JLG 800A-AJ Parts Manual

5 (4)

Illustrated Parts Manual

Models 800A 800AJ

S/N 0300069000 to S/N 0300140000

P/N

3121854

April 30, 2014

REVISION LOG

GROUND MODULE MODULE IDENTIFICATION

MODULE ON MACHINES

MODULE ON MACHINES

“WITHOUT UGM”

“WITH UGM”

(UNIVERSAL

(UNIVERSAL

GROUND MODULE)

GROUND MODULE)

September 30, 2002 - Original Issue Of Manual (Manual edited to 0010580 Revision 21)

February 7, 2003 - Revised (Manual edited to 0010580 Revision 30)

June 30, 2003 - Revised (Manual edited to 0010580 Revision 45)

October 14, 2003 - Revised (Manual edited to 0010580 Revision 49)

February 10, 2004 - Revised (Manual edited to 0010580 Revision 49)

June 8, 2004 - Revised (Manual edited to 0010580 Revision 58)

October 19, 2004 - Revised (Manual edited to 0010580 Revision 64)

March 14, 2005 - Revised (Manual edited to 0010580 Revision 71)

July 15, 2005 - Revised (Manual edited to 0010580 Revision 74)

January 31, 2006 - Revised (Manual edited to 0010580 Revision 81)

May 31, 2006 - Revised (Manual edited to 0010580 Revision 88)

September 25, 2006 - Revised (Manual edited to 0010580 Revision 92)

April 17, 2007 - Revised (Manual edited to 0010580 Revision 101)

July 30, 2007 - Revised (Manual edited to 0010580 Revision 103)

December 7, 2007 - Revised (Manual edited to 0010580 Revision 105)

March 15, 2008 - Revised (Manual edited to 0010580 Revision 106)

November 28, 2008 - Revised (Manual edited to 0010580 Revision 115)

May 15, 2009 - Revised (Manual edited to 0010580 Revision 117)

October 15, 2009 - Revised Manual (Manual edited to 0010580 Revision 135)

April 15, 2010 - Revised Manual (Manual edited to 0010580 Revision 143)

December 30, 2010 - Revised Manual (Manual edited to 0010580 Revision 153)

April 27, 2011 - Revised Manual

July 29, 2011 - Revised Manual

October 21, 2011 - Revised Manual

January 10, 2012 - Revised Manual

May 31, 2012 - Revised Manual

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REVISION LOG

July 31, 2012 - Revised Manual

December 14, 2012 - Revised Manual

March 26, 2013 - Revised Manual

June 20, 2013 - Revised Manual

September 16, 2013 - Revised Manual

December 30, 2013 - Revised Manual

April 30, 2014 - Revised Manual

B

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TABLE OF CONTENTS

FIGURE NO.

TITLE

PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .1-1

1-1 AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 TIRE AND WHEEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1-3 DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) . . . . . . . . . . . . . . . 1-12 1-4 DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) . . . . . . . . . . . . . . . . . 1-16 1-5 DRIVE MOTOR ASSEMBLY (SN 0300069000 TO SN 0300083332) . . . . . . . . . . . . . . 1-20 1-6 DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO

SN 0300140000) (4 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1-7 DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO

SN 0300140000) (5 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 1-8 DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300069000 TO

SN 0300083332). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 1-9 DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO

SN 0300140000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 1-10 TOW PACKAGE INSTALLATION (2WS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVES & HORN INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-3 ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-4 AUXILIARY PUMP ASSEMBLY (SN 0300109067 TO SN 0300140000) . . . . . . . . . . . . 2-12 2-5 TURNTABLE BEARING AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . 2-16 2-6 SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353) . . . . . . . . . 2-18 2-7 SWING MOTOR/HUB ASSEMBLY (SN 0300134353 TO SN 0300140000) . . . . . . . . . 2-24 2-8 CATERPILLAR ENGINE INSTALLATION (SN 0300069000 to SN 0300139400) . . . . . 2-28 2-9 CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000). . . . . 2-38 2-10 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL). . . . 2-46 2-11 DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) . . . . . . . . . . 2-50 2-12 DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) . . . . . . . . . . 2-56 2-13 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL). . . . . . . . . . 2-68 2-14 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 2-15 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 2-16 ROTARY COUPLING INSTALLATION (SN 0300069000 TO SN 0300083332) . . . . . . 2-80 2-17 ROTARY COUPLING INSTALLATION (SN 0300083332 TO SN 0300137975). . . . . . . 2-82 2-18 ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000). . . . . . . 2-86 2-19 GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . . 2-90 2-20 GROUND CONTROL BOX ASSEMBLY (WITH UGM). . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 2-21 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . 2-98 2-22 HOODS INSTALLATION (SN 0300069000 TO SN 0300089982) . . . . . . . . . . . . . . . . . 2-102 2-23 HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) . . . . . . . . . . . . . . . . . 2-106 2-24 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112

SECTION 3 - BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 BOOM AND CYLINDER INSTALLATION - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 BOOM AND CYLINDER INSTALLATION - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-3 TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3-4 MAIN BOOM ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-5 ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 3-6 ROTATOR ASSEMBLY (SIDE ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-7 VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED). . . . . . . . . . . . . . . 3-24

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TABLE OF CONTENTS

FIGURE NO.

