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JLG H800AJ Boom Lift Parts Manual

540 pages · Publication 3121771

$69.85
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Models
H800AJ
Serial coverage
Prior to 0300270864
Manual type
Parts Manual
Pages
540
Publication
3121771
Condition
Brand new
JLG H800AJ Boom Lift Parts Manual, publication 3121771

What's inside

From the manual's own table of contents: 114 sections, 201 entries. See sample pages (PDF, 632 KB)

General50 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 (Prior to SN 0300247156)
  • FIGURE 1-8. DRIVE MOTOR ASSEMBLY
  • FIGURE 1-9. TIRE & WHEEL INSTALLATION - 15-625 NHS FOAM-FILLED
  • FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 18-625 NHS FOAM-FILLED
  • FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 18-625 NHS FOAM-FILLED NON-MARKING (Prior to SN 0300247156)
  • FIGURE 1-13. FRAME SHIELDS INSTALLATION
  • FIGURE 1-14. TOW PACKAGE INSTALLATION (OPTIONAL) (ANSI, ANSI EXPORT AND CHINA SPECS)
  • SECTION 2 - TURNTABLE
  • FIGURE 2-1. VALVES INSTALLATION - WITHOUT LSS
  • FIGURE 2-2. VALVES INSTALLATION - WITH LSS
  • FIGURE 2-3. MAIN VALVE ASSEMBLY (Prior to SN 0300247156)
  • FIGURE 2-5. BRAKE/2 SPEED VALVE ASSEMBLY
  • FIGURE 2-6. SWING DRIVE INSTALLATION
  • FIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (Prior to SN 0300268294)
  • FIGURE 2-9. TURNTABLE BEARING AND LUBE INSTALLATION
  • FIGURE 2-10. TURNTABLE LOCK INSTALLATION
  • FIGURE 2-11. ROTARY COUPLING INSTALLATION
  • FIGURE 2-12. TANKS INSTALLATION
  • FIGURE 2-13. HYDRAULIC TANK ASSEMBLY
  • FIGURE 2-14. FUEL TANK ASSEMBLY
  • FIGURE 2-15. COOLER INSTALLATION
  • FIGURE 2-16. BATTERY BOXES INSTALLATION
  • FIGURE 2-17. BATTERY CHARGERS INSTALLATION (FACTORY SUPPLIED 220V PLUG)
  • FIGURE 2-18. BATTERY CHARGERS INSTALLATION (CUSTOMER SUPPLIED PLUG)
  • FIGURE 2-19. ELECTRICAL SYSTEM INSTALLATION
  • FIGURE 2-20. IMG CONTROL BOX ASSEMBLY
  • FIGURE 2-21. ELECTRICAL ASSEMBLY - 12V FUSE BOX
  • FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY
  • FIGURE 2-23. GROUND CONTROL PANEL DECAL INSTALLATION (WITHOUT MSSO)
  • FIGURE 2-24. GROUND CONTROL PANEL DECAL INSTALLATION (WITH MSSO)
  • FIGURE 2-25. ALARM INSTALLATION
  • FIGURE 2-26. STROBE LIGHT INSTALLATION - AMBER (OPTIONAL)
  • FIGURE 2-27. STROBE LIGHT INSTALLATION - BLUE (OPTIONAL) (Prior to SN 0300259698)
  • FIGURE 2-29. STROBE LIGHT INSTALLATION - RED (OPTIONAL) (Prior to SN 0300259698)
  • 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
  • FIGURE 3-2. ENGINE AND PUMPS SUB-ASSEMBLY (Prior to SN 0300259343)
  • FIGURE 3-4. ENGINE AND TRAY ASSEMBLY (Prior to SN 0300259343)
  • FIGURE 3-6. ENGINE AND GENERATOR ASSEMBLY (Prior to SN 0300259343)
  • FIGURE 3-8. ENGINE AND CLUTCH ASSEMBLY (Prior to SN 0300259343)
FIGURE 3-10. ENGINE FAN MOUNTING ASSEMBLY
FIGURE 3-11. KUBOTA ENGINE COMPONENTS (Prior to SN 0300259343)
FIGURE 3-13. GENERATOR ASSEMBLY
FIGURE 3-14. VARIABLE PUMP ASSEMBLY
FIGURE 3-15. HYDROSTATIC PUMP ASSEMBLY
FIGURE 3-16. FUEL/WATER SEPARATOR ASSEMBLY
FIGURE 3-17. ENGINE HOOD BAFFLES INSTALLATION
FIGURE 3-18. TRAY JACK INSTALLATION
FIGURE 3-19. 4000W GENERATOR INSTALLATION - 220V/50HZ (OPTIONAL)
FIGURE 3-20. 7500W SKYPOWER GENERATOR INSTALLATION - 220V/50HZ (OPTIONAL)
FIGURE 3-21. 7500W SKYPOWER GENERATOR INSTALLATION - 110V/60HZ (OPTIONAL)
