JLG 800A-AJ Parts Manual

Illustrated Parts Manual

Models

800A

800AJ

Prior to

S/N 0300069000

P/N

3120741

April 30, 2014

REVISION LOG

Note: See Note Below to Identify whether Machine is Equipped with ADE System.

ADE SYSTEM

All 800A and 800AJ machines from S/N 0300064432 to present incorporate the ADE System, but no clean S/N break exists. The following machine serial numbers prior to S/N 0300064432 also utilize ADE: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975, 0300064000-0300064017, 0300064390, 0300064392 & 0300064411. A machine that incorporates ADE System can be outwardly identified by the analyzer connection at the base of the platform console box.

October 1998 - Original Issue Of Manual

December 1998 - Revised

May 31, 1999 - Revised

September 1, 1999 - Revised (Edited to B/M 0010551 Revision 5)

November 9, 1999 - Updated Page 6-12

March 24, 2000 - (Edited to B/M 0010551 Revision 7)

May 4, 2001 - Revised (Manual edited to 0010551 Revision 16)

(Manual edited to 0010580 Revision 2 With ADE System)

October 20, 2001 - Revised (Manual edited to 0010580 Revision 5 With ADE System)

January 24, 2002 - Revised

July 16, 2002 - Revised (Manual edited to B/M 0010580 Revision 21 With ADE System)

September 30, 2002 - Added "Prior to S/N 0300069000" to Front Cover. Refer to Parts Manual 3121176 for Machines Built S/N 0300069000 to Present.

February 1, 2003 - Updated Section 3

June 30, 2003 - Revised

October 8, 2004 - Revised

March 1, 2005 - Revised

June 1, 2006 - Revised

September 25, 2006 - Revised

April 18, 2007 - Revised

July 31, 2007 - Revised

December 10, 2007 - Revised

3120741 A

March 15, 2008 - Revised

November 28, 2008 - Revised

May 15, 2009 - Revised

October 15, 2009 - Revised

April 15, 2010 - Revised

December 30, 2010 - Revised

April 27, 2011 - Revised

July 29, 2011 - Revised

October 21, 2011 - Revised

January 10, 2012 - Revised

May 31, 2012 - Revised

July 31, 2012 - Revised

December 14, 2012 - Revised

March 26, 2013 - Revised

June 20, 2013 - Revised

September 16, 2013 - Revised

December 30, 2013 - Revised

REVISION LOG

April 30, 2014 - Revised

B 3120741

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 DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-3 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-4 DRIVE HUB ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-5 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

1-6 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

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

2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4 TURNTABLE AND SWING DRIVE INSTALLATIONS (PRIOR TO SN 0300068040) . . . .2-12

2-5 TURNTABLE AND SWING DRIVE INSTALLATIONS (SN 0300068040 TO

SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-6 SWING HUB ASSEMBLY (PRIOR TO SN 0300068040) . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-7 SWING BRAKE ASSEMBLY (PRIOR TO SN 0300068040) . . . . . . . . . . . . . . . . . . . . . . .2-20

2-8 SWING MOTOR ASSEMBLY (PRIOR TO SN 0300068040) . . . . . . . . . . . . . . . . . . . . . .2-22

2-9 SWING MOTOR/HUB ASSEMBLY (SN 0300068040 TO SN 0300069000) . . . . . . . . . .2-24

2-10 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-11 GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . . . . . . . .2-38

2-12 FORD ENGINE WITH CARBURETOR INSTALLATIONS (PRIOR TO

SN 0300048538) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-13 FORD ENGINE WITH EFI INSTALLATIONS (SN 0300048538 TO SN 0300069000) . . .2-48 2-14 DUAL FUEL INSTALLATIONS (FORD MACHINE OPTION) (PRIOR TO

