Oshkosh Corporation JLG H800AJ Setup guide

3121771 H800AJ 3

4 H800AJ 3121771

3121771 H800AJ 5

TABLE OF CONTENTS
3121771 H800AJ 7
SECTION 1 - FRAME......................................................................................................................................................................... 11
FIGURE 1-1. AXLE INSTALLATION - WITHOUT TOW PACKAGE............................................................................................... 12
FIGURE 1-2. AXLE INSTALLATION - WITH TOW PACKAGE ...................................................................................................... 14
FIGURE 1-3. STEER INSTALLATION - WITHOUT TOW PACKAGE............................................................................................ 16
FIGURE 1-4. STEER INSTALLATION - WITH TOW PACKAGE.................................................................................................... 18
FIGURE 1-5. WHEEL DRIVE AND FRAME VALVES INSTALLATION.......................................................................................... 20
FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (Prior to SN 0300247156) ................................................................................... 22
FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLY (SN 0300247156 to Present)............................................................................... 26
FIGURE 1-8. DRIVE MOTOR ASSEMBLY .................................................................................................................................... 28
FIGURE 1-9. TIRE & WHEEL INSTALLATION - 15-625 NHS FOAM-FILLED............................................................................... 30
FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 18-625 NHS FOAM-FILLED........................................................................ 32
FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 18-625 NHS FOAM-FILLED NON-MARKING (Prior to SN 0300247156)... 34
FIGURE 1-12. TIRE AND WHEEL INSTALLATION - 18-625 NHS FOAM-FILLED NON-MARKING (SN 0300247156 to Present)
........................................................................................................................................................................................................ 36
FIGURE 1-13. FRAME SHIELDS INSTALLATION......................................................................................................................... 38
FIGURE 1-14. TOW PACKAGE INSTALLATION (OPTIONAL) (ANSI, ANSI EXPORT AND CHINA SPECS).............................. 40
SECTION 2 - TURNTABLE................................................................................................................................................................ 43
FIGURE 2-1. VALVES INSTALLATION - WITHOUT LSS.............................................................................................................. 44
FIGURE 2-2. VALVES INSTALLATION - WITH LSS...................................................................................................................... 46
FIGURE 2-3. MAIN VALVE ASSEMBLY (Prior to SN 0300247156)............................................................................................... 48
FIGURE 2-4. MAIN VALVE ASSEMBLY (SN 0300247156 to Present).......................................................................................... 52
FIGURE 2-5. BRAKE/2 SPEED VALVE ASSEMBLY..................................................................................................................... 56
FIGURE 2-6. SWING DRIVE INSTALLATION ............................................................................................................................... 58
FIGURE 2-7. SWING MOTOR/HUB ASSEMBLY........................................................................................................................... 60
FIGURE 2-8. TURNTABLE BEARING AND LUBE INSTALLATION .............................................................................................. 64
FIGURE 2-9. TURNTABLE LOCK INSTALLATION........................................................................................................................ 66
FIGURE 2-10. ROTARY COUPLING INSTALLATION................................................................................................................... 68
FIGURE 2-11. TANKS INSTALLATION.......................................................................................................................................... 70
FIGURE 2-12. HYDRAULIC TANK ASSEMBLY............................................................................................................................. 72
FIGURE 2-13. FUEL TANK ASSEMBLY........................................................................................................................................ 74
