JLG 860SJ Parts Manual
Illustrated Parts Manual
Models
800S
860SJ
SN 0300182743
to Present
P/N
3121632
January 17, 2014
REVISION LOG
NOTES:
Note: S/N 0300174290, 030180894 & 0300181347 also built to the same specs as machines built S/N 0300182743 to
Present.
REVISION LOG:
January 17, 2014 - Original Issue of Manual (Edited to B/M 1001160050 Rev E & B/M 1001156802 Revision D)
3121632 800S 860SJ A
REVISION LOG
B 800S 860SJ 3121632
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE . . . . . . . . . . . . . 1-2
1-2 AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . 1-6
1-3 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-5 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-6 FRAME VALVES & SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-7 TOW PACKAGE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 70 CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 TURNTABLE BEARING & SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . 2-8
2-4 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-5 DEUTZ D2011 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-6 DEUTZ TD2.9L4 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-7 GM ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2-8 HYDROSTATIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-9 VARIABLE PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2-10 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2-11 LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) . . . . . . . . . . . . . . . . . . 2-54
2-12 ROTARY COUPLING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2-13 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
2-14 LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 2-62
2-15 HOODS INSTALLATION (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2-16 HOODS (STEEL) & LIFTING PLATE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . 2-72
2-17 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
2-18 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ ENGINES . . . . . . . . . 2-80
2-19 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES . . . . . . . . . . . . 2-86
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . 3-2
3-2 MAIN BOOM INSTALLATION - 800S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 MAIN BOOM INSTALLATION - 860SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4 MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-5 ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-6 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . 3-22
3-7 BOOM CABLE CLAMPS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 PLATFORM ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM) . . . . . 4-6
4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4 CONTROLLER ASSEMBLY (LIFT AND SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-5 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-6 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-7 PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . 4-18
3121632 800S 860SJ i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2 LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-3 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4 PLATFORM LEVEL (SLAVE) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-5 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-6 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
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 MANUAL DESCENT HYDRAULIC DIAGRAM ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONAL)6-12
6-5 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
6-6 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8-2 DECAL INSTALLATION (COUNTRY SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
8-3 DECAL INSTALLATION (AUSTRALIAN & CE SPEC) . . . . . . . . . . . . . . . . . . . . . . . . .8-12
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . . .9-1
SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10-1 SPECIAL OPTIONS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
ii 800S 860SJ 3121632
SECTION 1
FRAME
3121632 800S 860SJ 1-1
SECTION 1 FRAME
FIXED AXLE
OSCILLATING AXLE
115
114
106
116
101
102
17
6
201
203
201
202
201
202
214
204
214
204
201
203
1
3
1
4
103
101
104
101
1
2
108
112
105
105
111
109
110
107
115
113
8
13
12
5
10
11
7
14
9
15
5
16
216
213
213
209
205
206
207