SN 0300048538) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

2-15 DUAL FUEL INSTALLATIONS (FORD MACHINE OPTION) (SN 0300048538 TO

SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

2-16 GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . .2-64

2-17 ISUZU ENGINE INSTALLATIONS - 4JB1 (SN 0300060285 TO SN 0300069000) . . . . .2-68

2-18 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

2-19 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

2-20 ROTARY COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82

2-21 GROUND CONTROL BOX ASSEMBLY (PRIOR TO SN 0300064432) . . . . . . . . . . . . . .2-84

2-22 GROUND CONTROL BOX ASSEMBLY (ADE SYSTEM) (SN 0300064432 TO

SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

2-23 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . .2-94

2-24 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-98

2-25 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102

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 ASSEMBLIES (FRONT ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-6 ROTATOR ASSEMBLIES (SIDE ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-7 VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED). . . . . . . . . . . . . . . .3-24

3120741 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

4-1 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) . . . . . . . . . . . . . . . . . . . .4-6

4-3 PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300064432) . . . . . . . . . . . . . . . . 4-10

4-4 PLATFORM CONSOLE ASSEMBLY (WITH ADE SYSTEM) (SN 0300064009 ONLY) . .4-16 4-5 PLATFORM CONSOLE ASSEMBLY (WITH ADE SYSTEM) (SN 0300064432 TO

SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-6 CONTROLLER ASSEMBLY (SWING AND LIFT) (PRIOR TO SN 0300064432) . . . . . . .4-26

4-7 CONTROLLER ASSEMBLY (SWING & LIFT) (WITH ADE SYSTEM) (SN 0300064432

TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4-8 CONTROLLER ASSEMBLY (DRIVE AND STEER) (PRIOR TO SN 0300064432) . . . . . 4-32

4-9 CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)

(SN 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

4-10 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-3 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-4 STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND

AUXILIARY PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-5 STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) . . . .6-16

6-6 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

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

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 HARNESS COMPONENTS INSTALLATION (PRIOR TO SN 0300064432) . . . . . . . . . .7-6

7-3 HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)

(SN 0300064009 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7-4 HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)

(SN 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

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

8-1 DECALS INSTALLATION - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATION - COUNTRY SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1

ii 3120741

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3120741 iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 3120741

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 DRIVE HUB ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 DRIVE VALVES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

E C T

I O N

3120741 1-1

SECTION 1 FRAME

S E C T

I O N

FIGURE 1-1. AXLE AND STEERING INSTALLATION

1-2 3120741

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258286 FIXED AXLE INSTALLATION Ref C

1 0100011 Compound, Locking AR 2 0681608 Bolt 3/8in-16NC x 1in (Grade 8) 4 3 Not Used 4 0641820 Bolt 1/2in-13NC x 2-1/2in 2 5 0642212 Bolt 3/4in-10NC x 1-1/2in 1 6 0962102 Bushing, Garmax 2 7 3422703 Pin, Axle Pivot 1 8 3538047 Shim, Wear 2

9 3539877 Plate, Stop 2 10 3539878 Plate, Stop 2 11 3841287 Keeper, Pin 1 12 4070878 Shim 1/16in AR 13 4070879 Shim 1/8in AR 14 4070944 Shim 1/16in AR 15 4070945 Shim 1/4in AR 16 4711600 Flatwasher 3/8in Narrow 4 17 4740472 Washer, Special 1 18 Not Used 19 4845658 Axle Weldment 1

S E

I O N

OSCILLATING AXLE INSTALLATIONS Ref 0258285 PRIOR TO SN 0300068040 Ref E 0272269 SN 0300068040 TO SN 0300069000 Ref A

101 0100011 Compound, Locking AR 102 0641414 Bolt 1/4in-20NC x 1-3/4in 4 103 0641608 Bolt 3/8in-16NC x1in 4 104 Not Used 105 0642212 Bolt 3/4in-10NC x 1-1/2in 1 106 0962102 Bushing, Composite 2 107 Not Used 108 1683078 Lockout Cylinder Assembly (See CYLINDER SECTION for

Breakdown)

109 to 111 Not Used

112 3422703 Pin, Main Pivot 1 113 3538047 Shim, Axle Wear 2 114 3841143 Shaft, Keeper 3/8in Dia x 3in 4 115 3841287 Shaft, Keeper 3/8in Dia x 6in 1 116 4070878 Shim, Axle Wear 2 117 4070879 Shim, Axle Wear 2 118 Not Used 119 4640871 Valve, Lockout 1