FIGURE 2-14. COOLER INSTALLATION ...................................................................................................................................... 76
FIGURE 2-15. BATTERY BOXES INSTALLATION........................................................................................................................ 78
FIGURE 2-16. BATTERY CHARGERS INSTALLATION (FACTORY SUPPLIED 220V PLUG)..................................................... 82
FIGURE 2-17. BATTERY CHARGERS INSTALLATION (CUSTOMER SUPPLIED PLUG)........................................................... 84
FIGURE 2-18. ELECTRICAL SYSTEM INSTALLATION................................................................................................................ 86
FIGURE 2-19. IMG CONTROL BOX ASSEMBLY.......................................................................................................................... 88
FIGURE 2-20. ELECTRICAL ASSEMBLY - 12V FUSE BOX......................................................................................................... 92
FIGURE 2-21. GROUND CONTROL BOX ASSEMBLY................................................................................................................. 94
FIGURE 2-22. GROUND CONTROL PANEL DECAL INSTALLATION (WITHOUT MSSO).......................................................... 96
FIGURE 2-23. GROUND CONTROL PANEL DECAL INSTALLATION (WITH MSSO).................................................................. 98
FIGURE 2-24. ALARM INSTALLATION....................................................................................................................................... 100
FIGURE 2-25. STROBE LIGHT INSTLLATION - AMBER (OPTIONAL) ...................................................................................... 102
FIGURE 2-26. STROBE LIGHT INSTLLATION - BLUE (OPTIONAL).......................................................................................... 104
FIGURE 2-27. STROBE LIGHT INSTLLATION - RED (OPTIONAL)............................................................................................ 106
FIGURE 2-28. HEAT SHIELD AND ACCESS PANELS INSTALLATION..................................................................................... 108
FIGURE 2-29. HOODS INSTALLATION ...................................................................................................................................... 110
FIGURE 2-30. HOOD ASSEMBLY - TANK SIDE......................................................................................................................... 114
FIGURE 2-31. HOOD ASSEMBLY - ENGINE SIDE..................................................................................................................... 116
SECTION 3 - ENGINE ..................................................................................................................................................................... 119
FIGURE 3-1. ENGINE INSTALLATION........................................................................................................................................ 120
FIGURE 3-2. ENGINE AND PUMPS SUB-ASSEMBLY............................................................................................................... 124
FIGURE 3-3. ENGINE AND TRAY ASSEMBLY........................................................................................................................... 126
FIGURE 3-4. ENGINE AND GENERATOR ASSEMBLY.............................................................................................................. 130
FIGURE 3-5. ENGINE AND CLUTCH ASSEMBLY...................................................................................................................... 132
FIGURE 3-6. KUBOTA ENGINE COMPONENTS........................................................................................................................ 134
FIGURE 3-7. GENERATOR ASSEMBLY..................................................................................................................................... 138
FIGURE 3-8. VARIABLE PUMP ASSEMBLY............................................................................................................................... 140
FIGURE 3-9. HYDROSTATIC PUMP ASSEMBLY....................................................................................................................... 144
FIGURE 3-10. FUEL/WATER SEPARATOR ASSEMBLY............................................................................................................ 146
FIGURE 3-11. ENGINE HOOD BAFFLES INSTALLATION......................................................................................................... 148
FIGURE 3-12. TRAY JACK INSTALLATION................................................................................................................................ 150