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SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) . . . . . . . . 4-2 4-2 PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM) . . . . . . . . . . 4-6 4-3 PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM) . . . . . 4-10 4-4 PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) . . . . . . . . 4-12 4-5 PLATFORM CONSOLE ASSEMBLY (SN 0300137975 TO SN 0300140000) . . . . . . . . 4-18 4-6 CONTROLLER ASSEMBLY (SWING & LIFT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 4-7 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 4-8 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-2 UPRIGHT LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-3 LIFT CYLINDER ASSEMBLY - JIB (800AJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5-4 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-5 LIFT CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5-6 MASTER CYLINDER ASSEMBLY - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5-7 MASTER CYLINDER ASSEMBLY - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5-8 SLAVE CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5-9 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5-10 TELESCOPE CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5-11 TELESCOPE CYLINDER ASSEMBLY - TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-2 DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332) . . . . . . . 6-4 6-3 DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000) . . . . . . . 6-8 6-4 DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332). . . 6-14 6-5 DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000). . . 6-18 6-6 STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND

AUXILIARY PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 6-7 STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) . . . 6-28 6-8 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-2 HARNESS COMPONENTS INSTALLATION WITHOUT UGM . . . . . . . . . . . . . . . . . . . 7-4 7-3 HARNESS COMPONENTS INSTALLATION WITH UGM . . . . . . . . . . . . . . . . . . . . . . . 7-24

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8-1 DECAL INSTALLATION (SN 0300069000 TO SN 0300078346) . . . . . . . . . . . . . . . . . . 8-2 8-2 DECAL INSTALLATION (SN 0300078346 TO SN 0300089982) . . . . . . . . . . . . . . . . . . 8-6 8-3 DECAL INSTALLATION (SN 0300089982 TO SN 0300140000) . . . . . . . . . . . . . . . . . . 8-10

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

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JLG 800A-AJ Parts Manual

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1-2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

800A 800AJ

3121854

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

0258286

Ref

FIXED AXLE INSTALLATION

C

1

0100011

AR

Compound, Locking

 

2

0681608

4

Bolt 3/8in-16NC x 1in (Grade 8)

 

3

Not Used

 

 

 

4

0641820

2

Bolt 1/2in-13NC x 2-1/2in

 

5

0642212

1

Bolt 3/4in-10NC x 1-1/2in

 

6

0962102

2

Bushing, Garmax

 

7

3422703

1

Pin, Axle Pivot

 

8

3538047

2

Shim, Wear

 

9

3539877

2

Plate, Stop

 

10

3539878

2

Plate, Stop

 

11

3841287

1

Keeper, Pin

 

12

4070878

AR

Shim 1/16in

 

13

4070879

AR

Shim 1/8in

 

14

4070944

AR

Shim 1/16in

 

15

4070945

AR

Shim 1/4in

 

16

4711600

4

Flatwasher 3/8in Narrow

 

17

4740472

1

Washer, Special

 

18

Not Used

 

 

 

19

4845658

1

Axle Weldment

 

 

 

Ref

OSCILLATING AXLE INSTALLATIONS

 

 

 

Ref

Oscillating Axle Without Tow Package

 

 

0272269

Ref

SN 0300069000 to SN 0300083332

A

 

0274264

Ref

SN 0300083332 to SN 0300140000

B

 

 

Ref

Oscillating Axle With Tow Package

 

 

0272655

Ref

SN 0300069000 to SN 0300083332

A

 

0274265

Ref

SN 0300083332 to SN 0300138599 (Note: No Longer

B

 

 

 

Available after SN 0300138599)

 

101

0100011

AR

Compound, Locking

 

102

0641414

4

Bolt 1/4in-20NC x 1-3/4in (SN 0300069000 to

 

 

 

 

SN 0300083332 Only)

 

103

0641608

4

Bolt 3/8in-16NC x1in

 

104

Not Used

 

 

 

105

0642212

1

Bolt 3/4in-10NC x 1-1/2in

 

106

0962102

2

Bushing, Composite

 

107

Not Used

 

 

 

108

1683078

2

Lockout Cylinder Assembly (See CYLINDER SECTION for

 

 

 

 

Breakdown)

 

109 to 111

Not Used

 

 

 

112

3422703

1

Pin, Main Pivot

 

113

3538047

2

Shim, Axle Wear

 

114

3841143

4

Shaft, Keeper 3/8in Dia x 3in

 

115

3841287

1

Shaft, Keeper 3/8in Dia x 6in

 

116

4070878

2

Shim, Axle Wear

 

117

4070879

2

Shim, Axle Wear

 

118

Not Used

 

 

 

 

 

 

 

 

3121854

800A 800AJ

1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

119

4640871

1

Valve, Lockout (SN 0300069000 to SN 0300083332 Only)

 

 

7012693

1

Seal Kit - 4640871 Valve

 

 

7002840

1

Pin Removal Tool

 

120

4711400

4

Flatwasher 1/4in Narrow (SN 0300069000 to

 

 

 

 

SN 0300083332 Only)

 

121

4711600

4

Flatwasher 3/8in Narrow

 

122

4740472

1

Washer, Special

 

123

Not Used

 

 

 

124

 

1

Axle Weldment Options:

 

 

4845658

 

Axle Without Tow Package

 

 

4846413

 

Axle With

 

125

0641816

2

Bolt 1/2in-13NC x 2in (SN 0300069000 to SN 0300083332

 

 

 

 

Only)

 