7012693 Seal Kit - 4640871 Valve 1 7002840 Pin Removal Tool 1

120 4711400 Flatwasher 1/4in Narrow 4 121 4711600 Flatwasher 3/8in Narrow 4 122 4740472 Washer, Special 1

3120741 1-3

SECTION 1 FRAME

S E

I O N

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

123 Not Used 124 4845658 Axle Weldment 1 125 Bolt Options: 2

0641814 Bolt 1/2in-13NC x 1-3/4in (Prior to SN 0300068040) 0641816 Bolt 1/2in-13NC x 2in (SN 0300068040 to

SN 0300069000) 126 1100086 Plate, Cam Lockout 1 127 4751800 Flatwasher 1/2in 4 128 3422702 Pin 2 129 3422755 Pin 2 130 0681608 Bolt 3/8in-16NC x1in (Grade 8) 4 131 4568514 Spacer, Tube (SN 0300068040 to SN 0300069000) 2

STEERING INSTALLATIONS Ref 0258287 2WS Ref F 0258909 4WS (Rear Steering Typical / Double Qty Listed for 4WS) Ref A

1001137261 King Pin Kit Ref A

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

201 0100011 Compound, Locking AR 202 0362726 Tie-Rod 1 203 0641608 Bolt 3/8in-16NC x 1in 14 204 Not Used 205 0962224 Bearing, Garmax 4 206 0962152 Bearing, Garmax 2 207 Not Used 208 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown)

Use 1683740 2WS - Original Equipment (was p/n 1683605)

1683740 2WS - Service Replacement 1683740 4WS

209 to 210 Not Used

211 3422701 Pin, Steer, Spindle Attach 2 212 3422702 Pin, Tie-Rod 2 213 Not Used 214 3841143 Shaft, Keeper 3/8in x 3in 6 215 4130357 Spindle Weldment (Right Side) 1 216 4130358 Spindle Weldment (Left Side) 1 217 4740111 Washer, Special 4 218 Not Used 219 4740463 Washer, Thrust 2 220 4740473 Washer, Special 2 221 Not Used 222 4740256 Washer, Thrust 2

1-4 3120741

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

223 3422753 Kingpin 4 224 3422754 Pin, Attach 2

HUB INSTALLATION (2WD ONLY) OPTIONS: Ref 0258288 Prior to SN 0300056875 Ref C 0270209 SN 0300056875 to SN 0300069000 Ref B

301 to 302 Not Used

303 0682016 Bolt 5/8in-16NC x 2in (Grade 8) 16

304 to 305 Not Used

306 2780229 Hub Assembly (See Items 401-412 for Breakdown) 2 307 Not Used 308 3300007 Lugnut 20

2780229 HUB ASSEMBLY (2WD ONLY) Ref A

401 7017052 Spindle (1 per Assembly) 2 402 7017053 Housing (1 per Assembly) 2 403 7010404 Cup, Bearing - Inner (1 per Assembly) 2 404 7010405 Cone, Bearing - Inner (1 per Assembly) 2 405 7017056 Cup, Bearing - Outer (1 per Assembly) 2 406 7017055 Cone, Bearing - Outer (1 per Assembly) 2 407 7010406 Seal, Lip (1 per Assembly) 2 408 7000265 Stud (10 per Assembly) 20 409 7017054 Dust Cap (1 per Assembly) 2 410 7017051 Washer, Special (1 per Assembly) 2 411 7017057 Washer, Tanged (1 per Assembly) 2 412 7017058 Nut, Bearing (1 per Assembly) 2

S E

I O N

501 FRAME WELDMENT OPTIONS: Ref

Frame Weldment - 2WD/2WS with Pneumatic Tires Options: 1 2360461 Prior to SN 0300068040 2360587 SN 0300068040 to SN 0300068374 2360600 SN 0300068374 to SN 0300069000

Frame Weldment - 2WD/2WS with Foam-Filled Tires Options: 1 2360488 Prior to SN 0300068040 2360588 SN 0300068040 to SN 0300068374 2360601 SN 0300068374 to SN 0300069000

