JLG 800A-AJ Parts Manual

4.7 (3)

Illustrated Parts Manual

Models 800A 800AJ

Prior to

S/N 0300069000

P/N

3120859

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.

December 11, 1998 - Original Issue Of Manual

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 - Revised (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 B/M 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 3121854 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

3120859

A

REVISION LOG

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

June 20, 2013 - Revised

September 16, 2013 - Revised

December 30, 2013 - Revised

April 30, 2014 - Revised

B

3120859

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 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

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 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42 2-13 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 2-14 ROTARY COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 2-15 GROUND CONTROL BOX ASSEMBLY (PRIOR TO SN 0300064432) . . . . . . . . . . . . . .2-50 2-16 GROUND CONTROL BOX ASSEMBLY (ADE SYSTEM) (SN 0300064432 TO

SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54 2-17 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . .2-58 2-18 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62 2-19 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

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

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

4-1 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) . . . . . . . . . . . . . . . . . . .4-2 4-2 PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) . . . . . . . . . . . . . . . . . . . .4-8 4-3 PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300064432). . . . . . . . . . . . . . . . .4-12 4-4 PLATFORM CONSOLE ASSEMBLY (WITH ADE SYSTEM) (SN 0300064432 TO

SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 4-5 CONTROLLER ASSEMBLY (SWING AND LIFT) (PRIOR TO SN 0300064432) . . . . . . .4-24 4-6 CONTROLLER ASSEMBLY (SWING AND LIFT) (WITH ADE SYSTEM)

(SN 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 4-7 CONTROLLER ASSEMBLY (DRIVE AND STEER) (PRIOR TO SN 0300064432) . . . . .4-30

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FIGURE NO.

TITLE

PAGE NO.

4-8 CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)

(SN 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 4-9 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 4-10 LOAD SENSING SYSTEM INSTALLATION (FRENCH SPEC) (PRIOR TO

SN 0300067883) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 4-11 PLATFORM SUPPORT (LOAD SENSING) (SN 0300067883 TO SN 0300069000). . . . 4-44

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 ASSEMBLY800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

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

8-1

DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

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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SECTION 1 FRAME

 

 

 

 

 

 

 

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FIGURE

DESCRIPTION

PAGE

 

T

 

 

 

 

 

 

 

 

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1-1 AXLE AND STEERING INSTALLATION

1-2

 

 

 

 

 

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

1-6. . .

 

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1-3

DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1-10. .

 

 

1-4

DRIVE HUB ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1-12. .

 

N

 

1-5

DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1-16. .

 

 

 

1-6

DRIVE VALVES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1-18. .

 

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FIGURE 1-1. AXLE AND STEERING INSTALLATION

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A

M

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1-2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3120859

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

OSCILLATING AXLE INSTALLATION

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

2

 

 

 

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

 

 

 

 

 

 

S E C T I O N

1

F

R A M E

3120859

1-3

S E C T I O N

1

F

R A M E

SECTION 1 FRAME

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

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

 

 

 

 

122

4740472

Washer, Special

1

 

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

Ref

 

 

 

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.

 

 

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

2

 

 

 

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 Dia x 3in

6

 

215

4130357

Spindle Weldment (RH)

1

 

216

4130358

Spindle Weldment (LH)

1

 

217

4740111

Washer, Special

4

 

218

Not Used

 

 

 

219

4740463

Washer, Thrust

2

 

220

4740473

Washer, Special

2

 

221

Not Used

 

 

 

 

 

 

 

 

1-4

3120859

SECTION 1 FRAME

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

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

 

 

 

 

222

4740256

Washer, Thrust

2

 

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

 

501

 

FRAME WELDMENT OPTIONS:

Ref

 

 

 

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 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 Foam-Filled Tires Options:

1

 

 

2360494

Prior to SN 0300068040

 

 

 

2360591

SN 0300068040 to SN 0300069000

 

 

 

 

 

 

 

S E C T I O N

1

F

R A M E

3120859

1-5

S E C T I O N

1

F

R A M E

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

7

106

15

4

104

115

201

5

105

13

113 10

109

301

114

3

103

8

 

107

302

 

303

1-6

3120859

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

2

 

 

 

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

2

 

 

 

Breakdown)

 

 

6

Not Used

 

 

 