126

1100086

1

Plate, Cam Lockout (SN 0300069000 to SN 0300083332

 

 

 

 

Only)

 

127

4751800

4

Flatwasher 1/2in (SN 0300069000 to SN 0300083332 Only)

 

128

3422702

2

Pin

 

129

3422755

2

Pin

 

130

0681608

4

Bolt 3/8in-16NC x1in (Grade 8)

 

131

4568514

2

Spacer, Tube (SN 0300069000 to SN 0300083332)

 

 

 

Ref

STEERING INSTALLATIONS

 

 

 

Ref

2WS

 

 

0258287

Ref

SN 0300069000 to SN 0300069775

F

 

0272003

Ref

SN 0300069775 to SN 0300140000

B

 

 

Ref

4WS (Rear Steering Typical / Double Qty Listed for 4WS)

 

 

0258909

Ref

SN 0300069000 to SN 0300132176

C

 

1001100156

Ref

SN 0300132176 to SN 0300140000

B

 

1001137261

Ref

King Pin Kit

A

 

 

Ref

Note: Before ordering king pin kit, verify that machines is

 

 

 

 

equipped with the original components (king pin with 4 bolt

 

 

 

 

holes) or service kit components (king pin with 8 bolt

 

 

 

 

holes).

 

 

 

 

- If the king pin hole in the axle measurement exceeds

 

 

 

 

2.252in OD or is elongated, use King Pin Kit

 

 

 

 

p/n 1001137261.

 

 

 

Ref

Note: See Tow Package Installation for Steering

 

 

 

 

Components on Machines with Tow Option.

 

201

0100011

AR

Compound, Locking

 

202

0362726

1

Tie-Rod

 

203

0641608

6

Bolt 3/8in-16NC x 1in

 

204

 

AR

Bolt Options:

 

 

 

 

2WS

 

 

0641608

8

SN 0300069000 to SN 0300069775 (3/8in-16NC x 1in)

 

 

0641810

16

SN 0300069775 to SN 0300140000

 

 

 

 

(1/2in-13NC x 1-1/4in)

 

 

 

 

4WS

 

 

0641608

8

SN 0300069000 to SN 0300132176 (3/8in-16NC x 1in)

 

 

0641810

16

SN 0300132176 to SN 0300140000

 

 

 

 

(1/2in-13NC x 1-1/4in)

 

 

 

 

 

 

1-4

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

205

 

4

Bearing Options:

 

 

 

 

2WS

 

 

0962224

 

SN 0300069000 to SN 0300069775

 

 

0962448

 

SN 0300069775 to SN 0300140000

 

 

 

 

4WS

 

 

0962224

 

SN 0300069000 to SN 0300132176

 

 

0962448

 

SN 0300132176 to SN 0300140000

 

206

0962152

2

Bearing, Garmax

 

207

Not Used

 

 

 

208

1683740

2

Steer Cylinder Assembly (See CYLINDER SECTION for

 

 

 

 

Breakdown)

 

209 to 210

Not Used

 

 

 

211

3422701

2

Pin, Steer, Spindle Attach

 

212

3422702

2

Pin, Tie-Rod

 

213

Not Used

 

 

 

214

3841143

6

Shaft, Keeper 3/8in x 3in

 

215

 

1

Spindle Weldment (Right Side) Options:

 

 

 

 

2WS

 

 

4130357

 

SN 0300069000 to SN 0300069775

 

 

4130389

 

SN 0300069775 to SN 0300140000

 

 

 

 

4WS

 

 

4130357

 

SN 0300069000 to SN 0300132176

 

 

4130389

 

SN 0300132176 to SN 0300140000

 

216

 

1

Spindle Weldment (Left Side) Options:

 

 

 

 

2WS

 

 

4130358

 

SN 0300069000 to SN 0300069775

 

 

4130390

 

SN 0300069775 to SN 0300140000

 

 

 

 

4WS

 

 

4130358

 

SN 0300069000 to SN 0300132176

 

 

4130390

 

SN 0300132176 to SN 0300140000

 

217

4740111

4

Washer, Special

 

218

Not Used

 

 

 

219

4740463

AR

Washer, Thrust (.250in)

 

220

4740473

2

Washer, Special

 

221

1001103810

AR

Washer, Thrust (.187in)

 

222

4740256

AR

Washer, Thrust (.125in)

 

223

 

4

Kingpin Options:

 

 

 

 

2WS

 

 

3422753

 

SN 0300069000 to SN 0300069775

 

 

3422972

 

SN 0300069775 to SN 0300140000

 

 

 

 

4WS

 

 

3422753

 

SN 0300069000 to SN 0300132176

 

 

3422972

 

SN 0300132176 to SN 0300140000

 

224

3422754

2

Pin, Attach

 

 

 

 

 

 

3121854

800A 800AJ

1-5

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

 

Ref

HUB INSTALLATION (2WD ONLY)

 

 

0270209

Ref

SN 0300069000 to SN 0300083332

B

 

0273378

Ref

SN 0300083332 to SN 0300140000

D

301

0100011

AR

Compound, Locking

 

302 to 303

Not Used

 

 

 

304

0682016

16

Bolt 5/8in-16NC x 2in (Grade 8)

 

305

Not Used

 

 

 

306

2780229

2

Hub Assembly (See Items 401-412 for Breakdown)

 

307 to 309

Not Used

 

 

 

