JLG 800A-AJ Parts Manual

Illustrated Parts Manual

Models

800A

800AJ

S/N 0300069000

to S/N 0300140000

P/N

3121854

April 30, 2014

REVISION LOG

MODULE ON MACHINES

“WITHOUT UGM”

(UNIVERSAL

GROUND MODULE)

MODULE ON MACHINES

“WITH UGM” (UNIVERSAL

GROUND MODULE)

GROUND MODULE MODULE IDENTIFICATION

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

3121854 800A 800AJ A

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

REVISION LOG

B 800A 800AJ 3121854

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

3121854 800A 800AJ i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

ii 800A 800AJ 3121854

SECTION 1

FRAME

3121854 800A 800AJ 1-1

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) 3Not 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

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

104

101

113

114

106

108

SN 0300069000

TO SN 0300083332

SN 0300083332 TO SN 0300140000

202

203

204

201

109

202

203

204

301

303

302

201

301

303

302

FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS

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

6Not Used 7 3160204 2 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for

Breakdown)

8 3300007 20 Nut, Wheel 9Not 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

1A1B1C

1D1N1G1F1E1H2

161615

2WD

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

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

10531111

110

112

121

102

119

122

123

104

103

101

109

107

108

114 113

116

115

118

117

120

1A1B1C

1N1G1F1E1H

126A

126B

127 128

125

106

1061J1J

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

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

1615141312

11109

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

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

393837

343536

324021

51A 51B

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

0300140000) (4 BOLT ASSEMBLY)

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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