Frame Weldment - 4WD/2WS with Pneumatic Tires Options: 1 2360489 Prior to SN 0300068040 2360589 SN 0300068040 to SN 0300068374 2360602 SN 0300068374 to SN 0300069000

Frame Weldment - 4WD/2WS with Foam-Filled Tires Options: 1 2360490 Prior to SN 0300068040 2360590 SN 0300068040 to SN 0300068374 2360603 SN 0300068374 to SN 0300069000

Frame Weldment - 4WD/4WS with Pneumatic Tires Options: 1 2360502 Prior to SN 0300068040 2360592 SN 0300068040 to SN 0300069000

3120741 1-5

SECTION 1 FRAME

S E

I O N

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Frame Weldment - 4WD/4WS with Foam-Filled Tires Options: 1 2360494 Prior to SN 0300068040 2360591 SN 0300068040 to SN 0300069000

1-6 3120741

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120741 1-7

SECTION 1 FRAME

115

113

104

106

109

103

105

114

107

202

203

205

206

204

201

207

301

303

302

S E

I O N

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

1-8 3120741

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

WHEEL DRIVE INSTALLATION OPTIONS: (2WD/2WS) Ref 0258288 Prior to SN 0300056875 Ref C 0270209 SN 0300056875 to SN 0300069000 Ref B

1 to 2 Not Used

3 0682016 Bolt 5/8in-11NC x 2in (Grade 8) 16 4 Drive Brake Assembly Options: (See DRIVE BRAKE

ASSEMBLY for Breakdown)

0920112 Prior to SN 0300056875

Use 0920119 SN 0300056875 to SN 0300069000 (was p/n 0920117)

5 2780227 Drive Hub Assembly (See DRIVE HUB ASSEMBLIES for

Breakdown) 6 Not Used 7 3160204 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY

for Breakdown) 8 3300007 Nut, Wheel 20 9 Not Used

10 Stud Options: 4

4300130 Prior to SN 0300056875 4300097 SN 0300056875 to SN 0300069000

11 to 12 Not Used

13 4891800 Flatwasher 1/2in 4 14 Not Used 15 Nut Options: 4

3311805 Locknut 1/2in-13 NC (Prior to SN 0300056875) 3311801 Nut 1/2in-13 NC (SN 0300056875 to SN 0300069000)

S E

I O N

WHEEL DRIVE INSTALLATION OPTIONS: Ref 0258289 Prior to SN 0300056875 (4WD/2WS) Ref D 0270210 SN 0300056875 to SN 0300069000 (4WD/2WS) Ref B 0258910 Prior to SN 0300056875 (4WD/4WS) Ref A 0270211 SN 0300056875 to SN 0300069000 (4WD/4WS) Ref B

101 to 102 Not Used

103 0682016 Bolt 5/8in-11NC x 2in (Grade 8) 32 104 Drive Brake Assembly Options: (See DRIVE BRAKE

ASSEMBLY for Breakdown)

0920112 Prior to SN 0300056875

Use 0920119 SN 0300056875 to SN 0300069000 (was p/n 0920117)

105 2780228 Drive Hub Assembly (See DRIVE HUB ASSEMBLIES for

Breakdown)

106 3160204 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY

for Breakdown) 107 3300007 Nut, Wheel 40 108 Not Used 109 Stud Options: 8

4300130 Prior to SN 0300056875 4300097 SN 0300056875 to SN 0300069000

110 to 112 Not Used

3120741 1-9

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

113 4891800 Flatwasher, 1/2in 8 114 4892000 Flatwasher, 5/8in 32 115 Nut Options: 8

3311805 Locknut 1/2in - 13NC (Prior to SN 0300056875) 3311801 Nut 1/2in - 13NC (SN 0300056875 to SN 0300069000)

TIRE AND WHEEL INSTALLATIONS Ref

0258396 IN385/65D19.5 (15 x 19.5) Pneumatic (Prior to

SN 0300068040)

0270885 15-625 Pneumatic (SN 0300068040 to SN 0300069000) Ref A 0272322 15-625 Pneumatic W/Sealant (SN 0300066290 to

SN 0300069000)

0258397 IN385/65D19.5 (15 x 19.5) Foam-Filled (Prior to

SN 0300068040)

