JLG 860SJ Parts Manual
Illustrated Parts Manual
Models
800S
860SJ
SN 0300140000 to
SN 0300182743
&
SN B300000100 to
Present
P/N
3121270
January 17, 2014
REVISION LOG
NOTES:
NOTE: USA Built Machines with SNs 0300174290, 0300180894 & 0300181347 are also built to the same specs as
USA Built Machines SN 0300182743 to Present - Use Parts Manual P/N 3121632.
REVISION LOG:
April 21, 2011 - Original Issue Of Manual (Edited to B/M 0010575 Revision 124)
July 22, 2011 - Revised Manual (Edited to B/M 0010575 Revision 127)
October 14, 2011 - Revised Manual (Edited to B/M 0010575 Revision D)
January 10, 2012 - Revised Manual (Edited to B/M 0010575 Revision D)
June 15, 2012 - Revised Manual (Edited to B/M 0010575 Revision E)
August 2, 2012 - Revised Manual (Edited to B/M 0010575 Revision E)
January 4, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)
April 2, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)
June 28, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)
September 23, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)
January 17, 2014 - Revised Manual (Edited to B/M 0010575 Revision AL)
3121270 800S 860SJ A
REVISION LOG
B 800S 860SJ 3121270
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-6 FRAME VALVES & SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-7 TOW PACKAGE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-4 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-5 CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-6 DEUTZ ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-7 GM ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-8 PUMP ASSEMBLY (SAUER-DANFOSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-9 PUMP ASSEMBLY (EATON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-10 LOAD SENSING PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2-11 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2-12 LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) . . . . . . . . . . . . . . . . . . 2-54
2-13 ROTARY COUPLING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2-14 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
2-15 LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 2-62
2-16 HOODS INSTALLATION (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2-17 HOODS INSTALLATION (STEEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
2-18 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
2-19 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-80
2-20 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-84
2-21 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) . . . . . . . . . . . 2-88
2-22 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
2-23 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES . . . . . . . . . . . . 2-100
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 ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . 4-8
4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-4 CONTROLLER ASSEMBLY (LIFT AND SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-5 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-6 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . 4-24
3121270 800S 860SJ i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
4-7 PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . .4-26
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 CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-5 STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 0300140000 TO
SN 0300142666) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-6 STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 03000142666 TO
SN 0300182743 ONLY & CHINA BUILT MACHINES SN B300000100 TO
PRESENT ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-7 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