SECTION 4 - BOOM
FIGURE 4-1. BOOM AND CYLINDER INSTALLATION (Prior to SN 0300261401)
FIGURE 4-4. MAIN BOOM ASSEMBLY
FIGURE 4-5. TOWER BOOM 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 - WITHOUT LSS
FIGURE 4-10. BOOM VALVES INSTALLATION - WITH LSS
FIGURE 4-11. BOOM VALVE ASSEMBLY
FIGURE 4-12. BOOM VALVE AND LIMIT SWITCHES INSTALLATION
FIGURE 4-13. TILT SENSOR INSTALLATION
Show all 115 sections
FIGURE 4-14. TRANSPORT POSITION SWITCH INSTALLATION (CE SPECS)
FIGURE 4-15. PLATFORM SUPPORT INSTALLATION - WITHOUT LSS
FIGURE 4-16. PLATFORM SUPPORT INSTALLATION - WITH LSS
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
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 (Prior to SN 0300259698)
FIGURE 5-13. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION (SN 0300259698 through 0300270863)
FIGURE 5-14. CONSOLE BOX ASSEMBLY (Prior to SN 0300259698)
FIGURE 5-16. LIGHT PANEL INSTALLATION
FIGURE 5-17. JIB SWITCH INSTALLATION
FIGURE 5-18. CONTROLLER ASSEMBLY (DRIVE AND STEER)
FIGURE 5-19. CONTROLLER ASSEMBLY (LIFT AND SWING)
FIGURE 5-20. FOOTSWITCH ASSEMBLY
FIGURE 5-21. SOFT TOUCH INSTALLATION - 6FT (1.83M) PLATFORM (OPTIONAL)
FIGURE 5-22. SOFT TOUCH INSTALLATION - 6FT (1.83M) FALL ARREST PLATFORM (OPTIONAL)
FIGURE 5-23. SOFT TOUCH INSTALLATION - 8FT (2.4M) PLATFORM (OPTIONAL)
FIGURE 5-24. SOFT TOUCH INSTALLATION - 8FT (2.4M) FALL ARREST PLATFORM (OPTIONAL)
FIGURE 5-25. SKYEYE INSTALLATION
FIGURE 5-26. SKYGUARD INSTALLATION (Prior to SN 0300259698)
FIGURE 5-28. SKYGLAZIER INSTALLATION (ANSI, ANSI EXPORT, AUSTRALIAN & CSA SPECS)
FIGURE 5-29. SKYLINE INSTALLATION
FIGURE 5-30. SKYWELDER INSTALLATION (50HZ)
FIGURE 5-31. SKYWELDER INSTALLATION (60HZ)
FIGURE 5-32. SKYWELDER PREP PACKAGE (60HZ)31 topics
  • FIGURE 5-33. WELDER ASSEMBLY
  • FIGURE 5-34. PIPE RACK INSTALLATION (ANSI AND CSA SPECS ONLY)
  • FIGURE 5-35. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (6FT/1.82M PLATFORM)
  • FIGURE 5-36. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (6FT/1.82M TRI-ENTRY PLATFORM)
  • FIGURE 5-37. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (8FT/2.4M PLATFORM)
  • SECTION 6 - CYLINDER
  • FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSMBLY
  • FIGURE 6-2. LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB (Prior to SN 0300247156)
  • FIGURE 6-4. LEVEL (SLAVE) CYLINDER ASSEMBLY - UPRIGHT (Prior to SN 0300247156)
  • FIGURE 6-7. LIFT CYLINDER ASSEMBLY - JIB (Prior to SN 0300247156)
  • FIGURE 6-9. LIFT CYLINDER ASSEMBLY - MAIN BOOM (Prior to SN 0300247156)
  • FIGURE 6-12. LIFT CYLINDER ASSEMBLY - TOWER BOOM (Prior to SN 0300247156)
  • FIGURE 6-15. MASTER CYLINDER ASSEMBLY (Prior to SN 0300247156)
  • FIGURE 6-17. STEER CYLINDER ASSEMBLY
  • FIGURE 6-18. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (Prior to SN 0300247156)
  • FIGURE 6-19. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (SN 0300247156 through 0300270863)
  • FIGURE 6-20. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (Prior to SN 0300247156)
  • FIGURE 6-21. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (SN 0300247156 through 0300270863)
  • 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
  • FIGURE 7-5. HYDRAULIC DIAGRAM LIST
  • SECTION 8 - ELECTRICAL
  • FIGURE 8-1. ELECTRICAL DIAGRAM LIST
  • SPECS)
  • GENERATOR)
