLUE (OPTIONAL)
  • FIGURE 2-28. STROBE LIGHT INSTALLATION - RED (OPTIONAL)
  • FIGURE 2-29. HEAT SHIELD AND ACCESS PANELS INSTALLATION
  • FIGURE 2-30. HOODS INSTALLATION
  • FIGURE 2-31. HOOD ASSEMBLY - TANK SIDE
  • FIGURE 2-32. HOOD ASSEMBLY - ENGINE SIDE
  • SECTION 3 - ENGINE
  • FIGURE 3-1. ENGINE INSTALLATION
  • 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
  • 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. MAIN BOOM ASSEMBLY
FIGURE 4-4. TOWER BOOM ASSEMBLY
FIGURE 4-5. JIB ASSEMBLY
FIGURE 4-6. ROTATOR ASSEMBLY
FIGURE 4-7. POWER TRACK INSTALLATION - MAIN BOOM
FIGURE 4-8. POWER TRACK INSTALLATION - TOWER BOOM
FIGURE 4-9. BOOM VALVES INSTALLATION
FIGURE 4-10. BOOM VALVE ASSEMBLY
FIGURE 4-11. BOOM VALVE AND LIMIT SWITCHES INSTALLATION
FIGURE 4-12. TILT SENSOR INSTALLATION
FIGURE 4-13. TRANSPORT POSITION SWITCH INSTALLATION (CE 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
Show all 108 sections
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
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
FIGURE 5-13. PLATFORM CONSOLE BOX ASSEMBLY
FIGURE 5-14. LIGHT PANEL INSTALLATION
FIGURE 5-15. JIB SWITCH INSTALLATION
FIGURE 5-16. CONTROLLER ASSEMBLY (DRIVE AND STEER)
FIGURE 5-17. CONTROLLER ASSEMBLY (LIFT AND SWING)
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. PIPE RACK INSTALLATION (ANSI AND CSA SPECS ONLY)
FIGURE 5-32. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 4FT (76CM X 1.22M) PLATFORM
FIGURE 5-33. FALL ARREST INSTALLATION (BOLT-ON) 36IN X 6FT (91.2CM X 1.82M) PLATFORM
FIGURE 5-34. FALL ARREST INSTALLATION (BOLT-ON) 30IN X 6FT (76CM X 1.83M) PLATFORM
FIGURE 5-35. 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 BOOM37 topics
  • 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
  • SPECS)
  • GENERATOR)
  • FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V (ANSI, CSA & JAPANESE SPECS)
  • 4000W GENERATOR)
  • JAPANESE SPECS)
  • EXCEPT ANSI & CSA SPECS)
  • (ANSI & CSA SPECS)
  • (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 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 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 SPECS WITH 4000W GENERATOR)
  • FIGURE 8-29. BOOM CABLES INSTALLATION (AUSTRALIAN & CE SPECS WITH 7500W GENERATOR)
  • FIGURE 8-30. BOOM CABLE - MAIN BOOM
  • FIGURE 8-31. BOOM CABLE - TOWER BOOM
  • FIGURE 8-33. BREAKER BOX KIT - WITH 2 BREAKERS (CE SPECS WITH 4000W GENERATOR)
  • FIGURE 8-34. BREAKER BOX KIT - WITH 3 BREAKERS (CE SPECS WITH 4000W GENERATOR)
  • FIGURE 8-35. CHARGER HARNESS
  • FIGURE 8-36. CONTROL HARNESS
FIGURE 8-37. ELECTRICAL SYSTEM INSTALLATION
FIGURE 8-38. ENGINE HARNESS - KUBOTA
FIGURE 8-39. ENGINE TRAY HARNESS
FIGURE 8-40. GENERATOR HARNESS - 4000W
FIGURE 8-41. GENERATOR HARNESS - 7500W SKYPOWER
FIGURE 8-42. GENERATOR HARNESS - 4000W AND 7500W SKYPOWER
FIGURE 8-43. GROUND CONTROL BOX HARNESS
FIGURE 8-44. H-BRIDGE/CLUTCH HARNESS
FIGURE 8-45. HYBRID 84V HARNESS
FIGURE 8-46. MAIN VALVE HARNESS
FIGURE 8-47. PLATFORM CONSOLE BOX HARNESS
FIGURE 8-48. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)
FIGURE 8-49. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)
FIGURE 8-50. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE SPEC)
FIGURE 8-51. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE SPEC)
FIGURE 8-52. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)
FIGURE 8-53. RESOLVER/CONVERTER/INVERTER HARNESS
FIGURE 8-54. SKYEYE INTERMEDIATE HARNESS
FIGURE 8-55. SKYEYE RECEIVER HARNESS (PVC 2001)
FIGURE 8-56. SKYEYE RECEIVER HARNESS (PVC 2007)
FIGURE 8-57. SKYEYE EMITTER HARNESS (PVC 2001)
FIGURE 8-58. SKYEYE EMITTER HARNESS (PVC 2007)
FIGURE 8-59. SKYGUARD INTERFACE HARNESS
FIGURE 8-60. SKYLINE HARNESS
FIGURE 8-61. STROBE LIGHT CONTROL HARNESS (BLUE & RED LIGHTS)
FIGURE 8-62. TURNTABLE HARNESS
FIGURE 8-63. TURNTABLE/FUSE PANEL HARNESS
FIGURE 8-64. 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 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 - OPTIONAL
FIGURE 9-11. SKYWELDER DECAL INSTALLATION - 50HZ
FIGURE 9-12. SKYWELDER DECAL INSTALLATION - 60HZ (PVC 2001)
FIGURE 9-13. DECAL INSTALLATION - SKYWELDER (60HZ) (PVC 2007)
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK
SECTION 11 - SPECIAL OPTIONS
FIGURE 11-1. SPECIAL OPTIONS
PART NUMBER INDEX

Inside this manual

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Sample pages from the JLG H800AJ Boom Lift Parts Manual: Parts illustration, Parts illustration, Parts illustration
  • Parts illustration, page 225: SECTION 5 - PLATFORM
  • Parts illustration, page 281: SECTION 6 - CYLINDER
  • Parts illustration, page 470: SECTION 11 - SPECIAL OPTIONS

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Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

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Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

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Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

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JLG H800AJParts Manual · 3121771 · $69.85

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