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
SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
ii 800S 860SJ 3121270
SECTION 1
FRAME
3121270 800S 860SJ 1-1
SECTION 1 FRAME
8
1213101
117
112
116
115
2
16
4
9
14
15
19
119
107
210
215
215
203
212
207
207
209
209
205
205
218
218
212
212
213
203
204
211
211
212
208
401
407
404
403
402
307
408
309
301
316
405
406
410
411
412
409
214
203
203
202
17
6
106
110
106
6
7
11
114
5
104
118
107
103
103
113
113
111
109
220
220
217
216
10
1
102
201
201
101
101
201
201
105
1
1
201
204
201
304
219
206
206
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE
1-2 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0258286 Ref FIXED AXLE INSTALLATION C
1 0100011 AR Compound, Locking
2 0681608 4 Bolt 3/8in-16NC x 1in (Grade 8)
3Not Used
4 0641820 2 Bolt 1/2in-13NC x 2-1/2in
5 0642212 1 Bolt 3/4in-10NC x 1-1/2in
6 0962102 2 Bushing, Garmax
7 3422703 1 Pin, Axle Pivot
8 3538047 2 Shim, Wear
9 3539877 2 Plate, Stop
10 3539878 2 Plate, Stop
11 3841287 1 Keeper, Pin
12 4070878 AR Shim 1/16in
13 4070879 AR Shim 1/8in
14 4070944 AR Shim 1/16in
15 4070945 AR Shim 1/4in
16 4711600 4 Flatwasher 3/8in Thin
17 4740472 1 Washer, Special
18 Not Used
19 4845658 1 Axle Weldment
0274571 Ref OSCILLATING AXLE INSTALLATION C
101 0100011 AR Compound, Locking
102 0100019 AR Compound, Locking
103 0641608 4 Bolt 3/8in-16NC x1in
104 0642212 1 Bolt 3/4in-10NC x 1-1/2in
105 0681608 4 Bolt 3/8in-16NC x1in (Grade 8)
106 0962102 2 Bushing, Garmax
107 1683078 2 Lockout Cylinder Assembly (See CYLINDER SECTION for
Breakdown)
108 Not Used
109 3422702 2 Pin
110 3422703 1 Pin, Main Pivot
111 3422755 2 Pin
112 3538047 2 Shim, Axle Wear
113 3841143 4 Shaft, Keeper 3/8in Dia x 3in
114 3841287 1 Shaft, Keeper 3/8in Dia x 6in
115 4070878 2 Shim, Axle Wear
116 4070879 2 Shim, Axle Wear
117 4711600 4 Flatwasher 3/8in Thin
118 4740472 1 Washer, Special
119 4845658 1 Axle Weldment
3121270 800S 860SJ 1-3
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0272003 Ref STEERING INSTALLATIONS (2WS) E
Ref Note: Before ordering king pin kit, verify that machines is
equipped with the original components (king pin with 4 bolt
holes) or service kit components (king pin with 8 bolt holes).
- If the king pin hole in the axle measurement exceeds 2.252in
OD or is elongated, use King Pin Kit p/n 1001137261.
201 0100011 AR Compound, Locking
202 0362726 1 Tie-Rod
203 0641608 6 Bolt 3/8in-16NC x 1in
204 0641810 16 Bolt 1/2in-13NC x 1-1/4in
205 0962152 2 Bearing
206 4 Bearing Options:
0962448 Bearing, Garmax - Composite (USA Built Machines
SN 0300140000 to SN 0300150055 Only & China Built
Machines SN B300000100 to SN B300000282 Only)
1001112651 Bearing, Bronze Limited - Aluminum/Bronze (USA Built
Machines SN 0300150055 to SN 0300182743 Only & China
Built Machines SN B300000282 to Present Only)
207 2 Steer Cylinder Assembly Options (See CYLINDER SECTION for
Breakdown):
1683740 USA Built Machines SN 0300140000 to SN 0300142666 Only
1001097243 USA Built Machines SN 0300142666 to SN 0300182743 Only &
China Built Machines SN B300000100 to Present Only
208 3422701 2 Pin, Steer, Spindle Attach
209 3422702 2 Pin, Tie-Rod
210 3422754 2 Pin, Attach
211 3422849 4 Kingpin
212 3841143 6 Shaft, Keeper 3/8in x 3in
213 4130389 1 Spindle Weldment (RH)
214 4130390 1 Spindle Weldment (LH)
215 4740111 4 Washer, Special
216 4740256 AR Thrustwasher
217 4740463 2 Washer, Special
218 4740473 2 Thrustwasher
219 1001103810 2 Thrustwasher
220 3020029 AR Grease, Bearing
0273378 Ref HUB INSTALLATION (2WD ONLY) E
301 0100011 AR Compound, Locking
302 to 303 Not Used
304 0682016 16 Bolt 5/8in-16NC x 2in (Grade 8)
305 to 306 Not Used
307 2780229 2 Hub Assembly (See Items 401-412 for Breakdown)
308 Not Used
309 3300007 20 Lugnut
310 to 315 Not Used
316 4892000 16 Flatwasher 5/8in Hardened