310

3300007

20

Lugnut

 

311 to 314

Not Used

 

 

 

315

4892000

16

Flatwasher 5/8in Hardened

 

 

2780229

Ref

HUB ASSEMBLY (2WD ONLY)

A

401

7017052

2

Spindle (1 per Assembly)

 

402

7017053

2

Housing (1 per Assembly)

 

403

7010404

2

Cup, Bearing - Inner (1 per Assembly)

 

404

7010405

2

Cone, Bearing - Inner (1 per Assembly)

 

405

7017056

2

Cup, Bearing - Outer (1 per Assembly)

 

406

7017055

2

Cone, Bearing - Outer (1 per Assembly)

 

407

7010406

2

Seal, Lip (1 per Assembly)

 

408

7000265

20

Stud (10 per Assembly)

 

409

7017054

2

Dust Cap (1 per Assembly)

 

410

7017051

2

Washer, Special (1 per Assembly)

 

411

7017057

2

Washer, Tanged (1 per Assembly)

 

412

7017058

2

Nut, Bearing (1 per Assembly)

 

501

 

Ref

FRAME WELDMENT OPTIONS:

 

 

 

Ref

SN 0300069000 to SN 0300083332

 

 

2360601

 

2WD/2WS with Foam-Filled Tires

 

 

2360603

 

4WD/2WS with Foam-Filled Tires

 

 

2360591

 

4WD/4WS with Foam-Filled Tires

 

 

 

Ref

SN 0300083332 to SN 0300140000

 

 

Use 2360645

 

2WD/2WS with Foam-Filled Tires (was p/n 2360639)

 

 

Use 2360647

 

4WD/2WS with Foam-Filled Tires (was p/n 2360641)

 

 

Use 2360709

 

4WD/4WS with Foam-Filled Tires (was p/n 2360643)

 

 

 

 

 

 

1-6

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

 

 

 

 

3121854

800A 800AJ

1-7

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS

7

 

 

4

 

202

 

5

15

 

13

203

10

SN 0300069000

201

 

TO SN 0300083332

301

 

 

302

14

303

3

 

8

 

108

101

204

 

 

 

 

104

 

101

 

114

202

 

106

103

113

 

 

203

201

SN 0300083332 TO SN 0300140000

301

302

303

109

204

1-8

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

 

Ref

WHEEL DRIVE INSTALLATIONS (SN 0300069000 TO

 

 

 

 

SN 0300083332)

 

 

0270209

Ref

2WD/2WS

B

 

0270210

Ref

4WD/2WS

B

 

0270211

Ref

4WD/4WS

B

 

 

Ref

Note: 2WD Qty Shown For 4WD, Double Qty Shown.

 

1 to 2

Not Used

 

 

 

3

0682016

16

Bolt 5/8in-11NC x 2in (Grade 8)

 

4

Use 0920119

4

Drive Brake Assembly (was p/n 0920117)

 

 

7018612

1

Repair Kit (Includes Case Seal, Piston Inner & Outer O-Rings

 

 

 

 

& Back-up Rings, Stator Disc, Rotor Disc, Return Plate,

 

 

 

 

Springs, Oil Seal, Bearing, 2 Retaining Rings & 2 Mounting

 

 

 

 

Face Gaskets) (1 Per Assembly)

 

 

7000731

2

Gasket, Mounting Face (2 Per Assembly)

 

 

7007990

1

O-Ring, Mounting (1 Per Assembly) (0920119 Brake)

 

 

 

Ref

Note: No Other Parts Available.

 

5

 

2

Drive Hub Assembly Options: (See DRIVE HUB ASSEMBLIES

 

 

 

 

for Breakdown)

 

 

2780227

 

2WD

 

 

2780228

 

4WD

 

6

Not Used

 

 

 

7

3160204

2

Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for

 

 

 

 

Breakdown)

 

8

3300007

20

Nut, Wheel

 

9

Not Used

 

 

 

10

4300097

4

Stud

 

11 to 12

Not Used

 

 

 

13

4891800

4

Flatwasher 1/2in

 

14

4892000

16

Flatwasher, 5/8in Hardened

 

15

3311801

4

Nut 1/2in-13 NC

 

 

 

Ref

WHEEL DRIVE INSTALLATION (SN 0300083332 TO

 

 

 

 

SN 0300140000)

 

 

0273378

Ref

2WD/2WS

E

 

0273704

Ref

4WD/2WS

D

 

0274232

Ref

4WD/4WS

D

 

 

Ref

Note: 2WD Qty Shown. For 4WD, Double Qty Shown.

 

101

0100011

AR

Compound, Locking

 

102

Not Used

 

 

 

103

3311801

4

Nut 1/2in-13 NC

 

104

0682016

16

Bolt 5/8in-11NC x 2in (Grade 8)

 

105

2300016

AR

Fluid, Hydraulic (Not Shown)

 

106

2780272

2

Drive Hub Assembly (See DRIVE HUB ASSEMBLY for

 

 

 

 

Breakdown)

 

107

3020008

AR

Lubricant (Not Shown)

 

 

 

 

 

 

3121854

800A 800AJ

1-9

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

108

 

2

Drive Motor Assembly Options:

 

 

Use 3160347

2

2WD Rear (SN 0300083332 to SN 0300098925 p/n was

 

 

 

 

3160308 - See DRIVE MOTOR ASSEMBLY (4 BOLT

 