TABLE OF CONTENTS
8 H800AJ 3121771
FIGURE 3-13. 4000W GENERATOR INSTALLATION - 220V/50HZ (OPTIONAL) ......................................................................152
FIGURE 3-14. 7500W SKYPOWER GENERATOR INSTALLATION - 220V/50HZ (OPTIONAL).................................................156
FIGURE 3-15. 7500W SKYPOWER GENERATOR INSTALLATION - 110V/60HZ (OPTIONAL).................................................160
SECTION 4 - BOOM.........................................................................................................................................................................165
FIGURE 4-1. BOOM AND CYLINDER INSTALLATION................................................................................................................166
FIGURE 4-2. MAIN BOOM ASSEMBLY .......................................................................................................................................170
FIGURE 4-3. TOWER BOOM ASSEMBLY...................................................................................................................................172
FIGURE 4-4. ROTATOR ASSEMBLY...........................................................................................................................................174
FIGURE 4-5. POWER TRACK INSTALLATION - MAIN BOOM ...................................................................................................176
FIGURE 4-6. POWER TRACK INSTALLATION - TOWER BOOM...............................................................................................178
FIGURE 4-7. BOOM VALVES INSTALLATION - WITHOUT LSS.................................................................................................180
FIGURE 4-8. BOOM VALVES INSTALLATION - WITH LSS........................................................................................................182
FIGURE 4-9. BOOM VALVE ASSEMBLY.....................................................................................................................................184
FIGURE 4-10. BOOM VALVE AND LIMIT SWITCHES INSTALLATION......................................................................................186
FIGURE 4-11. TILT SENSOR INSTALLATION.............................................................................................................................188
FIGURE 4-12. TRANSPORT POSITION SWITCH INSTALLATION (CE SPECS)........................................................................190
FIGURE 4-13. PLATFORM SUPPORT INSTALLATION - WITHOUT LSS...................................................................................192
FIGURE 4-14. PLATFORM SUPPORT INSTALLATION - WITH LSS ..........................................................................................194
SECTION 5 - PLATFORM................................................................................................................................................................197
FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) WITH SWING GATE ......................................................198
FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) WITH DROP BAR ..........................................................200
FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) WITH SWING GATE......................................................202
FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) WITH DROP BAR ..........................................................204
FIGURE 5-5. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH SWING GATE...................................................206
FIGURE 5-6. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH DROP BAR .......................................................208
FIGURE 5-7. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (ANSI, ANSI EXPORT, CHINA &
CSA SPECS) ................................................................................................................................................................................210
FIGURE 5-8. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH SWING GATE ...................................................212
FIGURE 5-9. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH DROP BAR .......................................................214
FIGURE 5-10. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST................................................216
FIGURE 5-11. TRAY ASSEMBLY.................................................................................................................................................218
