JLG 860SJ Parts Manual

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Page 1

Illustrated Parts Manual

Models

800S

860SJ

SN 0300140000 to

SN 0300182743

SN B300000100 to

Present

P/N

3121270

January 17, 2014

Page 2

Page 3

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

Page 4

REVISION LOG

B 800S 860SJ 3121270

Page 5

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

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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

Page 7

SECTION 1

FRAME

3121270 800S 860SJ 1-1

Page 8

SECTION 1 FRAME

1213101

117

112

116

115

9 14 15

119

107

210

215

203 212

207

209

205

218

212

213

203

204

211

212

208

401

407

404

403

402

307

408

309

301

316

405

406

410

411

412

409

214

203

202

106

110

106

114

104

118

107

103

113

111

109

220

217

216

102

201

101

201

105

201

204

201

304

219

206

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

1-2 800S 860SJ 3121270

Page 9

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

Page 10

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

Page 11

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

Page 12

SECTION 1 FRAME

106

110

106

114

102

118

107

103

113

111

109

105

117

112

116

115

119

228

230

229

107

212

205

225

218

220

218

211

204

227

213

227

213

218

210

401

407

404

403

402

307

408

309

301

405

406

410

411

412

409

219

204

202

231

224

214

221

204

218

209

223

209

217

216

207

221

226

207

222

208

215

204

203

218

104

201

218

201

304

201

101

201

101

315

206

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

1-6 800S 860SJ 3121270

Page 13

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

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

Page 14

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

1-8 800S 860SJ 3121270

Page 15

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

Page 16

SECTION 1 FRAME

102

104

107

103

106

105

101

DETAIL OF

VALVE STEM

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

1-10 800S 860SJ 3121270

Page 17

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

3121270 800S 860SJ 1-11

Page 18

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

Page 19

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 1-13

Page 20

SECTION 1 FRAME

10531111

110

112

121

102

119

122

123

104

103

101

109

107

108

114 113

116

115

118

117

120

27191A1B1C

1D1N1G1F1E1H26

133B3F3C3D

106

200A

200B

201D

201C

201B

201A

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY

1-14 800S 860SJ 3121270

Page 21

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

Page 22

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

Page 23

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)

Friction Disc Kit - 7024182 Brake (Includes Items 103, 104, 106 & 107)

3121270 800S 860SJ 1-17

Page 24

SECTION 1 FRAME

41340193830343332

313231

129107A13

100

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)

1-18 800S 860SJ 3121270

Page 25

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

Page 26

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

Page 27

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 1-21

Page 28

SECTION 1 FRAME

VALVE ROTATED FOR CLARITY

12C

12B

111

102

112

12A

12C

12D

112

110

111C

111A

111B

111C

111D

111E

111B

203

202

205

201

12F

12E

111F

111G

FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS

1-22 800S 860SJ 3121270

Page 29

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

Page 30

SECTION 1 FRAME

102

121

113

114

117

112

115

120

103

105

104

109

110

106

108

119

109

110

116

118

116

107

111

116

101

105

101

105

101

105

101

105

101

105

101

FIGURE 1-7. TOW PACKAGE INSTALLATION

1-24 800S 860SJ 3121270

Page 31

SECTION 1 FRAME

FIGURE 1-7. TOW PACKAGE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TOW BAR INSTALLATION

0271354 Ref ANSI, ANSI Export & CSA Specs E

1001166809 Ref CE Specs A

1 0250528 1 Tow Bar Assembly (See Items 101-121 for Breakdown) 2 0641504 2 Bolt 5/16in-18NC x 1/2in 3 3539662 1 Plate, Valve Mounting 4 4640261 1 Valve, Select 5 4711500 2 Flatwasher 5/16in Thin 6 0100011 AR Compound, Locking 7 2 Decal - Crushing Options:

1704578 ANSI, ANSI Export & CSA Specs

1706960 CE Specs

8 AR Decal - Towing Instructions Options:

1705090 1 ANSI, ANSI Export & CSA Specs

Not Required 0 CE Specs

9 1 Decal/Nameplate - Steer/Tow Select Valve Options:

3250872 ANSI, ANSI Export & CSA Specs

1706957 CE Specs

10 3820001 4 Rivet (ANSI, ANSI Export & CSA Specs Only) 11 4420051 AR Tape, Safety

0270528 Ref TOW BAR ASSEMBLY A

101 0100011 AR Compound, Locking 102 0362910 1 Pintle, Draw Eye 103 0642010 4 Bolt 5/8in-11NC x 1-1/4in 104 0721004 2 Screw, Hex Machine 105 0741607 24 Screw, Countersunk 3/8in-16NC x 7/8in 106 1060584 6 Cable, Lanyard 107 3420372 2 Pin, Cotter 108 3420447 1 Pin, Towing 109 3421565 2 Pin, Snap 110 3422841 2 Pin 111 3422847 1 Pin 112 3572009 2 Plate, Slide Stop 113 3572010 2 Plate, Slide Stop 114 3572011 2 Plate, Slide Stop 115 3572012 2 Plate, Slide Stop 116 3760170 8 Ring, Split 117 4568133 1 Tube, Tow Bar 118 4740036 1 Flatwasher 119 4751000 2 Flatwasher #10 Regular 120 4846295 1 Tow Bar Attach Weldment 121 4846296 1 Pintle Attach Weldment

3121270 800S 860SJ 1-25

Page 32

SECTION 1 FRAME

FIGURE 1-7. TOW PACKAGE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-26 800S 860SJ 3121270

Page 33

SECTION 2

TURNTABLE

3121270 800S 860SJ 2-1

Page 34

SECTION 2 TURNTABLE

222

221

225

201

220

223

224

217

227

209

213

216

206

203

228

217

202

229

215

205

207

213A

213C

213B

102

101

12A

12B

17151

152

154

155

153

FIGURE 2-1. CONTROL VALVES INSTALLATIONS

2-2 800S 860SJ 3121270

Page 35

SECTION 2 TURNTABLE

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274644 Ref Machines Without Hostile Environment K 0274644 Ref Machines With Hostile Environment (USA Built Machines

1001155814 Ref Machines With Hostile Environment (USA Built Machines

0274645 Ref 860SJ I

1001151209 Ref AUXILIARY PUMP INSTALLATION A

1 0100011 AR Compound, Locking 2 0140001 1 Horn 3 Not Used 4 0641408 1 Bolt 1/4in-20NC x 1in 5 0641418 2 Bolt1/4in-20NC x 2-1/4in 6 AR Bolt Options:

0641408 3 Bolt 1/4in-20NC x 1in

0641606 4 Bolt 3/8in-16NC x 3/4in 7 0641612 4 Bolt 3/8in-16NC x 1-1/2in 8 2 Bolt Options:

0641612 800S - Bolt 3/8in-16NC x 1-1/2in

0641620 860SJ - Bolt 3/8in-16NC x 2-1/2in 9 Not Used

10 AR Hydraulic Pressure Filter Assembly Options:

2120209 1 Hydraulic Pressure Filter Assembly

2120210 1 Element, Filter

7020020 1 Manual Indicator

70000934 1 O-Ring Filter Bowl

1001108617 1 Hydraulic Pressure Filter Assembly

70002231 1 Element, Filter 11 3311405 3 Locknut 1/4in-20NC 12 1 Auxiliary Pump Assembly Options:

12A 3600424 Auxiliary Pump Assembly (Haldex Brand) (See Items 101 &

12B 1001137459 Auxiliary Pump Assembly (Bucher Hydraulics Brand) (See

13 4641432 1 Main Control Valve Assembly (See MAIN CONTROL VALVE

14 Not Used 15 4641317 1 Dual Select Valve Assembly C

7012944 2 Coil 7012941 2 Cartridge Less Coil

7010543 2 Seal Kit - 7012941 Valve (1 Per Cartridge) 16 4711400 14 Flatwasher 1/4in Thin 17 Not Used

FIGURE 2-1. CONTROL VALVES INSTALLATIONS

Ref VALVES INSTALLATIONS Ref 800S ‘

SN 0300140000 to SN 0300174927 & China Built Machines SN B300000100 to SN B300000804)

SN 0300174927 to SN 0300182743 & China Built Machines SN B300000804 to Present)