 

 

 

ASSEMBLY) for Breakdown) (SN 0300098925 to

 

 

 

 

SN 0300140000 p/n 3160347 - See DRIVE MOTOR

 

 

 

 

ASSEMBLY (5 BOLT ASSEMBLY) for Breakdown)

 

 

Use 3160348

4

4WD Front & Rear (SN 0300083332 to SN 0300098644 p/n

 

 

 

 

was 3160266 - See DRIVE MOTOR ASSEMBLY (4 BOLT

 

 

 

 

ASSEMBLY) for Breakdown) (SN 0300098644 to

 

 

 

 

SN 0300140000 p/n 3160348 - See DRIVE MOTOR

 

 

 

 

ASSEMBLY (5 BOLT ASSEMBLY) for Breakdown)

 

109

3300007

20

Nut, Wheel

 

110 to 112

Not Used

 

 

 

113

4891800

4

Flatwasher, 1/2in Hardened

 

114

4892000

16

Flatwasher, 5/8in Hardened

 

 

 

Ref

TIRE AND WHEEL INSTALLATIONS

 

 

0270886

Ref

15-625 Foam-Filled

A

 

0270888

Ref

18-625 Foam-Filled

A

 

0258399

Ref

IN445/55D19.5 Foam-Filled

B

 

0274177

Ref

IN385/65D19.5 Foam-Filled

A

 

0271085

2

15-625 Foam-Filled Left Side

 

 

0271086

2

15-625 Foam-Filled Right Side

 

 

0271090

2

18-625 Foam-Filled Left Side

 

 

0271091

2

18-625 Foam-Filled Right Side

 

 

0258333

2

IN445/55D19.5 Foam-Filled Left Side

 

 

0258334

2

IN445/55D19.5 Foam-Filled Right Side

 

 

4520348

2

IN385/65D19.5 Non-Marking Foam-Filled Left Side

 

 

4520347

2

IN385/65D19.5 Non-Marking Foam-Filled Right Side

 

 

 

Ref

Note: Assemblies may require ballast/foam filling to

 

 

 

 

manufacturer’s specifications prior to installing on a

 

 

 

 

machine. Refer to Operation & Safety or Service &

 

 

 

 

Maintenance Manuals. Purchase individual tire and/or rim

 

 

 

 

only if able to foam fill tire & wheel assembly, otherwise,

 

 

 

 

purchase complete assembly,

 

201

Not Required

1

Decal

 

202

 

1

Tire Options:

 

 

4520252

 

15-625

 

 

4520253

 

18.625

 

 

4520205

 

IN445/55D19.5

 

 

4520242

 

IN385/65D19.5 Non-Marking (15 x 19.5)

 

203

Not Required

1

Valve, Air

 

204

 

1

Rim, Wheel Options:

 

 

4860224

 

13 x 24.5

 

 

4860225

 

15 x 24.5

 

 

4860188

 

14 x 19.5

 

 

 

 

 

 

1-10

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

0256196

Ref

WHEEL COVER INSTALLATION (OPTIONAL)

2/A

301

1670776

4

Cover, Wheel

 

302

0641550

20

Bolt 5/16in - 18NC x 6-1/4in

 

303

0100011

AR

Compound, Locking

 

 

 

 

 

 

3121854

800A 800AJ

1-11

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332)

6C

 

6D

9

21

17

6E

10

6F

7

6H

 

6

8

6B

7

 

6G

 

6A

11

 

2020 2

5

1 4

5

15

16

15

3G

3A

3E

 

 

 

 

 

1J

 

3B

 

 

3C

3

 

 

14

3D

 

2WD

3C

 

13

 

 

4WD

3F

 

 

 

12

 

 

 

3B

 

15

16

15

25

1H

1E

1F

1G

1J

1

1N

1D

1C

1B

1A

19

1-12

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

2780227

Ref

DRIVE HUB ASSEMBLY (2WD)

A

 

2780228

Ref

DRIVE HUB ASSEMBLY (4WD)

D

1

See Note

1

Spindle/Housing Assembly (Note: Not Available - Purchase

 

 

 

 

Individual Components.)

 

1A

7010464

1

Spindle

 

1B

7000236

1

Seal

 

1C

7000273

1

Cone, Bearing

 

1D

7000272

1

Cup, Bearing

 

1E

7000275

1

Cone, Bearing

 

1F

7000274

1

Cup, Bearing

 

1G

7017033

1

Housing

 

1H

7000239

1

Washer, Thrust

 

1I

7000240

1

Ring, Retaining

 

1J

7001928

1

Plug, Pipe

 

1K

Not Used

 

 

 

1L

Not Used

 

 

 

1M

Not Used

 

 

 

1N

7000265

10

Stud, Wheel

 

2

7017034

1

Gear, Ring

 

3

See Note

1

Carrier Assembly (Note: Not Available - Purchase Individual

 

 

 

 

Components.)

 

3A

7017036

1

Carrier

 

3B

7001901

6

Thrustwasher, Tanged

 

3C

7001902

96

Bearing, Needle

 

3D

7001903

3

Spacer, Thrust

 

3E

7017040

3

Shaft, Planet

 

3F

7017037

3

Gear, Cluster

 

3G

7001906

3

Rollpin

 

4

7017035

1

Gear, Internal

 

5

7000224

2

O-Ring

 

6

See Note

1

Cover Assembly (Note: Not Available - Purchase Individual

 

 

 

 

Components.)