FIGURE 5-12. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION.............................................................................220
FIGURE 5-13. CONSOLE BOX ASSEMBLY................................................................................................................................222
FIGURE 5-14. LIGHT PANEL INSTALLATION.............................................................................................................................226
FIGURE 5-15. JIB SWITCH INSTALLATION................................................................................................................................228
FIGURE 5-16. CONTROLLER ASSEMBLY (DRIVE AND STEER)..............................................................................................230
FIGURE 5-17. CONTROLLER ASSEMBLY (LIFT AND SWING) .................................................................................................232
FIGURE 5-18. FOOTSWITCH ASSEMBLY ..................................................................................................................................236
FIGURE 5-19. SKYGUARD INSTALLATION................................................................................................................................238
FIGURE 5-20. SOFT TOUCH INSTALLATION - 6FT (1.83M) PLATFORM (OPTIONAL) ............................................................240
FIGURE 5-21. SOFT TOUCH INSTALLATION - 6FT (1.83M) FALL ARREST PLATFORM (OPTIONAL)...................................242
FIGURE 5-22. SOFT TOUCH INSTALLATION - 8FT (2.4M) PLATFORM (OPTIONAL)..............................................................244
FIGURE 5-23. SOFT TOUCH INSTALLATION - 8FT (2.4M) FALL ARREST PLATFORM (OPTIONAL) .....................................246
FIGURE 5-24. SKYGLAZIER INSTALLATION (ANSI, ANSI EXPORT, AUSTRALIAN & CSA SPECS).......................................248
FIGURE 5-25. SKYWELDER INSTALLATION (50HZ)..................................................................................................................250
FIGURE 5-26. SKYWELDER INSTALLATION (60HZ)..................................................................................................................252
FIGURE 5-27. SKYWELDER PREP PACKAGE (60HZ)...............................................................................................................254
FIGURE 5-28. WELDER ASSEMBLY...........................................................................................................................................256
FIGURE 5-29. PIPE RACK INSTALLATION (ANSI AND CSA SPECS ONLY).............................................................................258
FIGURE 5-30. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (6FT/1.82M PLATFORM)............................................260
FIGURE 5-31. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (6FT/1.82M TRI-ENTRY PLATFORM)........................262
FIGURE 5-32. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (8FT/2.4M PLATFORM)..............................................264
SECTION 6 - CYLINDER..................................................................................................................................................................267
FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSMBLY................................................................................................................268
FIGURE 6-2. LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB (Prior to SN 0300247156).............................................................270
FIGURE 6-3. LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB (SN 0300247156 to Present) ........................................................272
FIGURE 6-4. LEVEL (SLAVE) CYLINDER ASSEMBLY - UPRIGHT (Prior to SN 0300247156)..................................................274
FIGURE 6-5. LEVEL (SLAVE) CYLINDER ASSEMBLY - UPRIGHT (SN 0300247156 to Present) .............................................276
FIGURE 6-6. LIFT CYLINDER ASSEMBLY - JIB (Prior to SN 0300247156)...............................................................................278
FIGURE 6-7. LIFT CYLINDER ASSEMBLY - JIB (SN 0300247156 to Present)...........................................................................280
FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MAIN BOOM (Prior to SN 0300247156)................................................................282