0270886 15-625 Foam-Filled (SN 0300068040 to SN 0300069000) Ref A 0258398 IN445/55D19.5 (18 x 19.5) Pneumatic Ref A 0258399 IN445/55D19.5 (18 x 19.5) Foam-Filled (Prior to

SN 0300068040)

0270888 18-625 Foam-Filled (SN 0300068040 to SN 0300069000) Ref A

Ref B

Ref 1

Ref B

0258323 IN385/65D19.5 (15 x 19.5) Pneumatic Left Side (Prior to

SN 0300068040)

0271083 15-625 Pneumatic Left Side (SN 0300068040 to

SN 0300069000)

0272334 15-625 Pneumatic/TS Left Side (SN 0300066290 to

SN 0300069000)

0258324 IN385/65D19.5 (15 x 19.5) Pneumatic Right Side (Prior to

SN 0300068040)

0271084 15-625 Pneumatic Right Side (SN 0300068040 to

SN 0300069000)

0272333 15-625 Pneumatic/TS Right Side (SN 0300066290 to

SN 0300069000)

0258327 IN385/65D19.5 (15 x 19.5) Foam-Filled Left Side (Prior to

SN 0300068040)

0271085 15-625 Foam-Filled Left Side (SN 0300068040 to

SN 0300069000)

0258328 IN385/65D19.5 (15 x 19.5) Foam-Filled Right Side (Prior to

SN 0300068040)

0271086 15-625 Foam-Filled Right Side (SN 0300068040 to

SN 0300069000) 0258330 IN445/55D19.5 (18 x 19.5) Pneumatic Left Side 2 0258331 IN445/55D19.5 (18 x 19.5) Pneumatic Right Side 2 0258333 IN445/55D19.5 (18 x 19.5) Foam-Filled Left Side (Prior to

SN 0300068040) 0271090 18-625 Foam-Filled Left Side (SN 0300068040 to

SN 0300069000) 0258334 IN445/55D19.5 (18 x 19.5) Foam-Filled Right Side (Prior to

SN 0300068040) 0271091 18-625 Foam-Filled Right Side (SN 0300068040 to

SN 0300069000)

1-10 3120741

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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 Decal Options: 1

1702701 95 PSI IN385/65D19.5 (15 x 19.5 Tires) 1702739 85 PSI IN445/55D19.5 (18 x 19.5 Tires)

202 Tire Options: 1

4520204 IN385/65D19.5 (15 x 19.5) 4520252 15-625 4520205 IN445/55D19.5 (18 x 19.5)

4520253 18.625 203 4640113 Valve, Air 1 204 Rim, Wheel Options: 1

4860148 11.75 x 19.5

4860224 13 x 24.5

4860188 14 x 19.5

4860225 15 x 24.5 205 1120552 Cap Valve Stem (Green) (W/Sealant Only) 1 206 1300019 Chemical, Tire Sealant (Green) (W/Sealant Only) AR 207 1705364 Decal - Tire Sealant (W/Sealant Only) 1

Ref

S E

I O N

0256196 WHEEL COVER INSTALLATION (OPTIONAL) Ref 2/A

301 1670776 Cover, Wheel 4 302 0641550 Bolt 5/16in - 18NC x 6-1/4in 20 303 0100011 Compound, Locking AR

3120741 1-11

SECTION 1 FRAME

1617181922

233025

NOTE: Figure Applies to Machines

Prior to SN 0300056875 Only.

For Machines SN 0300056875 to

SN 0300069000 See Parts List.