 

6A

7024155

1

Cover

 

6B

7017042

1

Cap

 

6C

7000220

4

Bolt 1/4in-20NC x 3/4in

 

6D

7000231

1

Cap, Disengage

 

6E

7000235

1

Rod, Disengage

 

6F

7000213

1

O-Ring

 

6G

7000238

1

O-Ring

 

6H

7017048

1

Plug, Pipe

 

7

7000282

2

Thrustwasher

 

8

7000283

1

O-Ring

 

9

7000284

1

Ring, Retaining

 

10

7017027

1

Ring, Retaining

 

11

 

1

Shaft, Input Options:

 

 

7017039

 

2WD

 

 

7017044

 

4WD

 

 

 

 

 

 

3121854

800A 800AJ

1-13

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

12

 

1

Spacer, Input Options:

 

 

7017041

 

2WD

 

 

7017045

 

4WD

 

13

 

1

Gear, Sun Options:

 

 

7017038

 

2WD

 

 

7017043

 

4WD

 

14

 

AR

Spacer, Input Options:

 

 

Not Required

0

2WD

 

 

7017046

1

4WD

 

15

7000287

4

Thrustwasher

 

16

7000288

2

Thrustwasher

 

17

7000289

12

Bolt 3/8in-16NC x 2-1/2in (Grade 8)

 

18

Not Used

 

 

 

19

7000290

1

Coupling

 

20

7017047

2

Pin, Dowel

 

21

 

AR

Thrustwasher Options:

 

 

7017050

1

2WD

 

 

Not Required

0

4WD

 

22 to 24

Not Used

 

 

 

25

7017068

1

Seal Kit (Includes Items 1B, 1I, 5, 6F, 6G, 15 &16)

 

 

 

 

 

 

1-14

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

 

 

 

 

3121854

800A 800AJ

1-15

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000)

6C

 

 

6D

17

9

6E

21

 

 

10

6F

 

 

7

6H

 

6

 

8

6B

 

 

 

6G

 

7

 

 

 

6A

11

 

 

2020

2 5

1 4

 

 

 

1H

5

 

 

1E

 

 

 

 

15

 

1F

 

 

 

 

16

 

1

 

 

 

 

15

3G

1G

 

 

 

 

 

 

 

 

1J

3

 

 

3E

3A

 

 

 

 

 

 

 

1J

 

3B

1N

13

3C

1D

 

3D

12

 

3C

 

 

 

 

1C

15

3F

16

1B

3B

 

15

1A

 

35

 

125

 

126A

19

126B

 

127

 

128

27

 

111

110

112

121

102

122

123

119

104

103

106

103

106 26

101

116

115

109

118

117

107

120

 

108

114

31

113

 

105

 

28

 

29

1-16

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

2780272

Ref

DRIVE HUB/BRAKE ASSEMBLY

B

 

2780227

Ref

Hub Assembly

A

1

See Note

1

Spindle/Housing Assembly (Note: Not Available - Purchase

 

 

 

 

Individual Components.)

 

1A

7010464

1

Spindle

 

1B

7000236

1

Seal

 

1C

7000273

1

Cone, Bearing

 

1D

7000272

1

Cup, Bearing

 

1E

7000275

1

Cone, Bearing

 

1F

7000274

1

Cup, Bearing

 

1G

7017033

1

Housing

 

1H

7000239

1

Washer, Thrust

 

1I

7000240

1

Ring, Retaining

 

1J

7001928

1

Plug, Pipe

 

1K

Not Used

 

 

 

1L

Not Used

 

 

 

1M

Not Used

 

 

 

1N

7000265

10

Stud, Wheel

 

2

7024782

1

Gear, Ring

 

3

See Note

1

Carrier Assembly (Note: Not Available - Purchase Individual

 

 

 

 

Components.)

 

3A

7024147

1

Carrier

 

3B

7001901

6

Thrustwasher, Tanged

 

3C

7001902

96

Bearing, Needle

 

3D

7001903

3

Spacer, Thrust

 

3E

7024146

3

Shaft, Planet

 

3F

7024148

3

Gear, Cluster

 

3G

7001906

3

Rollpin

 

4

7024151

1

Gear, Internal

 

5

7000224

1

O-Ring

 

6

See Note

1

Cover Assembly (Note: Not Available - Purchase Individual

 

 

 

 

Components.)

 

6A

7024155

1

Cover

 

6B

7024783

1

Cap

 

6C

7000220

4

Bolt 1/4in-20NC x 3/4in

 

6D

7000231

1

Cap, Disengage

 

6E

7000235

1

Rod, Disengage

 

6F

7000213

1

O-Ring

 

6G

7000238

1

O-Ring

 

6H

7017048

1

Plug, Pipe

 

7

7000282

2

Thrustwasher

 

8

7000283

1

O-Ring

 

9

7000284

1

Ring, Retaining

 

10

7000285

1

Ring, Retaining

 

11

7024781

1

Shaft, Input

 

12

7024154

1

Spacer, Input

 

13

7024149

1

Gear, Sun

 

14

Not Used

 

 

 

 

 

 

 

 

3121854

800A 800AJ

1-17

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

15

7000287

4

Thrustwasher

 

16

7000288

2

Thrustwasher

 

17

7000289

12

Bolt 3/8in-16NC x 2-1/2in (Grade 8)