207
208
210
218
211
211
217
215
212
212
215
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE
1-2 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE
ITEM # PART NUMBER QTY. DESCRIPTION REV.
1001151037 Ref FIXED AXLE INSTALLATION B
1 0100011 AR Compound, Locking
2 0641818 2 Bolt 1/2in-13NC x 2-1/4in
3 0642212 1 Bolt 3/4in-10NC x 1-1/2in
4 0681608 4 Bolt 3/8in-16NC x 1in Grade 8
5 0962102 2 Bushing, Garmax
6 3020039 AR Lubricant
7 3538047 AR Shim, Wear
8 3539877 2 Plate, Stop
9 3841287 1 Keeper, Pin
10 4070878 AR Shim 1/16in
11 4070879 AR Shim 1/8in
12 4070944 AR Shim 1/16in
13 4070945 AR Shim 1/4in
14 4711600 4 Flatwasher 3/8in Thin
15 4740472 1 Washer, Special
16 1001152719 1 Axle
17 1001156710 1 Pin
1001154584 Ref OSCILLATING AXLE INSTALLATION B
101 0100011 AR Compound, Locking
102 0642212 1 Bolt 3/4in-10NC x 1-1/2in
103 0681608 4 Bolt 3/8in-16NC x1in Grade 8
104 0682236 8 Bolt 3/4in-10NC x 4-1/2in Grade 8
105 0962102 2 Bushing, Garmax
106 3020039 AR Lubricant
107 3538047 AR Shim, Axle Wear
108 3841287 1 Shaft, Keeper 3/8in Dia x 6in
109 4070878 AR Shim, Axle Wear
110 4070879 AR Shim, Axle Wear
111 4711600 4 Flatwasher 3/8in Thin
112 4740472 1 Washer, Special
113 4892200 8 Flatwasher 3/4in Hardened
114 1001152719 1 Axle
115 1001154258 2 Axle Lockout Cylinder Assembly (See CYLINDER SECTION for
Breakdown)
116 1001156710 1 Pin
1001151034 Ref STEERING INSTALLATIONS (2WS) E
201 0100011 AR Compound, Locking
202 0641607 4 Bolt 3/8in-16NC x 7/8in
203 0641810 16 Bolt 1/2in-13NC x 1-1/4in
204 3020039 AR Lubricant
205 3422417 2 Pin
206 3422790 2 Pin
207 3841520 4 Keeper, Pin
3121632 800S 860SJ 1-3
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
208 4740256 AR Thrustwasher
209 4740473 2 Washer, Special
210 1001103813 AR Thrustwasher
211 1001165657 4 Bearing
212 1001150372 2 Spindle
213 1001150539 2 Steer Cylinder Assembly (See CYLINDER SECTION for
Breakdown)
214 1001161355 4 Kingpin
215 1001150937 4 Plate
216 1001151980 1 Tie-Rod
217 1001161399 2 Thrustwasher
218 4740463 AR Thrustwasher
1-4 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121632 800S 860SJ 1-5
SECTION 1 FRAME
115
114
106
116
101
103
102
101
203
201
204
214
204
214
215
215
203
201
202
201
202
201
202
201
202
201
101
104
108
112
105
105
111
109
110
107
115
113
207
220
220
205
207
207
207
206
208
210
224
211
211
217
223
223A
222
213
216
216A
216B
218
219
221
209
216
212
212
213
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE
1-6 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE
ITEM # PART NUMBER QTY. DESCRIPTION REV.
1001155194 Ref OSCILLATING AXLE INSTALLATION B
101 0100011 AR Compound, Locking
102 0642212 1 Bolt 3/4in-10NC x 1-1/2in
103 0681608 4 Bolt 3/8in-16NC x1in Grade 8
104 0682236 8 Bolt 3/4in-10NC x 4-1/2in Grade 8
105 0962102 2 Bushing, Garmax
106 3020039 AR Lubricant
107 3538047 AR Shim, Axle Wear
108 3841287 1 Shaft, Keeper 3/8in Dia x 6in
109 4070878 AR Shim, Axle Wear
110 4070879 AR Shim, Axle Wear
111 4711600 4 Flatwasher 3/8in Thin
112 4740472 1 Washer, Special
113 4892200 8 Flatwasher 3/4in Hardened
114 1001154875 1 Axle
115 1001154258 2 Axle Lockout Cylinder Assembly (See CYLINDER SECTION for
Breakdown)
116 1001156710 1 Pin
1001155192 Ref STEERING INSTALLATION D
201 0100011 AR Compound, Locking
202 0641607 6 Bolt 3/8in-16NC x 7/8in
203 0641810 16 Bolt 1/2in-13NC x 1-1/4in
204 3020029 AR Lubricant
205 3422417 2 Pin
206 3422790 2 Pin
207 3841520 6 Keeper, Pin
208 4740256 AR Thrustwasher
209 4740473 2 Washer, Special
210 1001103810 AR Thrustwasher
211 1001165657 4 Bearing
212 1001150372 2 Spindle
213 1001150539 2 Steer Cylinder Assembly (See CYLINDER SECTION for
Breakdown)
214 1001161355 4 Kingpin
215 1001150937 4 Plate
216 1001154931 2 Tie-Rod
216A 0962181 1 Bushing
216B 0962152 1 Bushing
217 1001161399 2 Thrustwasher
218 0741609 4 Screw 3/8in-16NC x 1-1/8in
219 3340966 2 Pad, Stop
220 3422848 2 Pin, Hitch
221 4071059 AR Shim
222 4740155 3 Thrustwasher
223 1001155035 1 Link
223A 0962348 1 Bushing
224 4740463 AR Thrustwasher
3121632 800S 860SJ 1-7
SECTION 1 FRAME
302
304
307
303
306
305
301
DETAIL OF
VALVE STEM
9
6
14
4
8
13
3
1
1
101
201
202
205
206
207
208
209
203
204
106
110
210
211
212
104
115
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
1-8 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
ITEM # PART NUMBER QTY. DESCRIPTION REV.