TABLE OF CONTENTS
3121771 H800AJ 9
FIGURE 6-9. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN 0300247156 to Present)........................................................... 284
FIGURE 6-10. LIFT CYLINDER ASSEMBLY - TOWER BOOM (Prior to SN 0300247156)......................................................... 286
FIGURE 6-11. LIFT CYLINDER ASSEMBLY - TOWER BOOM (SN 0300247156 to Present) .................................................... 288
FIGURE 6-12. MASTER CYLINDER ASSEMBLY (Prior to SN 0300247156).............................................................................. 290
FIGURE 6-13. MASTER CYLINDER ASSEMBLY (SN 0300247156 to Present) ......................................................................... 292
FIGURE 6-14. STEER CYLINDER ASSEMBLY........................................................................................................................... 294
FIGURE 6-15. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (Prior to SN 0300247156)............................................... 296
FIGURE 6-16. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (SN 0300247156 to Present)........................................... 298
FIGURE 6-17. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (Prior to SN 0300247156).......................................... 300
FIGURE 6-18. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (SN 0300247156 to Present) ...................................... 302
SECTION 7 - HYDRAULIC .............................................................................................................................................................. 305
FIGURE 7-1. AXLE LOCKOUT HYDRAULIC DIAGRAM............................................................................................................. 306
FIGURE 7-2. DRIVE HYDRAULIC DIAGRAM.............................................................................................................................. 308
FIGURE 7-3. STANDARD HYDRAULIC DIAGRAM..................................................................................................................... 314
FIGURE 7-4. TOW HYDRAULIC DIAGRAM................................................................................................................................ 318
FIGURE 7-5. HYDRAULIC DIAGRAM LIST................................................................................................................................. 320
SECTION 8 - ELECTRICAL............................................................................................................................................................. 321
FIGURE 8-1. ELECTRICAL DIAGRAM LIST................................................................................................................................ 322
FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V GFI RECEPTACLE (ALL SPECS EXCEPT AUSTRALIAN & CE
SPECS)........................................................................................................................................................................................ 324
FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS) (MACHINES WITHOUT 4000W
GENERATOR).............................................................................................................................................................................. 326
FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS) (MACHINES WITH 4000W
GENERATOR).............................................................................................................................................................................. 328
FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V (ANSI, CSA & JAPANESE SPECS) ......................................... 330
FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS) (MACHINES WITHOUT 4000W
GENERATOR).............................................................................................................................................................................. 332
FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS) (MACHINES WITH 4000W
GENERATOR).............................................................................................................................................................................. 334
FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 POST GROUND (CE SPECS) (MACHINES WITHOUT
4000W GENERATOR) ................................................................................................................................................................. 336
FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 POST GROUND (CE SPECS) (MACHINES WITH
4000W GENERATOR) ................................................................................................................................................................. 338
FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 SIDE GROUND (CE SPECS) (MACHINES WITHOUT
4000W GENERATOR) ................................................................................................................................................................. 340
FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2X4 SIDE GROUND (CE SPECS) (MACHINES WITH
4000W GENERATOR) ................................................................................................................................................................. 342
FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE SPECS) (MACHINES WITHOUT 4000W
GENERATOR).............................................................................................................................................................................. 344
FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE SPECS) (MACHINES WITH 4000W
GENERATOR).............................................................................................................................................................................. 346
FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - BOX WITH COVER (ANSI EXPORT, AUSTRALIAN, CHINA &
JAPANESE SPECS)..................................................................................................................................................................... 348
FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 240V RECEPTACLE (WITH 4000W GENERATOR) (ALL SPECS
EXCEPT ANSI & CSA SPECS).................................................................................................................................................... 350
FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 240V RECEPTACLE (WITH 7500W SKYPOWER GENERATOR)
(ANSI & CSA SPECS).................................................................................................................................................................. 352
FIGURE 8-17. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT 7500W SKYPOWER GENERATOR)
(ALL SPECS EXCEPT ANSI & CSA SPECS) .............................................................................................................................. 354
FIGURE 8-18. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITH 7500W SKYPOWER GENERATOR)........ 356
FIGURE 8-19. AC BREAKER BOX INSTALLATION - WITH 2 BREAKERS (CE SPECS WITHOUT 4000W GENERATOR) (Prior
to SN 0300247156)....................................................................................................................................................................... 358
FIGURE 8-20. AC BREAKER BOX INSTALLATION - WITH 2 BREAKERS (CE SPECS WITH 4000W GENERATOR) (SN
0300247156 to Present)............................................................................................................................................................... 360
FIGURE 8-21. AC BREAKER BOX INSTALLATION - WITH 2 BREAKERS (BRAZIL SPECS) ................................................... 362
FIGURE 8-22. AC BREAKER BOX INSTALLATION - WITH 3 BREAKERS (CE SPECS WITH 4000W GENERATOR)............. 364
FIGURE 8-23. BATTERY CABLES INSTALLATION.................................................................................................................... 366
FIGURE 8-24. BATTERY STACK HARNESS (LH) ...................................................................................................................... 368
FIGURE 8-25. BATTERY STACK HARNESS (RH)...................................................................................................................... 370
FIGURE 8-26. BOOM VALVE HARNESS.................................................................................................................................... 372
FIGURE 8-27. BOOM CABLES INSTALLATION (MACHINES WITHOUT GENERATOR).......................................................... 374
FIGURE 8-28. BOOM CABLES INSTALLATION (AUSTRALIAN SPECS WITH 4000W GENERATOR)..................................... 376
FIGURE 8-29. BOOM CABLES INSTALLATION (CE SPECS WITH 4000W GENERATOR)...................................................... 378