1-4 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
2780229 Ref HUB ASSEMBLY (2WD ONLY) A
401 7017052 2 Spindle (1 per Assembly)
402 7017053 2 Housing (1 per Assembly)
403 7010404 2 Cup, Bearing - Inner (1 per Assembly)
404 7010405 2 Cone, Bearing - Inner (1 per Assembly)
405 7017056 2 Cup, Bearing - Outer (1 per Assembly)
406 7017055 2 Cone, Bearing - Outer (1 per Assembly)
407 7010406 2 Seal, Lip (1 per Assembly)
408 7000265 20 Stud (10 per Assembly)
409 7017054 2 Dust Cap (1 per Assembly)
410 7017051 2 Washer, Special (1 per Assembly)
411 7017057 2 Washer, Tanged (1 per Assembly)
412 7017058 2 Nut, Bearing (1 per Assembly)
3121270 800S 860SJ 1-5
SECTION 1 FRAME
106
110
106
114
102
118
107
103
103
113
113
111
109
105
117
112
116
115
119
228
230
229
107
212
212
205
205
225
225
218
218
220
218
211
204
204
227
213
227
213
218
210
401
407
404
403
402
307
408
309
301
405
406
410
411
412
409
219
204
204
202
231
231
224
214
221
221
204
218
209
223
209
217
216
207
221
226
207
222
222
208
215
204
203
218
104
201
201
201
201
218
201
201
201
304
201
101
201
101
101
315
206
206
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE
1-6 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0274572 Ref OSCILLATING AXLE INSTALLATION C
101 0100011 AR Compound, Locking
102 0100019 AR Compound, Locking
103 0641608 4 Bolt 3/8in-16NC x1in
104 0642212 1 Bolt 3/4in-10NC x 1-1/2in
105 0681608 4 Bolt 3/8in-16NC x1in (Grade 8)
106 0962102 2 Bushing, Garmax
107 1683078 2 Lockout Cylinder Assembly (See CYLINDER SECTION for
Breakdown)
108 Not Used
109 3422702 2 Pin
110 3422703 1 Pin, Main Pivot
111 3422755 2 Pin
112 3538047 2 Shim, Axle Wear
113 3841143 4 Shaft, Keeper 3/8in Dia x 3in
114 3841287 1 Shaft, Keeper 3/8in Dia x 6in
115 4070878 2 Shim, Axle Wear
116 4070879 2 Shim, Axle Wear
117 4711600 4 Flatwasher 3/8in Thin
118 4740472 1 Washer, Special
119 4846413 1 Axle Weldment
0271352 Ref STEERING INSTALLATION H
Ref Note: Before ordering king pin kit, verify that machines is
equipped with the original components (king pin with 4 bolt
holes) or service kit components (king pin with 8 bolt holes).
- If the king pin hole in the axle measurement exceeds 2.252in
OD or is elongated, use King Pin Kit p/n 1001137261.
201 0100011 AR Compound, Locking
202 0362726 1 Tie-Rod
203 0641508 1 Bolt 5/16in- 18NC x 1in
204 0641608 7 Bolt 3/8in-16NC x 1in
205 0962152 2 Bearing, Garmax
206 4 Bearing Options:
0962448 Bearing, Garmax - Composite (USA Built Machines
SN 0300140000 to SN 0300150055 Only & China Built
Machines SN B300000100 to SN B300000282 Only)
1001112651 Bearing, Bronze Limited - Aluminum/Bronze (USA Built
Machines SN 0300150055to SN 0300182743 Only & China
Built Machines SN B300000282 to Present Only)
207 0962292 2 Bearing, Garmax
208 0962348 1 Bearing, Garmax
209 2 Steer Cylinder Assembly Options (See CYLINDER SECTION for
Breakdown):
1683740 USA Built Machines SN 0300140000 to SN 0300142666 Only
1001097243 USA Built Machines SN 0300142666 to SN 0300182743 Only
China Built Machines SN B300000100 to Present Only
210 3422567 1 Pin, Steer Spindle Attach (RH)
211 3422701 1 Pin, Steer Spindle Attach (LH)
3121270 800S 860SJ 1-7
SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
212 3422702 2 Pin, Tie-Rod
213 3422972 4 Kingpin
214 3422754 2 Pin, Attach
215 3422813 1 Pin
216 3422848 1 Pin, Hitch
217 2573001 1 Link, Connecting
218 3841143 8 Shaft, Keeper 3/8in x 3in
219 4130390 1 Spindle Weldment (LH)
220 4130388 1 Spindle Weldment (RH)
221 4740111 6 Washer, Special
222 4740155 2 Thrustwasher
223 4740256 4 Thrustwasher
224 4740463 2 Thrustwasher
225 4740473 2 Washer, Special
226 4846935 1 Bar, Pivot
227 0641810 16 Bolt 1/2in-13NC x 1-1/4in
228 0741609 4 Screw 3/8in-16NC x 1-1/4in
229 3340966 2 Pad, Stop
230 4071059 4 Shim