7

3160204

Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY

2

 

 

 

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)

 

 

 

 

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

4

 

 

 

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

4

 

 

 

Breakdown)

 

 

106

3160204

Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY

4

 

 

 

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

 

 

 

 

 

 

 

 

S E C T I O N

1

F

R A M E

3120859

1-7

S E C T I O N

1

F

R A M E

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

 

 

 

 

113

4891800

Flatwasher, 1/2in Dia Plain Steel

8

 

114

4892000

Flatwasher, 5/8in Dia Plain Steel

32

 

115

 

Nut Options:

8

 

 

3311805

Locknut 1/2in - 13 NC (Prior to SN 0300056875)

 

 

 

3311801

Nut 1/2in - 13 NC (SN 0300056875 to SN 0300069000)

 

 

 

 

TIRE AND WHEEL INSTALLATIONS

Ref

 

 

0258397

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

Ref

B

 

 

SN 0300068040)

 

 

 

0270886

15-625 Foam-Filled (SN 0300068040 to SN 0300069000)

Ref

A

 

0258399

IN445/55D19.5 (18 x 19.5) Foam-Filled (Prior to

Ref

B

 

 

SN 0300068040)

 

 

 

0270888

18-625 Foam-Filled (SN 0300068040 to SN 0300069000)

Ref

A

201

 

Prior to SN 0300068040:

 

 

 

0258327

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

2

 

 

0258328

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

2

 

 

0258333

IN445/55D19.5 (18 x 19.5) Foam-Filled Left Side

2

 

 

0258334

IN445/55D19.5 (18 x 19.5) Foam-Filled Right Side

2

 

 

 

SN 0300068040 to SN 0300069000:

 

 

 

0271085

15-625 Foam-Filled Left Side

2

 

 

0271086

15-625 Foam-Filled Right Side

2

 

 

0271090

18-625 Foam-Filled Left Side

2

 

 

0271091

18-625 Foam-Filled Right Side

2

 

 

 

Note: Assemblies may require ballast/foam filling to

Ref

 

 

 

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,

 

 

 

 

Replacement 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

 

 

 

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

 

 

 

 

 

 

1-8

3120859

 

 

SECTION 1 FRAME

 

 

 

S

 

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

 

 

 

 

 

 

 

 

 

 

E

 

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

C

 

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I

 

 

 

 

 

 

 

O

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

M

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3120859

1-9

S E C T I O N

1

F

R A M E

SECTION 1 FRAME

FIGURE 1-3. DRIVE BRAKE ASSEMBLY

25

1

3

11

12

14

12

14

15

16

17

30

NOTE: Figure applies to Machines prior to SN 0300056875 only. For Machines SN 0300056875 to

SN 0300069000 see Parts List.

2

4

5

6

7

8

9

10

18

19 22

21

23

24

25

1-10

3120859

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

1

 

 

 

Purchase.)

 

 

 

Use 0920119

DRIVE BRAKE ASSEMBLY (SN 0300056875 TO

Ref

B

 

 

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

 

 

 

7018612

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

1

 

 

 

& 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

 

 

 

 

 

 

S E C T I O N

1

F

R A M E

3120859

1-11

 

 

SECTION 1 FRAME

S

FIGURE 1-4. DRIVE HUB ASSEMBLIES

 

E

 

 

 

C

6C

 

 

T

6D

 

9

 

 

 

I

6E

17

21

 

10

O

6H

 

 

 

6F

 

7

N

6B

 

 

6

 

8

 

 

 

7

1

6G

 

11

 

6A

 

 

 

F

20

20

 

R

 

 

 

 

2

A

5

 

 

 

 

 

M

 

 

1

E

4

 

 

5

 

 

15

 

 

16

 

 

15

3G

 

 

 

3A

3E

 

 

 

 

 

1J

 

3B

 

 

3C

3

 

 

14

3D

 

2WD

3C

 

13

 

 

4WD

3F

 

 

 

12

 

 

 

3B

 

15

16

15

19

25

1H

1E

1F

1G

1J

1

1N

1D

1C

1B

1A

1-12

3120859

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

1

 

 

 

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

1

 

 

 

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

1

 

 

 

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 C T I O N

1

F

R A M E

3120859

1-13

S E C T I O N

1

F

R A M E

SECTION 1 FRAME

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

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

 