 

18

Not Used

 

 

 

19

7000290

1

Coupling

 

20

7017047

2

Pin, Dowel

 

21

7017050

1

Thrustwasher

 

22 to 25

Not Used

 

 

 

26

7024182

1

Brake Assembly (Includes Items 101-123)

 

27

7024763

2

O-Ring

 

28

7024717

2

Stud 1/2in-13NC x 4-5/8in

 

29

7024718

2

Nut 1/2in-13NC

 

30

Not Used

 

 

 

31

7000731

1

Gasket

 

32 to 34

Not Used

 

 

 

35

7017068

1

Seal Kit - Hub (Includes Items 1B,5,6F,6G & 8)

 

 

7024182

Ref

BRAKE ASSEMBLY

 

101

7024189

1

Shaft

 

102

Use 7024182

1

Housing (Note: Not Available - Purchase Complete Assy.)

 

103

Use 7024193

2

Plate, Friction

 

104

Use 7024193

1

Plate, Pressure

 

105

7000731

1

Gasket

 

106

Use 7024193

2

Plate, Outer

 

107

See Note

1

Gasket (Note: Use Item 125, 127 or 128.)

 

108

7024191

1

Cylinder

 

109

7024192

1

Piston

 

110

Use 7024197

1

Bearing, Ball

 

111

Use 7024197

1

Ring, Retaining

 

112

Use 7024197

1

Seal, Shaft

 

113

See Note

6

Capscrew (Note: Not Available for Purchase.)

 

114

See Note

6

Lockwasher (Note: Not Available for Purchase.)

 

115

Use 7024194

1

O-Ring

 

116

Use 7024194

1

Ring, Back-up

 

117

Use 7024194

1

O-Ring

 

118

Use 7024194

1

Ring, Back-up

 

119

7024190

2

Pin, Dowel

 

120

See Note

1

Plug (Note: Not Available - Purchase Locally.)

 

121

See Note

2

Plug (Note: Not Available - Purchase Locally.)

 

122

Use 7024195

10

Spring Kit (Natural)

 

123

Use 7024196

2

Spring Kit (Blue)

 

124

Not Used

 

 

 

125

7024194

1

Seal Kit - Brake (Includes Items 105, 107 & 115-118)

 

126

 

 

Spring Kit - Brake Options:

 

126A

7024195

1

Includes 12 Natural Colored Springs Item 122

 

 

 

 

(was p/n 7024195)

 

 

 

 

Note: Spring Kit no Longer Available, Purchase Kit p/n

 

 

 

 

7024196.

 

126B

7024196

1

Includes 12 Natural & 2 Blue Colored Springs Items 122 & 123

 

 

 

 

 

 

1-18

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

127

7024193

1

Friction Disc Kit - Brake (Includes Items 103, 104, 106 & 107)

 

128

7024197

1

Bearing Kit - Brake (Includes Items 107 & 110-112)

 

 

 

 

 

 

3121854

800A 800AJ

1-19

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (SN 0300069000 TO SN 0300083332)

4

 

 

7

5

6

8

 

 

 

3

9

10

2

1

11

12

13

23

22

 

 

 

 

15

14

21

 

19

 

 

 

18

 

 

20

17

16

 

 

 

 

 

 

 

 

 

24

 

 

 

 

 

 

 

 

 

30

 

 

 

 

 

 

31

1-20

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (SN 0300069000 TO SN 0300083332)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

3160204

Ref

DRIVE MOTOR ASSEMBLY

A

1

7012701

1

Shaft - 13 Teeth

 

2

Use 2900788

1

Seal, Shaft

 

3

7012702

2

Bearing, Cradle

 

4

See Note

1

Housing (Note: Not Available - Purchase Complete Assy.)

 

5

7012703

1

Rod, Piston

 

6

7012704

1

Piston, Stroking

 

7

Use 2900788

1

O-Ring

 

8

7012705

1

Nut, Adapter

 

9

7012706

1

Bearing, Roller

 

10

7012707

4

Bolt, Metric Socket Head M12 x 65

 

11

7012708

1

Block, Port

 

12

7012709

1

Shim

 

13

7012710

1

Pin, Dowel M6 x 18

 

14

Use 2900788

1

O-Ring

 

15

7012711

1

Nut, Cap M10 x 1in

 

16

7012712

1

Screw, Adjusting

 

17

Use 2900788

2

O-Ring

 

18

7012713

1

Nut, Jam M10 x 1in

 

19

Use 7012716

1

Rotary Group Assembly

 

20

See Note

1

Plug (Note: Not Available - Purchase Locally.)