USA Built Machines SN 0300140000 to SN 0300141319 Only

USA Built Machines SN 0300141319 to SN 0300182743 Only & China Built Machines SN B300000100 to Present Only

102 for Breakdown)

Items 151 & 155 for Breakdown)

ASSEMBLY for Breakdown)

3121270 800S 860SJ 2-3

Page 36

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

18 AR Flatwasher Options:

4711400 3 Flatwasher 1/4in Thin 4711600 4 Flatwasher 3/8in Thin

19 4751600 10 Flatwasher 3/8in Regular

3600424 Ref AUXILIARY PUMP ASSEMBLY (HALDEX BRAND) B

101 70001056 1 Motor Kit

7011062 1 Bracket, Motor/Pump 7011016 1 Coupling 7029592 2 Setscrew

102 7029593 1 Pump Kit

7011016 1 Coupling 7011044 1 Gasket 7011048 4 Flatwasher 7011043 4 Screw

1001137459 Ref AUXILIARY PUMP ASSEMBLY (BUCHER HYDRAULICS

BRAND)

151 70002998 1 Motor 152 70004266 1 Pump 153 70001020 4 Screw 154 70003612 2 O-Ring 155 70004267 1 O-Ring

0272750 Ref MANUAL DESCENT INSTALLATION (OPTIONAL) B

201 0641420 2 Bolt 1/4in-20NC x 2-1/2in 202 0641514 2 Bolt 5/16in-18NC x 1-3/4in 203 1702927 1 Decal - #2 204 1705589 1 Decal - Manual Descent (Not Shown - Located on Hydraulic Tank) 205 2900062 1 Kit, Valve Mounting 206 3311405 2 Locknut 1/4in-20NC 207 3311505 2 Locknut 5/16in-18NC 208 Not Used 209 3574179 1 Plate, Valve Mounting

210 to 212 Not Used

213 4640930 1 Manifold, Manual Descent Assembly

213A AR Cartridge, Needle Options:

Use 4640902 4 Cartridge, Needle (was p/n 7012954) (Original Equipment)

7012953 4 Seal, Kit - 7012954 Cartridge 4640902 4 Cartridge, Needle (Service Replacement)

7012953 4 Seal, Kit - 4640902 Cartridge 213B 7012961 4 Knob 213C AR Cartridge, Pump Options:

Use 70004019 1 Cartridge, Pump (was p/n 7012694) (Original Equipment)

7012699 1 Seal, Kit - 7012694 Cartridge

70004019 1 Cartridge, Pump (Service Replacement)

Use 7017496 1 Seal, Kit - 70004019 Cartridge (was p/n 2900756)

2-4 800S 860SJ 3121270

Page 37

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

214 Not Used 215 4641263 1 Valve, Metering 216 4751400 2 Flatwasher 1/4in Regular 217 4751500 4 Flatwasher 5/16in Regular

218 to 219 Not Used

220 1380136 2 Clip, Gripper 221 2560122 1 Handle 222 2560123 1 Handle, Grip 223 3311005 2 Locknut #10-24NC 224 3911008 2 Screw 225 4751000 2 Flatwasher #10 Regular 226 1702901 1 Decal - Manual Descent (Not Shown - Located on hood) 227 1702903 1 Decal - #1 228 1702924 1 Decal - #3 229 1702925 1 Decal - #4

3121270 800S 860SJ 2-5

Page 38

SECTION 2 TURNTABLE

254

13 15

11 15

12 14

10 14

17A

FIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

2-6 800S 860SJ 3121270

Page 39

SECTION 2 TURNTABLE

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641432 Ref MAIN CONTROL VALVE ASSEMBLY A

1 7023918 1 Cartridge, Check Valve

7023919 1 Seal Kit - 7023918 Cartridge

2 7012975 1 Cartridge, Check Valve

Use 7012967 1 Seal Kit - 7012975 Cartridge (was p/n 7012540)

3 7023985 1 Cartridge, Check Valve

7017496 1 Seal Kit - 7023985 Cartridge

4 7023986 1 Cartridge, Flow Regulator (Steer)

7010545 1 Seal Kit - 7023986 Cartridge

5Use 10837580 2 Cartridge, Load Sensing (Steer & Swing) (was p/n 7010542)