TABLE OF CONTENTS
10 H800AJ 3121771
FIGURE 8-30. BOOM CABLES INSTALLATION (ANSI, ANSI EXPORT, CHINA, CSA & JAPANESE SPECS WITH 7500W
GENERATOR) ..............................................................................................................................................................................380
FIGURE 8-31. BOOM CABLES INSTALLATION (AUSTRALIAN & CE SPECS WITH 7500W GENERATOR)............................382
FIGURE 8-32. BOOM CABLE - MAIN BOOM...............................................................................................................................384
FIGURE 8-33. BOOM CABLE - TOWER BOOM ..........................................................................................................................386
FIGURE 8-34. BREAKER BOX KIT - WITH 2 BREAKERS (CE SPECS WITHOUT 4000W GENERATOR & BRAZIL SPECS)..388
FIGURE 8-35. BREAKER BOX KIT - WITH 2 BREAKERS (CE SPECS WITH 4000W GENERATOR).......................................390
FIGURE 8-36. BREAKER BOX KIT - WITH 3 BREAKERS (CE SPECS WITH 4000W GENERATOR).......................................392
FIGURE 8-37. CHARGER HARNESS ..........................................................................................................................................394
FIGURE 8-38. CONTROL HARNESS...........................................................................................................................................396
FIGURE 8-39. ELECTRICAL SYSTEM INSTALLATION ..............................................................................................................398
FIGURE 8-40. ENGINE HARNESS - KUBOTA.............................................................................................................................400
FIGURE 8-41. ENGINE TRAY HARNESS....................................................................................................................................402
FIGURE 8-42. GENERATOR HARNESS - 4000W.......................................................................................................................404
FIGURE 8-43. GENERATOR HARNESS - 7500W SKYPOWER .................................................................................................406
FIGURE 8-44. GENERATOR HARNESS - 4000W AND 7500W SKYPOWER.............................................................................408
FIGURE 8-45. GROUND CONTROL BOX HARNESS .................................................................................................................410
FIGURE 8-46. H-BRIDGE/CLUTCH HARNESS ...........................................................................................................................412
FIGURE 8-47. HYBRID 84V HARNESS .......................................................................................................................................414
FIGURE 8-48. MAIN VALVE HARNESS.......................................................................................................................................416
FIGURE 8-49. PLATFORM CONSOLE BOX HARNESS.............................................................................................................418
FIGURE 8-50. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)..................................................................................422
FIGURE 8-51. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)........................................................................................424
FIGURE 8-52. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE SPEC)...................................................426
FIGURE 8-53. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE SPEC).....................................................................428
FIGURE 8-54. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC) ....................................................................................430
FIGURE 8-55. RESOLVER/CONVERTER/INVERTER HARNESS ..............................................................................................432
FIGURE 8-56. STROBE LIGHT CONTROL HARNESS (BLUE & RED LIGHTS).........................................................................434
FIGURE 8-57. TURNTABLE HARNESS.......................................................................................................................................436
FIGURE 8-58. TURNTABLE/FUSE PANEL HARNESS................................................................................................................438
SECTION 9 - DECALS .....................................................................................................................................................................441
FIGURE 9-1. DECAL INSTALLATION - ANSI SPECS (ENGLISH LANGUAGE)..........................................................................442
FIGURE 9-2. DECAL INSTALLATION - AUSTRALIAN SPECS (ENGLISH LANGUAGE)............................................................444
FIGURE 9-3. DECAL INSTALLATION - BRAZIL SPECS (ENGLISH/PORTUGUESE LANGUAGES).........................................446
FIGURE 9-4. DECAL INSTALLATION - CE SPECS (ENGLISH LANGUAGE).............................................................................448
FIGURE 9-5. DECAL INSTALLATION - CHINA SPECS (ENGLISH/CHINESE LANGUAGES)....................................................450
FIGURE 9-6. DECAL INSTALLATION - CSA SPECS (ENGLISH/FRENCH LANGUAGES) ........................................................452
FIGURE 9-7. DECAL INSTALLATION - JAPANESE SPECS (ENGLISH/JAPANESE LANGUAGES) .........................................454
FIGURE 9-8. DECAL INSTALLATION - KOREAN SPECS (ENGLISH/KOREAN LANGUAGES) ................................................456
FIGURE 9-9. DECAL INSTALLATION - LATIN AMERICAN SPECS (ENGLISH/SPANISH LANGUAGES).................................458
FIGURE 9-10. DECALS INSTALLATION - OPTIONS...................................................................................................................460
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK..........................................................................................................463
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK.......................................................................................................464
SECTION 11 - SPECIAL OPTIONS .................................................................................................................................................467
FIGURE 11-1. SPECIAL OPTIONS ..............................................................................................................................................468
PART NUMBER INDEX....................................................................................................................................................................471