Ref WHEEL DRIVE INSTALLATION
1001157015 Ref 2WD A
1001157016 Ref 4WD A
Ref Note: 2WD Qty Shown. For 4WD, Double Qty Shown.
1 0100011 AR Compound, Locking
2Not Used
3 3311801 4 Nut 1/2in-13 NC
4 0682016 16 Bolt 5/8in-11NC x 2in Grade 8
5 2300016 AR Fluid, Hydraulic (Not Shown)
6 2780272 2 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for
Breakdown)
7 3020008 AR Lubricant (Not Shown)
8 2 Drive Motor Assembly Options (See DRIVE MOTOR
ASSEMBLY for Breakdown):
3160347 2 2WD Rear
3160348 4 4WD Front & Rear
9 3300007 20 Nut, Wheel
10 to 12 Not Used
13 4891800 4 Flatwasher, 1/2in Hardened
14 4892000 16 Flatwasher 5/8in Hardened
1001157015 Ref HUB INSTALLATION (2WD ONLY) A
101 0100011 AR Compound, Locking
102 to 103 Not Used
104 0682016 16 Bolt 5/8in-16NC x 2in Grade 8
105 Not Used
106 2780229 2 Hub Assembly (See Items 401-412 for Breakdown)
107 to 109 Not Used
110 3300007 20 Lugnut
111 to 114 Not Used
115 4892000 16 Flatwasher 5/8in Hardened
2780229 Ref HUB ASSEMBLY (2WD ONLY) A
201 7017052 2 Spindle (1 per Assembly)
202 7017053 2 Housing (1 per Assembly)
203 7010404 2 Cup, Bearing - Inner (1 per Assembly)
204 7010405 2 Cone, Bearing - Inner (1 per Assembly)
205 7017056 2 Cup, Bearing - Outer (1 per Assembly)
206 7017055 2 Cone, Bearing - Outer (1 per Assembly)
207 7010406 2 Seal, Lip (1 per Assembly)
208 7000265 20 Stud (10 per Assembly)
209 7017054 2 Dust Cap (1 per Assembly)
210 7017051 2 Washer, Special (1 per Assembly)
211 7017057 2 Washer, Tanged (1 per Assembly)
212 7017058 2 Nut, Bearing (1 per Assembly)
3121632 800S 860SJ 1-9
SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
Ref TIRE AND WHEEL INSTALLATIONS
0270885 Ref 15-625 NHS Pneumatic (Available on All Specs Except
Australian & CE Specs)
0272322 Ref 15-625 NHS Pneumatic W/Sealant (Available on ANSI Specs
Only)
0270886 Ref 15-625 NHS Foam-Filled (Available on All Specs) C
0270888 Ref 18-625 NHS Foam-Filled (Available on All Specs) C
0271083 2 15-625 NHS Pneumatic Left Side
0271084 2 15-625 NHS Pneumatic Right Side
0272334 2 15-625 NHS Pneumatic W/Sealant Left Side
0272333 2 15-625 NHS Pneumatic W/Sealant Right Side
0271085 2 15-625 NHS Foam-Filled Left Side
0271086 2 15-625 NHS Foam-Filled Right Side
0271090 2 18-625 NHS Foam-Filled Left Side
0271091 2 18-625 NHS 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.
301 1702701 1 Decal - 95 PSI/6.5 Bar (15-625 Tires) (Pneumatic Only)
302 1 Tire Options:
4520252 15-625 Tire
4520253 18-625 Tire
303 4640113 1 Valve, Air
304 1 Rim, Wheel Options:
4860224 13 x 24.5 Rim (Use with 15-625 Tires)
4860225 15 x 24.5 Rim (Use with 18-625 Tires)
305 1705364 AR Decal - Tire Sealant (W/Sealant Only)
306 1300019 AR Chemical, Tire Sealant (Green) (W/Sealant Only)
307 1120552 AR Cap, Valve Stem (Green) (W/Sealant Only)
C
C
1-10 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121632 800S 860SJ 1-11
SECTION 1 FRAME
10531111
110
112
121
102
119
122
123
104
103
103
101
109
107
108
28
29
114
113
116
115
118
117
120
27
19
1A1B1C
1D
1N1G1F1E1H
26
2
6A
6
16
16
151515
15
12
133B3F3C3D3C3B
3
3A
3E
3G
5
1
4
5
6B
6H
6G
20
20
6F
6E
6D
6C
17
1
106
106
1J
1J
11
7
7
21
8
9
10
200A
200B
201D
201C
201B
201A
FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY
1-12 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY
ITEM # PART NUMBER QTY. DESCRIPTION REV.