S E

I O N

FIGURE 1-3. DRIVE BRAKE ASSEMBLY

1-12 3120741

SECTION 1 FRAME

FIGURE 1-3. DRIVE BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0920112 DRIVE BRAKE ASSEMBLY (PRIOR TO SN 0300056875) Ref B

1 7003451 Housing 1 2 7003452 Gasket 1 3 7003094 Pin, Torque 2 4 7003049 Bearing, Ball 1 5 7003453 Ring, Retaining 1 6 7003050 Seal 1 7 7003454 Retainer, Spring 1 8 7000798 Spring, Compression (Small) 10

9 7000782 Spring, Compression (Large) 10 10 7003455 Shaft 1 11 7003456 Disc, Primary 1 12 7003457 Disc, Rotating 2 13 Not Used 14 7003459 Disc, Stationary 2 15 7003460 Piston 1 16 7000722 Ring, Back-Up 1 17 7000723 O-Ring 1 18 7000724 Ring, Back-Up 1 19 7000725 O-Ring 1 20 7000796 Screw, Bleeder 1 21 7003461 Plate, Power 1 22 7000728 Plug, Protective 1 23 7003462 Flatwasher 1/2in 4 24 7003463 Bolt 1/2in-13NC 4 25 7000731 Gasket 2

26 to 29 Not Used

30 See Note Seal Kit - 0920112 Brake (Note: Not Available for

Purchase.)

S E

I O N

Use 0920119 DRIVE BRAKE ASSEMBLY (SN 0300056875 TO

SN 0300069000) (WAS P/N 0920117 - NOT SHOWN)

7018612 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) 7000731 Gasket, Mounting Face 2 7007990 O-Ring, Mounting (1 Per Assembly) (0920119 Brake)

Note: No Other Parts Available. Ref

3120741 1-13

Ref B

SECTION 1 FRAME

1D1N1G1F1E

161615

2WD

4WD

S E

I O N

FIGURE 1-4. DRIVE HUB ASSEMBLIES

1-14 3120741

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLIES

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780227 DRIVE HUB ASSEMBLY (2WD) Ref A 2780228 DRIVE HUB ASSEMBLY (4WD) Ref A

1 See Note Spindle/Housing Assembly (Note: Not Available - Purchase

Individual Components.)

1A 7017031 Spindle 1 1B 7000236 Seal 1 1C 7000273 Cone, Bearing 1 1D 7000272 Cup, Bearing 1 1E 7000275 Cone, Bearing 1 1F 7000274 Cup, Bearing 1 1G 7017033 Housing 1 1H 7000239 Washer, Thrust 1

1I 7000240 Ring, Retaining 1

1J 7001928 Plug, Pipe 1 1K Not Used 1L Not Used 1M Not Used 1N 7000265 Stud, Wheel 10

2 7017034 Gear, Ring 1 3 See Note Carrier Assembly (Note: Not Available - Purchase

Individual Components.)

3A 7017036 Carrier 1 3B 7001901 Thrustwasher, Tanged 6 3C 7001902 Bearing, Needle 96 3D 7001903 Spacer, Thrust 3 3E 7017040 Shaft, Planet 3 3F 7017037 Gear, Cluster 3 3G 7001906 Rollpin 3

4 7017035 Gear, Internal 1 5 7000224 O-Ring 1 6 See Note Cover Assembly (Note: Not Available - Purchase Individual

Components.)

6A 7024155 Cover 1 6B 7017042 Cap 1 6C 7000220 Bolt 1/4in-20NC x 3/4in 4 6D 7000231 Cap, Disengage 1 6E 7000235 Rod, Disengage 1 6F 7000213 O-Ring 1 6G 7000238 O-Ring 1 6H 7017048 Plug, Pipe 1

7 7000282 Thrustwasher 2 8 7000283 O-Ring 1

9 7000284 Ring, Retaining 1 10 7017027 Ring, Retaining 1 11 Shaft, Input Options: 1

7017039 2WD 7017044 4WD

S E

I O N

3120741 1-15

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. DRIVE HUB ASSEMBLIES

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

12 Spacer, Input Options: 1

7017041 2WD 7017045 4WD

13 Gear, Sun Options: 1

7017038 2WD 7017043 4WD

14 Spacer, Input Options: AR

Not Required 2WD 0

7017046 4WD 1 15 7000287 Thrustwasher 4 16 7000288 Thrustwasher 2 17 7000289 Bolt 3/8in-16NC x 2-1/2in (Grade 8) 12 18 Not Used 19 7000290 Coupling 1 20 7017047 Pin, Dowel 2 21 Thrustwasher Options: AR