 

21

Use 7012716

1

Plate, Swash

 

22

7012714

1

Bearing, Roller

 

23

7012715

1

V-Ring

 

24

7012700

1

Control Plate Assembly

 

25 to 29

Not Used

 

 

 

30

2900788

1

Seal Kit (Includes Items 2,7,14,17 and O-Rings under Item 24)

 

31

7012716

1

Rotary Group Kit (Includes Items 19 and 21)

 

 

 

 

 

 

3121854

800A 800AJ

1-21

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN

0300140000) (4 BOLT ASSEMBLY)

 

30

 

29

 

 

 

 

 

 

 

27

28

 

7

 

 

26

 

 

31

 

 

 

 

 

 

 

 

 

 

41

39

 

 

 

8

 

 

25

 

 

4

 

38

 

 

 

 

2

37

 

 

 

 

 

23

 

 

 

 

10

 

22

8

24

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

19

 

 

 

 

 

17

18

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

 

13

 

 

 

 

 

12

15

 

 

 

 

 

 

 

 

 

 

14

6

 

 

 

 

 

 

 

9

 

 

1

 

33

 

 

 

 

 

 

 

 

33

 

 

34

 

 

 

 

 

 

 

34

 

36

 

 

 

 

 

 

 

 

 

 

 

35

 

 

 

 

 

 

 

1

20

 

 

32

 

 

 

 

 

 

 

 

 

 

 

40

 

 

 

 

 

21

 

50

 

 

 

 

5

 

 

 

 

42

51A

 

 

 

 

51B

 

 

 

 

43

 

 

 

 

 

5

1-22

800A 800AJ

3121854

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN

0300140000) (4 BOLT ASSEMBLY)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

 

 

Ref

DRIVE MOTOR ASSEMBLY

 

 

3160308

Ref

2WD

C

 

3160266

Ref

4WD

C

 

 

Ref

Note: Original Equipment Motor p/n 3160308 & p/n 3160266

 

 

 

 

uses 4 bolts to assemble the motor. Service Replacement

 

 

 

 

Motor p/n 3160347 & p/n 3160348 motors use 5 bolts to

 

 

 

 

assemble the motor. Visually identify component before

 

 

 

 

ordering parts. If equipped with p/n 3160347 or p/n 3160348

 

 

 

 

Refer to next illustration.

 

1

7022302

2

Bearing, Journal

 

2

Use 7022328

1

O-Ring

 

3

Use 7022328

1

O-Ring

 

4

7007446

1

Pin

 

5

7007438

2

Ring, Retaining

 

6

 

1

Swashplate Options:

 

 

7024861

 

2WD

 

 

7022305

 

4WD

 

7

Use 7022328

1

O-Ring

 

8

 

AR

Pin Options:

 

 

7027435

2

2WD

 

 

Not Required

0

4WD

 

9

 

1

Cylinder Block Kit (Includes Items 11-19) Options:

 

 

7027740

 

2WD

 

 

7023907

 

4WD

 

10

 

1

Plate, Valve Options:

 

 

7024862

 

2WD

 

 

7023908

 

4WD

 

11

See Note

1

Block, Cylinder (Note: Use Item 51A or 51B.)

 

12

 

1

Guide, Slipper Retainer Options:

 

 

Use 7027740

 

2WD

 

 

7021277

 

4WD

 

13

7021275

3

Pin, Slipper Hold Down

 

14

 

9

Piston Assembly Options:

 

 

7024865

 

2WD

 

 

Use 7023907

 

4WD

 

15

 

1

Retainer, Slipper Options:

 

 

Use 7027740

 

2WD

 

 

7022310

 

4WD

 

16

7022311

1

Ring, Retaining

 

17

 

1

Spring Options:

 

 

7024867

 

2WD

 

 

7022312

 

4WD

 

18

 

1

Washer

 

 

7022313

 

2WD

 

 

Use 7023907

 

4WD

 

19

7022314

1

Retainer, Spring

 

20

7023910

1

Shaft

 

21

7007439

1

Ring, Retaining

 

 

 

 

 

 

3121854

800A 800AJ

1-23

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN

0300140000) (4 BOLT ASSEMBLY) (CONTINUED)

ITEM #

PART NUMBER

QTY.

DESCRIPTION

REV.

 

 

 

 

 

22

 

1

Cap, End - Axial Options:

 

 

See Note

 

2WD (Note: Not Available - Purchase Complete Assy.)

 

 

7022367

 

4WD

 

23

7022368

4

Screw

 

24

7021249

1

Bearing, Needle

 

25

7022321

1

Plug (Includes Item 26)

 

26

Use 7022328

1

O-Ring

 

27

7007420

1

Plug (Includes Item 28)

 

28

Use 7022328

1

O-Ring

 

29

7007419

2

Plug (Includes Item 30)

 

30

Use 7022328

2

O-Ring

 

31

 

1

Seat, Spring Options:

 

 

7027741

 

2WD

 

 

7022372

 

4WD

 

32

 

1

Housing Options:

 

 

7024870

 

2WD

 

 

7022370

 

4WD

 

33

7007419

2

Plug (Items Item 34)

 

34

Use 7022328

2

O-Ring

 

35

7022321

1

Plug (Items Item 36)

 

36

Use 7022328

1

O-Ring

 

37

Use 7022328

1

O-Ring

 

38

Use 7022328

1

Ring, Seal

 

39

 

1

Piston, Servo Options:

 

 

7024871

 

2WD (Includes Items 37 & 38)

 

 

7022323

 

4WD (Piston Only - Does not include items 37 & 38)

 

40

7007437

1

Bearing

 

41

7022326

1

Spring

 

42

Use 7022328

1

Seal, Lip

 

43

7022371

1

Washer, Support

 

44 to 49

Not Used

 

 

 

50

7022328

1

Seal Kit (Includes Items 2,3,7,26,28,30,34,36,37,38 and 42)

 

51

 

1

Cylinder Block Kit (Includes Items 11-19) Options:

 

51A

7027740

 

2WD

 

51B

7023907

 

4WD

 

 

 

 

 

 

1-24

800A 800AJ

3121854

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