2780272 Ref DRIVE HUB/BRAKE ASSEMBLY B
2780227 Ref Hub Assembly B
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 Thrustwasher
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
3121632 800S 860SJ 1-13
SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (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
7024182 Ref BRAKE ASSEMBLY
101 7024189 1 Shaft
102 See Note 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 Items 200B, 201C or 201D)
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 for Purchase.)
121 See Note 2 Plug (Note: Not Available for Purchase.)
122 Use 7024196 10 Spring Kit (Natural)
123 Use 7024196 2 Spring Kit (Blue)
Ref KIT OPTIONS:
200 AR Seal Kit Options:
200A 7017068 1 Seal Kit - Hub (Includes Items 1B,1I, 5, 6F, 6G, 15 & 16)
200B 7024194 1 Seal Kit - 7024182 Brake (Includes Items 105, 107 & 215-218)
1-14 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
201 AR Repair Kit Options:
201A Use 7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural Colored
Springs) (was p/n 7024195)
Note: Spring Kit no Longer Available, Purchase Kit p/n
7024196.
201B
201C 7024193
201D 7024197 1 Bearing Kit - 7024182 Brake (Includes Items 107 & 110-112)
7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural & 2 Blue Col-
ored Springs)
1
Friction Disc Kit - 7024182 Brake (Includes Items 103, 104, 106
& 107)
3121632 800S 860SJ 1-15
SECTION 1 FRAME
3
41340
1938303433
323132
31
18
1
1
4
11
129107A1316151714
7
8
6
2
5
5
22
20
21
23
24
25
26
28
27
37
36
35
39
29
100
FIGURE 1-5. DRIVE MOTOR ASSEMBLY
1-16 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY
ITEM # PART NUMBER QTY. DESCRIPTION REV.
Ref DRIVE MOTOR ASSEMBLIES:
3160347 Ref 2WD B
3160348 Ref 4WD B
1 7022302 2 Bearing, Journal
2 7007446 1 Pin
3 7007438 2 Ring, Retaining
4 1 Swashplate Options:
70000794 2WD
7022305 4WD
5 See Note 2 Pin (Note: Not Available for Purchase.)
6 Use 7022328 1 Gasket
7 1 Cylinder Block Kit (Includes Items 7A & 9-17)
7027740 2WD
7023907 4WD
7A See Note 1 Block, Cylinder (Note: Not Available - Purchase
Complete Cylinder Block Kit.)
8 1 Plate, Valve Options:
7024862 2WD
7023908 4WD
9 1 Guide, Slipper Retainer Options:
See Note 2WD (Note: Not Available for Purchase.)
7021277 4WD
10 7021275 3 Pin, Slipper Hold Down
11 See Note 9 Piston Assembly (Note: Not Available - Purchase Complete
Assy.)
12 1 Retainer, Slipper Options:
See Note 2WD (Note: Not Available for Purchase.)
7022310 4WD
13 1 Retainer, Hold Down Pin Options:
Not Required 2WD
7021276 4WD
14 7022311 1 Ring, Retaining
15 1 Spring Options:
7024867 2WD
7022312 4WD
16 1 Washer Options:
7022313 2WD
7024868 4WD
17 7022314 1 Retainer, Spring
18 7023910 1 Shaft
19 7007439 1 Ring, Retaining
20 1 Cap, End - Axial Options:
70000795 2WD
70000797 4WD
21 7022368 5 Screw
22 7021249 1 Bearing, Needle
23 2220886 1 Plug (Includes Item 24)
24 Use 7022328 1 O-Ring
3121632 800S 860SJ 1-17
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
25 2220883 1 Plug (Includes Item 26)
26 Use 7022328 1 O-Ring
27 2220888 2 Plug (Includes Item 28)
28 Use 7022328 2 O-Ring
29 1 Seat, Spring Options:
7027741 2WD
7022372 4WD
30 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.)