7017050 2WD 1

Not Required 4WD 0

22 to 24 Not Used

25 7017068 Seal Kit (Includes Items 1B, 1I, 5, 6F, 6G, 15 &16) 1

1-16 3120741

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLIES

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120741 1-17

SECTION 1 FRAME

1615141312

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

I O N

1-18 3120741

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160204 DRIVE MOTOR ASSEMBLY Ref A

1 7012701 Shaft - 13 Teeth 1 2 Use 2900788 Seal, Shaft 1 3 7012702 Bearing, Cradle 2 4 See Note Housing (Note: Not Available - Purchase Complete Assy.) 1 5 7012703 Rod, Piston 1 6 7012704 Piston, Stroking 1 7 Use 2900788 O-Ring 1 8 7012705 Nut, Adapter 1

9 7012706 Bearing, Roller 1 10 7012707 Bolt, Metric Socket Head M12 x 65 4 11 7012708 Block, Port 1 12 7012709 Shim 1 13 7012710 Pin, Dowel M6 x 18 1 14 Use 2900788 O-Ring 1 15 7012711 Nut, Cap M10 x 1 1 16 7012712 Screw, Adjusting 1 17 Use 2900788 O-Ring 2 18 7012713 Nut, Jam M10 x 1 1 19 Use 7012716 Rotary Group Assembly 1 20 See Note Plug (Note: Not Available - Purchase Locally.) 1 21 Use 7012716 Plate, Swash 1 22 7012714 Bearing, Roller 1 23 7012715 V-Ring 1 24 7012700 Control Plate Assembly 1

25 to 29 Not Used

30 2900788 Seal Kit (Includes Items 2,7,14,17 and O-Rings under Item

24)

31 7012716 Rotary Group Kit (Includes Items 19 and 21) 1

S E

I O N

3120741 1-19

SECTION 1 FRAME

111112101

102211211

B1111C11A101102112110B110110C110A

MOUNT

INS

IDE FRAME

.SHOW

N H

ERE FOR CLARITY

202

201

205

203

204

S E

I O N

FIGURE 1-6. DRIVE VALVES INSTALLATIONS

1-20 3120741

SECTION 1 FRAME

FIGURE 1-6. DRIVE VALVES INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE VALVES INSTALLATION - 2WD/2WS OPTIONS: Ref 0258288 Prior to SN 0300056875 Ref C 0270209 SN 0300056875 to SN 0300069000 Ref B

1 0100011 Compound, Locking, AR 2 0641628 Bolt 3/8in-16NC x 3-1/2in 2

3 to 10 Not Used

11 4641041 Flow Divider Valve Assembly 1

11A 7022396 Cartridge, Flow Divider 1

7021625 Seal Kit - 7022396 Cartridge 1

11B 7022398 Cartridge, Load Shuttle 1

7023900 Seal Kit - 7022398 Cartridge 1

11C 7022397 Cartridge, Check Valves 2

7022399 Seal Kit - 7022397 Cartridge 2

12 4751600 Flatwasher, 3/8in 2

S E

I O N

101 0100011 Compound, Locking AR 102 0641628 Bolt 5/8in-11NC x 3-1/2in 4

103 to 109 Not Used

110 4641041 Flow Divider Valve Assembly 1

110A 7022396 Cartridge, Flow Divider 1

7021625 Seal Kit - 7022396 Cartridge 1

110B 7022398 Cartridge, Load Shuttle 1

7023900 Seal Kit - 7022398 Cartridge 1

110C 7022397 Cartridge, Check Valves 2

7022399 Seal Kit - 7022397 Cartridge 2

111 4641042 Flow Divider Valve Assembly 1

7021656 Cartridge, Flow Divider 2 7021625 Seal Kit - 7021656 Cartridge 2

112 4751600 Flatwasher, 3/8in 4

113 to 114 Not Used

0258343 FRAME COVERS INSTALLATION Ref C

201 0100011 Compound, Locking AR 202 0641608 Bolt, 3/8in- 16NC x 1in 10 203 3570686 Plate, Cover Front 1 204 3570690 Plate, Cover Rear 1 205 4751600 Flatwasher, 3/8in 10

3120741 1-21

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. DRIVE VALVES INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-22 3120741

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