 

 

 

 

 

1-14

3120859

 

 

SECTION 1 FRAME

 

 

 

S

 

FIGURE 1-4. DRIVE HUB ASSEMBLIES

 

 

 

 

 

 

 

 

 

 

E

 

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

C

 

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I

 

 

 

 

 

 

 

O

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

M

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3120859

1-15

S E C T I O N

1

F

R A M E

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

4

 

7

6

8

5

3

9

10

2

1

11

12

13

23

22

 

 

 

 

15

14

21

 

19

 

 

 

18

 

 

20

17

16

 

 

 

 

 

 

 

 

 

24

 

 

30

 

 

 

 

 

 

 

 

 

 

 

 

31

1-16

3120859

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

1

 

 

 

24)

 

 

31

7012716

Rotary Group Kit (Includes Items 19 and 21)

1

 

 

 

 

 

 

S E C T I O N

1

F

R A M E

3120859

1-17

 

SECTION 1 FRAME

S

FIGURE 1-6. DRIVE VALVES INSTALLATIONS

E

 

C

 

T

 

I

 

O

 

N

 

1

F

R

A

M

E

1-18

3120859

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

 

 

 

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

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

 

 

 

 

 

 

S E C T I O N

1

F

R A M E

3120859

1-19

 

 

 

 

 

SECTION 1 FRAME

 

 

 

S

 

FIGURE 1-6. DRIVE VALVES INSTALLATIONS (CONTINUED)

 

 

 

E

 

 

 

 

 

 

 

C

 

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I

 

 

 

 

 

 

 

O

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

M

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1-20

3120859

SECTION 2 TURNTABLE

TABLE OF CONTENTS

FIGURE

DESCRIPTION

PAGE

 

 

 

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 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 2-13 TANK INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 2-14 ROTARY COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 2-15 GROUND CONTROL BOX ASSEMBLY (PRIOR TO SN 0300064432) . . . . . . . . . . . . . . . . . . . 2-50 2-16 GROUND CONTROL BOX ASSEMBLY (ADE SYSTEM) (SN 0300064432

TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 2-17 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . . . . . . . 2-58 2-18 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 2-19 ENGINE TRAY JACK INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

S E C T I O N

2

T U R N T A B L E

3120859

2-1

JLG 800A-AJ Parts Manual

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATIONS

S

E

C

T

I

O

N

2

T

U

R

N

T

A

B

L

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2-2

 

3120859

SECTION 2 TURNTABLE

.

FIGURE 2-1. CONTROL VALVES INSTALLATIONS

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

 

 

 

 

 

 

VALVES INSTALLATIONS

Ref

 

 

0258454

800A (2WS)

Ref

C

 

0258455

800A (4WS)

Ref

C

 

0258456

800AJ (2WS)

Ref

C

 

0258457

800AJ (4WS)

Ref

C

1

 

Main Control Valve Assembly Options (See MAIN

1

 

 

 

CONTROL VALVE ASSEMBLY for Breakdown):

 

 

 

Use 4641099

Prior to SN 0300040142 (was p/n 4641034)

 

 

 

Use 4641099

SN 0300040142 to SN 0300041275 (was p/n 4641093)

 

 

 

4641099

SN 0300041275 to SN 0300069000

 

 

2

2120167

Return Filter Assembly

1

 

 

2120168

Element, Filter

1

 

 

7020021

Indicator, Clogged

1

 

3

4640866

Valve Assembly (Level)

1

 

3A

7017466

Cartridge

1

 

 

2900708

Seal Kit - Cartridge

1

 

3B

7012959

Knob

1

 

4

2120163

Pressure Filter Assembly

1

 

 

2120150

Element, Filter

1

 

 

7023206

O-Ring, Filter Bowl

1

 

 

7023207

Ring, Filter Bowl Backup

1

 

 

7020020

Indicator

1

 

5

4641061

Solenoid Valve Assembly (Brake)

1

 

 

7012943

Coil

1

 

 

7017479

Cartridge without Coil

1

 

 

7012518

Seal Kit - 7017479 Cartridge

1

 

6

4640906

Solenoid Valve Assembly (2 Speed)

1

 

6A

7012944

Coil

1

 

 

7023981

Cartridge without Coil

1

 