7010543 2 Seal Kit - 7010542 Cartridge

6 7023987 1 Cartridge, Pilot

7012942 1 Seal Kit - 7023987 Cartridge

7 7023921 1 Cartridge, Proportional Flow (Tele)

7012925 1 Seal Kit - 7023921 Cartridge

8 7017422 2 Cartridge, Relief Valve (Steer & Swing)

7012998 2 Seal Kit - 7017422 Cartridge

9 7017489 1 Cartridge, Relief Valve (Tele Out Relief)

7012998 1 Seal Kit - 7017489 Cartridge

10 7023922 1 Cartridge, Solenoid (Swing)

7017402 1 Seal Kit - 7023922 Cartridge

11 7023923 1 Cartridge, Solenoid (Main Dump)

7023919 1 Seal Kit - 7023923 Cartridge

12 7021612 1 Cartridge, Solenoid (Lift Up Dump)

Use 7010543 1 Seal Kit - 7021612 Cartridge (was p/n 7012907)

13 7023925 1 Cartridge, Solenoid (Steer Direction)

7012903 1 Seal Kit - 7023925 Cartridge 14 7012944 3 Coil 15 7012943 3 Coil 16 7017451 1 Coil 17 70000579 1 Control Valve Assembly (Tele Direction)

70000583 1 Seal Kit

17A 70000582 1 Coil

70000580 1 Nut, Coil

18 See Note 4 Capscrew (Note: Not Available for Purchase.)

3121270 800S 860SJ 2-7

Page 40

SECTION 2 TURNTABLE

201

202

203

204

FRAME REF.

301

302

303

103

105

305

105

104

102

101

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION

2-8 800S 860SJ 3121270

Page 41

SECTION 2 TURNTABLE

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TURNTABLE WELDMENT 4620130 800S 4620131 860SJ

1001094899 Ref SWING DRIVE INSTALLATION B

1 0100019 AR Compound, Locking 2 0682216 4 Bolt 3/4in-10NC x 2in (Grade 8) 3 3312002 1 Nut, Jam 3/4in-10NC 4 3900293 1 Bolt, Shoulder 5 3952020 2 Setscrew 5/8in-11NC x 2-1/2in 6 4071009 1 Shim 7 4740057 4 Flatwasher 3/4in Hardened 8 1001101060 1 Swing Motor/Swing Hub Assembly (See SWING MOTOR/SWING

HUB ASSEMBLY for Breakdown)

0271002 Ref SWING BEARING INSTALLATION E

101 0100019 AR Compound, Locking 102 0440244 1 Bearing, Turntable 103 0682023 24 Bolt 5/8in - 11NC x 2-7/8in (Grade 8) 104 0682032 24 Bolt 5/8in - 11NC x 4in (Grade 8) 105 4892000 48 Flatwasher, 5/8in Hardened

0259147 Ref TURNTABLE LOCK INSTALLATION B

201 4844958 1 Pin 202 3421565 1 Pin, Snap 203 3760170 2 Ring, Quick Release 204 1260017

0271496 Ref REMOTE BEARING LUBE INSTALLATION B

301 2160001 1 Fitting, Grease 302 2180344 1 Fitting, Bulkhead 303 2220063 1 Fitting, Elbow 304 Not Used 305 2751032 1 Hose, Grease

9in/23cm

Chain

3121270 800S 860SJ 2-9

Page 42

SECTION 2 TURNTABLE

44811

5A612

201J24

253B3B3E3G

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY

2-10 800S 860SJ 3121270

Page 43

SECTION 2 TURNTABLE

212223

120

119

117

118

116

114

115

113

112

110

109

108

107

106

105

103

104

102

101

200A

200B

200C

201

8J8K8J8K8J

125

3121270 800S 860SJ 2-11

Page 44

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001101060 Ref SWING MOTOR/HUB ASSEMBLY A

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

Individual Components.)