  • FIGURE 8-5. 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 8-18. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITH 7500W SKYPOWER GENERATOR)
FIGURE 8-21. AC BREAKER BOX INSTALLATION - WITH 2 BREAKERS (BRAZIL SPECS)
FIGURE 8-22. AC BREAKER BOX INSTALLATION - WITH 3 BREAKERS (CE SPECS WITH 4000W GENERATOR)
FIGURE 8-23. BATTERY CABLES INSTALLATION
FIGURE 8-24. BATTERY STACK HARNESS (LH)
FIGURE 8-25. BATTERY STACK HARNESS (RH)
FIGURE 8-26. BOOM VALVE HARNESS
FIGURE 8-27. BOOM CABLES INSTALLATION (MACHINES WITHOUT GENERATOR)
FIGURE 8-28. BOOM CABLES INSTALLATION (AUSTRALIAN SPECS WITH 4000W GENERATOR)
FIGURE 8-29. BOOM CABLES INSTALLATION (CE SPECS WITH 4000W GENERATOR)
GENERATOR)
FIGURE 8-31. BOOM CABLES INSTALLATION (AUSTRALIAN & CE SPECS WITH 7500W GENERATOR)
FIGURE 8-32. BOOM CABLE - MAIN BOOM
FIGURE 8-33. BOOM CABLE - TOWER BOOM
FIGURE 8-34. BREAKER BOX KIT - WITH 2 BREAKERS (CE SPECS WITHOUT 4000W GENERATOR & BRAZIL SPECS)
FIGURE 8-35. BREAKER BOX KIT - WITH 2 BREAKERS (CE SPECS WITH 4000W GENERATOR)
FIGURE 8-36. BREAKER BOX KIT - WITH 3 BREAKERS (CE SPECS WITH 4000W GENERATOR)
FIGURE 8-37. CHARGER HARNESS
FIGURE 8-38. CONTROL HARNESS
FIGURE 8-39. ELECTRICAL SYSTEM INSTALLATION
FIGURE 8-40. ENGINE HARNESS - KUBOTA
FIGURE 8-41. ENGINE TRAY HARNESS
FIGURE 8-42. GENERATOR HARNESS - 4000W
FIGURE 8-43. GENERATOR HARNESS - 7500W SKYPOWER
FIGURE 8-44. GENERATOR HARNESS - 4000W AND 7500W SKYPOWER
FIGURE 8-45. GROUND CONTROL BOX HARNESS
FIGURE 8-46. H-BRIDGE/CLUTCH HARNESS
FIGURE 8-47. HYBRID 84V HARNESS
FIGURE 8-48. MAIN VALVE HARNESS
FIGURE 8-49. PLATFORM CONSOLE BOX HARNESS
FIGURE 8-50. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)
FIGURE 8-51. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)
FIGURE 8-52. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE SPEC)
FIGURE 8-53. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE SPEC)
FIGURE 8-54. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)
FIGURE 8-55. RESOLVER/CONVERTER/INVERTER HARNESS
FIGURE 8-56. SKYEYE INTERMEDIATE HARNESS
FIGURE 8-57. SKYEYE RECEIVER HARNESS
FIGURE 8-58. SKYEYE EMITTER HARNESS
FIGURE 8-59. SKYLINE HARNESS
FIGURE 8-60. STROBE LIGHT CONTROL HARNESS (BLUE & RED LIGHTS)
FIGURE 8-61. TURNTABLE HARNESS
FIGURE 8-62. TURNTABLE/FUSE PANEL HARNESS
FIGURE 8-63. PLATFORM INTERFACE 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)6 topics
  • FIGURE 9-10. DECALS INSTALLATION - OPTIONS
  • 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

Real pages from this parts manual (540 pages). Open the sample pages (PDF, 631 KB)

Sample pages from the JLG H800AJ Boom Lift Parts Manual: Parts illustration, Parts illustration, Parts illustration
  • Parts illustration, page 64: SECTION 2 - TURNTABLE
  • Parts illustration, page 368: FIGURE 8-1. ELECTRICAL DIAGRAM LIST
  • Parts illustration, page 520: SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

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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.

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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.

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

Keeping equipment running with less downtime

Factory manual, 540 pages

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JLG H800AJParts Manual · 31215044 · $69.75

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