 

7012905

Seal Kit - 7017480 Cartridge

1

 

6B

7017481

Cartridge, Check

2

 

 

7012972

Seal Kit - 7017481 Cartridge

2

 

7

3570979

Plate, Spacer

1

 

8

Not Used

 

 

 

9

3841340

Loop, Hose

4

 

10

2220893

Fitting, Adapter

1

 

11

0641614

Bolt 3/8in-16NC x 1-3/4in

3

 

12

0641606

Bolt 3/8in-16NC x 3/4in

8

 

13

4711600

Flatwasher 3/8in Narrow

6

 

14

0641508

Bolt 5/16in-18NC x 1in

2

 

15

4891500

Flatwasher 5/16in

2

 

16

4711500

Flatwasher 5/16in Narrow

2

 

17

0641418

Bolt 1/4in-20NC x 2-1/4in

2

 

18

Not Used

 

 

 

19

0641414

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

2

 

20

0651406

Bolt 1/4in-28NF x 3/4in

4

 

21

4711400

Flatwasher 1/4in Narrow

16

 

 

 

 

 

 

S E C T I O N

2

T U R N T A B L E

3120859

2-3

S E C T I O N

2

T U R N T A B L E

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED)

FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

 

 

 

 

 

22

3311405

Locknut 1/4in-20NC

6

 

23

0100011

Compound, Locking

AR

 

24

 

Valve Assembly (Jib Control) Options:

AR

 

 

Not Required

800A

0

 

 

4640921

800AJ

1

 

25

 

Harness Assembly (Jib Control) Options (Not Shown - See

AR

 

 

 

ELECTRICAL SECTION for Breakdown):

 

 

 

Not Required

800A

0

 

 

4921927

800AJ

1

 

26

 

Valve Assembly (4WS Control) Options:

AR

 

 

Not Required

2WS

0

 

 

4640922

4WS (See ACCESSORY VALVE ASSEMBLY for

1

 

 

 

Breakdown)

 

 

27

 

Harness Assembly (4WS Control) Options (Not Shown -

AR

 

 

 

See ELECTRICAL SECTION for Breakdown):

 

 

 

Not Required

2WS

0

 

 

4921928

4WS (See ACCESSORY VALVE ASSEMBLY for

1

 

 

 

Breakdown)

 

 

28

4420060

Tape, Double Sided

2in/5cm

 

 

0258411

TILT INDICATOR INSTALLATION (MACHINES WITHOUT

Ref

B

 

 

ADE SYSTEM ONLY)

 

 

101

4360416

Indicator, Tilt

1

 

102

0140001

Horn

1

 

103

0641406

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

3

 

104

4711400

Flatwasher 1/4in Narrow

5

 

105

3311405

Locknut 1/4in-20NC

3

 

 

0258670

AUXILIARY PUMP INSTALLATION

Ref

B

 

 

Note: Original Equipment pump may have been replaced

Ref

 

 

 

with various Service Replacement pump. Identify

 

 

 

 

component before ordering parts.

 

 

201

 

Auxiliary Pump Assembly Options:

 

 

 

Use

Auxiliary Pump Service Kit (Original Equipment)

1

 

 

1001143191

(was p/n 3600287 & 1001091424)

 

 

 

 

Service Parts for Fenner Brand (p/n 3600287 pump)

 

 

 

7016779

Replacement Motor Assembly (p/n 3600287 pump)

1

 

 

7016781

Brush Kit - 7016779 Motor

1

 

 

7016780

Replacement Pump Assembly (p/n 3600287 pump)

1

 

 

7016785

Seal Kit - 7016780 Pump

1

 

 

7016782

Coupling, Pump/Motor (p/n 3600287 pump)

1

 

 

7016783

Pump Mounting Kit (p/n 3600287 pump)

1

 

 

7016784

Relief Valve Assembly (p/n 3600287 pump)

 

 

 

Use

Auxiliary Pump Assembly (Service Replacement)

1

 

 

1001137460

(was p/n 3600458)

 

 

 

 

Service Parts for Haldex Brand (p/n 3600458 pump)

 

 

 

 

(Service Replacement)

 

 

 

70001059

Replacement Motor Assembly (p/n 3600458 pump)

1

 

 

 

 

 

 

2-4

3120859

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