SECTION 1 - FRAME
3121771 H800AJ 11
SECTION 1 - FRAME

SECTION 1 - FRAME
12 H800AJ 3121771
FIGURE 1-1. AXLE INSTALLATION - WITHOUT TOW PACKAGE

SECTION 1 - FRAME
3121771 H800AJ 13
FIGURE 1-1. AXLE INSTALLATION - WITHOUT TOW PACKAGE
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001154584
Ref
AXLE INSTALLATION
D
1
0100011
AR
Compound, Locking
2
0642212
1
Bolt 3/4 x 1-1/2
3
0681608
4
Bolt 3/8 x 1 Grade 8
4
0682236
8
Bolt 3/4 x 4-1/2 Grade 8
5
0962102
2
Bushing
6
3020039
AR
Lubricant
7
3538047
2
Shim .25
8
3841287
1
Keeper, Pin
9
4070878
AR
Shim 16 Gauge
10
4070879
AR
Shim 11 Gauge
11
4711600
4
Washer 3/8
12
4740472
1
Washer
13
4892200
8
Washer 3/4
14
1001152719
1
Axle
15
1001204560
2
Axle Lockout Cylinder Assembly (See Separate Breakdown in
CYLINDER SECTION)
16
1001156710
1
Pin

SECTION 1 - FRAME
14 H800AJ 3121771
FIGURE 1-2. AXLE INSTALLATION - WITH TOW PACKAGE

SECTION 1 - FRAME
3121771 H800AJ 15
FIGURE 1-2. AXLE INSTALLATION - WITH TOW PACKAGE
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001155194
Ref
AXLE INSTALLATION
D
1
0100011
AR
Compound, Locking
2
0642212
1
Bolt 3/4 x 1-1/2
3
0681608
4
Bolt 3/8 x 1 Grade 8
4
0682236
8
Bolt 3/4 x 4-1/2 Grade 8
5
0962102
2
Bushing
6
3020039
AR
Lubricant
7
3538047
2
Shim .25
8
3841287
1
Keeper, Pin
9
4070878
AR
Shim 16 Gauge
10
4070879
AR
Shim 11 Gauge
11
4711600
4
Washer 3/8
12
4740472
1
Washer
13
4892200
8
Washer 3/4
14
1001154875
1
Axle
15
1001204560
2
Axle Lockout Cylinder Assembly (See Separate Breakdown in
CYLINDER SECTION)
16
1001156710
1
Pin

SECTION 1 - FRAME
16 H800AJ 3121771
FIGURE 1-3. STEER INSTALLATION - WITHOUT TOW PACKAGE

SECTION 1 - FRAME
3121771 H800AJ 17
FIGURE 1-3. STEER INSTALLATION - WITHOUT TOW PACKAGE
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001151034
Ref
STEER INSTALLATION
F
1
0100011
AR
Compound, Locking
2
0641607
4
Bolt 3/8 x 7/8
3
0641810
16
Bolt 1/2 x 1-1/4
4
3020029
AR
Lubricant
5
3422417
2
Pin
6
3422790
2
Pin
7
3841520
4
Keeper, Pin
8
4740256
AR
Washer, Thrust
9
4740473
2
Washer
10
1001103810
AR
Washer, Thrust
11
1001165657
4
Bearing
12
1001150372
2
Spindle
13
1001150539
2
Steer Cylinder Assembly (See Separate Breakdown in CYLINDER
SECTION)
14
1001161355
4
Kingpin
15
1001150937
4
Plate
16
1001151980
1
Tie-Rod
17
1001161399
2
Washer,Thrust
18
4740463
AR
Washer, Thrust

SECTION 1 - FRAME
18 H800AJ 3121771
FIGURE 1-4. STEER INSTALLATION - WITH TOW PACKAGE

SECTION 1 - FRAME
3121771 H800AJ 19
FIGURE 1-4. STEER INSTALLATION - WITH TOW PACKAGE
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001155192
Ref
STEER INSTALLATION
D
1
0100011
AR
Compound, Locking
2
0641607
6
Bolt 3/8 x 7/8
3
0641810
16
Bolt 1/2 x 1-1/4
4
3020029
AR
Lubricant
5
3422417
2
Pin
6
3422790
2
Pin
7
3841520
6
Keeper, Pin
8
4740256
AR
Washer, Thrust
9
4740473
2
Washer
10
1001103810
AR
Washer, Thrust
11
1001165657
4
Bearing
12
1001150372
2
Spindle
13
1001150539
2
Steer Cylinder Assembly (See Separate Breakdown in CYLINDER
SECTION)
14
1001161355
4
Kingpin
15
1001150937
4
Plate
16
1001154931
2
Tie-Rod
16A
0962181
1
Bushing
16B
0962152
1
Bushing
17
1001161399
2
Washer, Thrust
18
0741609
4
Screw 3/8 x 1-1/8
19
3340966
2
Pad, Stop
20
3422848
2
Pin, Hitch
21
4071059
AR
Shim 16 Gauge
22
4740155
3
Washer, Thrust
23
1001155035
1
Link
23A
0962348
1
Bushing
24
4740463
AR
Washer, Thrust

SECTION 1 - FRAME
20 H800AJ 3121771
FIGURE 1-5. WHEEL DRIVE AND FRAME VALVES INSTALLATION