1A 7010492 1 Shaft, Output

1B 7000228 1 Seal, Lip 1C 7000255 1 Bearing Kit (Includes Cup & Cone) 1D Not Used 1E 7000257 1 Bearing Kit (Includes Cup & Cone) 1F Not Used 1G 7024762 1 Housing 1H 7007633 1 Thrustwasher

1I 7000229 1 Ring, Retaining

1J 7017072 1 Plug, Pipe

2 7000246 1 Gear, Internal

3 80424002 1 Carrier Assembly 3A 7001931 1 Carrier 3B 7001985 6 Washer, Tanged 3C 7001909 84 Bearing, Needle 3D 7000263 3 Thrustwasher 3E 7001911 3 Shaft, Planet 3F 7001912 3 Gear, Cluster 3G 7010474 3 Rollpin

4 7000248 1 Gear, Ring

5 7000230 1 O-Ring 5A 7017070 1 O-Ring

6 Use 1001101060 1 Housing, Brake (Note: Not Available - Purchase Complete

Assy.)

7 Not Used

8 70002065 1 Gear, Sun 8A 70000782 1 Piston

8B to 8C Not Used

8D 70002070 1 O-Ring 8E 70002071 1 Ring, Back-up 8F 70002073 1 O-Ring 8G Not Used 8H 70002072 1 Ring, Back-up

8I Not Used

8J 70002067 4 Disc, Rotor

8K 70002068 5 Disc, Stator

8L 70002066 14 Spring

9 to 10 Not Used

11 7000253 2 Thrustwasher 12 7000217 12 Bolt 3/8in-16NC x 2-1/4in (Grade 8) 13 7017080 4 Pin, Dowel

14 to 19 Not Used

20 7017072 1 Plug, Pipe 21 7024704 4 Bolt 5/16in-18NC x 2in (Grade 8) 22 See Note 4 Lockwasher (Note: Not Available for Purchase.)

2-12 800S 860SJ 3121270

Page 45

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

23 7017023 2 Plug, Pipe 24 See Note 1 Plate, ID (Note: Not Available for Purchase.) 25 7000281 2 Screw, Drive 26 7024763 1 O-Ring 27 Not Used 28 See Note 2 Lug, Lifting (Note: Not Available for Purchase.) 29 70002069 2 Bolt 1/2in-13NC x 2in (Grade 8) 30 7017085 2 Elbow 31 70002075 1 Motor Assembly (See Items 101-125 for Breakdown) 32 7024784 1 Valve Assembly - Complete (No Serviceable Parts)

33 to 34 Not Used

35 70002074 1 Tube

36 to 43 Not Used

44 7017028 1 Ring, Internal Retaining

70002075 Ref MOTOR ASSEMBLY

101 7024454 5 Bolt 102 7004035 1 Cover, End 103 7023318 1 Seal, Commutator 104 7004036 5 Seal, Ring 105 7024453 1 Commutator and Ring Assembly 106 Use 7024453 1 Ring 107 7024379 1 Manifold 108 7024455 1 Rotor Set 109 7024380 1 Plate, Wear 110 7024456 1 Link, Drive 111 Not Used 112 7024458 1 Shaft, Coupling 113 7024381 1 Bearing, Inner 114 7004043 1 Thrustwasher 115 7004044 1 Bearing, Thrust 116 7004049 1 Seal, Inner 117 7004045 1 Washer, Back-up 118 7024457 1 Housing 119 7024390 1 Bearing, Outer 120 7004047 1 Seal

121 to 124 Not Used

125 80424043 1 Washer, Back-up

Ref KIT OPTIONS:

200 1 Seal Kit Options: 200A 7024100 Swing Hub (Includes Items 1B, 1I, 5, 5A & 11) 200B 70002086 Swing Brake (Includes Items 8D, 8E, 8F, 8H & 26) 200C 7024396 Swing Motor (Includes Items 103, 104, 116, 117, 120 & 125)

201 70002085 1 Disc Kit - Swing Brake (Includes Items 8J & 8K)

3121270 800S 860SJ 2-13

Page 46

SECTION 2 TURNTABLE

56385

385

10820320121

211

210

411

410

403

48B

20362

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION

2-14 800S 860SJ 3121270

Page 47

SECTION 2 TURNTABLE

SUP

LYT

ANK R

711

540

215A

215B

215C

215D

106

121

11711910410

949

4078608502356

202

BATTERY

AUX POWER

PUMP

STARTER

GLOW PLUG

RELAY

ENGINE MOUNTING BOLT

MTG BOLT FOR

GLOW PLUG RELAY

ENGINE TRAY

KEEPER PIN

BOLT

INCLUDES ITEMS 215A THRU 215D

AUX PWR

RELAY

1161071121131021021071151

021

10107

3121270 800S 860SJ 2-15

Page 48

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001109065 Ref CATERPILLAR TIER IVi ENGINE ASSEMBLY D