31 2220883 2 Plug (Items Item 32)
32 Use 7022328 2 O-Ring
33 2220886 1 Plug (Items Item 34)
34 Use 7022328 1 O-Ring
35 Use 7022328 1 O-Ring
36 Use 7022328 1 Ring, Seal
37 1 Piston, Servo Options (Includes Items 35 & 36):
7024871 2WD
7024854 4WD
38 7007437 1 Bearing
39 7022326 1 Spring
40 Use 7022328 1 Seal, Lip
41 7022371 1 Washer, Support
Ref KIT OPTIONS:
100 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)
1-18 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121632 800S 860SJ 1-19
SECTION 1 FRAME
OR
VALVE ROTATED FOR CLARITY
VALVE ROTATED FOR CLARITY
12C
12B
12
111
2
102
13
112
12A
12C
12D
13
112
11
110
111C
111A
111B
111C
111D
111E
111B
12F
12E
111F
111F
111G
201
202
203
205
206
209
211
201
210
FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS
1-20 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS
ITEM # PART NUMBER QTY. DESCRIPTION REV.
1001157015 Ref DRIVE VALVES INSTALLATION - 2WD A
1Not Used
2 0641542 2 Bolt 5/16in-18NC x 5-1/4in
3 to 10 Not Used
11 3311505 2 Locknut 5/16in-18NC
12 1001099870 1 Flow Divider Valve Assembly A
12A 7023933 1 Cartridge, Flow Divider
7021625 1 Seal Kit - 7023933 Cartridge
70000781 1 Lockdown Kit
12B 7022397 2 Cartridge, Check
7022399 2 Seal Kit - 7022397 Cartridge
12C 70002390 2 Cartridge, Check
7022399 2 Seal Kit - 70002390 Cartridge
12D 7024881 1 Piston, Pilot
12E 7017406 1 Plug
12F 7024844 1 Plug
7017492 1 Orifice
13 4711500 4 Flatwasher 5/16in Thin
1001157016 Ref DRIVE VALVES INSTALLATION - 4WD A
101 Not Used
102 0641560 3 Bolt 5/16in-18NC x 7-1/2in
103 to 109 Not Used
110 3311505 3 Locknut 5/16in-18NC
111 4641303 1 Flow Divider Valve Assembly
111A 7023933 1 Cartridge, Flow Divider
7021625 1 Seal Kit - 7023933 Cartridge
111B 7022397 6 Cartridge, Check
7022399 6 Seal Kit - 7022397 Cartridge
111C 7021639 2 Cartridge, Check Valves
2900756 2 Seal Kit - 7022398 Cartridge
111D 7024881 1 Piston, Pilot
111E 7023917 2 Cartridge, Flow Divider
7021625 2 Seal Kit - 7023917 Cartridge
111F 70003935 2 Orifice
111G 70003936 1 Orifice
112 4711500 6 Flatwasher 5/16in Thin
1001158203 Ref FRAME SHIELDS INSTALLATIONS D
201 0100011 AR Compound, Locking
202 0641606 2 Bolt, 3/8in - 16NC x 3/4in
203 4751600 2 Flatwasher 3/8in Regular
204 1001158187 1 Cover
205 4280296 27in/
68cm
206 1001158188 1 Cover
Tr i m
3121632 800S 860SJ 1-21
SECTION 1 FRAME
FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
207to 208 Not Used
209 8580420 2 Nut, Well
210 0641410 2 Bolt 1/4in-20NC x 1-1/4in
211 4751400 2 Flatwasher 1/4in Regular
1-22 800S 860SJ 3121632
SECTION 1 FRAME
FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121632 800S 860SJ 1-23
SECTION 1 FRAME
102
121
113
113
114
114
117
112
112
115
115
120
103
105
105
104
109
110
106
106
106
106
106
106
108
119
109
110
116
116
118
116
107
107
111
1
4
5
2
6
11
8
9
10
116
116
116
11
7
101
101
101
105
101
105
101
105
101
105
101
105
101
FIGURE 1-7. TOW PACKAGE INSTALLATION
1-24 800S 860SJ 3121632
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