231 3020029 AR Grease, Bearing
0273378 Ref HUB INSTALLATION (2WD ONLY) E
301 0100011 AR Compound, Locking
302 to 303 Not Used
304 0682016 16 Bolt 5/8in-16NC x 2in (Grade 8)
305 to 306 Not Used
307 2780229 2 Hub Assembly (See Items 401-412 for Breakdown)
308 Not Used
309 3300007 20 Lugnut
310 to 314 Not Used
315 4892000 16 Flatwasher 5/8in Hardened
2780229 Ref HUB ASSEMBLY (2WD ONLY) A
401 7017052 2 Spindle (1 per Assembly)
402 7017053 2 Housing (1 per Assembly)
403 7010404 2 Cup, Bearing - Inner (1 per Assembly)
404 7010405 2 Cone, Bearing - Inner (1 per Assembly)
405 7017056 2 Cup, Bearing - Outer (1 per Assembly)
406 7017055 2 Cone, Bearing - Outer (1 per Assembly)
407 7010406 2 Seal, Lip (1 per Assembly)
408 7000265 20 Stud (10 per Assembly)
409 7017054 2 Dust Cap (1 per Assembly)
410 7017051 2 Washer, Special (1 per Assembly)
411 7017057 2 Washer, Tanged (1 per Assembly)
412 7017058 2 Nut, Bearing (1 per Assembly)
1-8 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121270 800S 860SJ 1-9
SECTION 1 FRAME
102
104
107
103
106
105
101
DETAIL OF
VALVE STEM
6
14
4
8
13
3
9
1
1
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
1-10 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
ITEM # PART NUMBER QTY. DESCRIPTION REV.
Ref WHEEL DRIVE INSTALLATION
0273378 Ref 2WD E
0273704 Ref 4WD D
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
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.
101 1702701 1 Decal - 95 PSI/6.5 Bar (15-625 Tires) (Pneumatic Only)
102 1 Tire Options:
4520252 15-625 Tire
4520253 18-625 Tire
103 4640113 1 Valve, Air
C
C
3121270 800S 860SJ 1-11
SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
104 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)
105 1705364 AR Decal - Tire Sealant (W/Sealant Only)
106 1300019 AR Chemical, Tire Sealant (Green) (W/Sealant Only)
107 1120552 AR Cap, Valve Stem (Green) (W/Sealant Only)
1-12 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121270 800S 860SJ 1-13
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
27191A1B1C
1D1N1G1F1E1H26
2
6A
6
16
16
15
15
15
15
12
133B3F3C3D
3C
3B
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
1-14 800S 860SJ 3121270
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
3121270 800S 860SJ 1-15
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)
1-16 800S 860SJ 3121270
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)
3121270 800S 860SJ 1-17
SECTION 1 FRAME
3
41340193830343332
313231
18
1
1
4
11
129107A13
16
15
17
14
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 (5 BOLT ASSEMBLY)
1-18 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT 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
3121270 800S 860SJ 1-19
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT 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)
1-20 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121270 800S 860SJ 1-21
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
203
202
205
201
12F
12E
111F
111F
111G
FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS
1-22 800S 860SJ 3121270
SECTION 1 FRAME
FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0273378 Ref DRIVE VALVES INSTALLATION - 2WD E
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
0273704 Ref DRIVE VALVES INSTALLATION - 4WD D
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
0274267 Ref FRAME SHIELDS INSTALLATIONS A
201 0100011 AR Compound, Locking
202 0641608 6 Bolt, 3/8in - 16NC x 1in
203 3575718 1 Plate, Cover Front
204 Not Used
205 4751600 6 Flatwasher 3/8in Regular
3121270 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
2
4
3
9
10
8
5
116
116
116
11
7
6
101
101
101
105
101
105
101
105
101
105
101
105
101
101
FIGURE 1-7. TOW PACKAGE INSTALLATION
1-24 800S 860SJ 3121270
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