1 0080181 1 Adaptor, Pump Mounting Plate 2 0080243 1 Adaptor, Fan Spacer 3 0100011 AR Compound, Locking 4 0340041 2 Band, Mounting 5 0340046 2 Band, Muffler 6 0400075 1 Battery 7 0641406 4 Bolt 1/4in-20NC x 3/4in 8 0641407 4 Bolt 1/4in-20NC x 7/8in

9 0701414 4 Bolt 1/4in-20NC x 3/4in 10 0641507 4 Bolt 5/16in-18NC x 7/8in 11 0641606 2 Bolt 3/8in-16NC x 3/4in 12 0641608 8 Bolt 3/8in-16NC x 1in 13 0641609 4 Bolt 3/8in-16NC x 1-1/8in 14 0641610 4 Bolt 3/8in-16NC x 1-1/4in 15 0641808 1 Bolt 1/2in-13NC x 1in 16 0641820 4 Bolt 1/2in-13NC x 2-1/2in 17 0700808 4 Bolt M8 x 16mm 18 0701010 8 Bolt M10 x 20mm 19 0701012 4 Bolt M10 x 25mm 20 0701015 8 Bolt M10 x 35mm 21 0711214 5 Bolt M12 x 30mm 22 0771212 3 Bolt M12 x 25mm 23 0940070 1 Bumper, Rubber 24 0961986 2 Bearing, Flange 25 1060637 1 Lanyard 26 1320016 2 Clamp, Hose 27 1320223 4 J-Clip 1/2in 28 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner 29 1580011 1 Container, Coolant Overflow 30 1660239 1 Coupling, Pump 31 1703162 2 Decal - Fan Blade 32 2060025 1 Fan 33 2720058 .33ft Hose 34 2720434 1 Elbow, Rubber 35 2720509 1 Hose, Radiator (Bottom) 36 2720515 1 Seal, Air Cleaner 37 3200406 4 Mount, Engine 38 1 Muffler Options:

3220113 Spark Arresting Muffler

70001017 1 Clamp

1001107116 Catalytic Muffler

70002705 1 Clamp

70002706 1 Plug, Brass 39 3290801 4 Nut M8 x 1.25 40 3311405 12 Locknut 1/4in-20NC 41 3311505 4 Locknut 5/16in-18NC

2-16 800S 860SJ 3121270

Page 49

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

42 3311605 AR Locknut 3/8in-16NC 43 3311801 1 Nut 1/2in-13NC 44 3311805 4 Locknut 1/2in-13NC 45 3574206 1 Plate, Motor Mount 46 3574207 1 Plate, Engine Mount (Rear) 47 3574208 1 Bracket, Muffler

48 3620047 1 Radiator 48A 7027412 1 Cap 48B 70004182 1 Shroud, Fan

49 3740067 3 Relay, Solenoid Assembly

50 3960468 1 Seal, Foam Gasket

51 3960469 1 Seal, Foam Gasket

52 4031911 4 Bolt Metric M8 x 35mm

53 4060805

54 4220191 2 Block, Spacer

55 4567073 1 Tube, Exhaust 55A 70001017 1 Clamp

56 4568721 1 Exhaust Tube Weldment

57 4711500 8 Flatwasher 5/16in Thin

58 4711600 2 Flatwasher 3/8in Thin

59 4740274 4 Washer, Snubbing

60 4751400 24 Flatwasher 1/4in Regular

61 4751500 2 Flatwasher 5/16in Regular

62 4751600 44 Flatwasher 3/8inv

63 4751800 1 Flatwasher 1/2in Regular

64 4811900 4 Flatwasher M8

65 4812100 8 Flatwasher 12m

66 4832000 8 Lockwasher M10

67 4846790 1 Tray Engine

68 4846805 1 Mount, Engine/Generator - Left

69 8405009 2 Clamp, Hose

70 8405104 4 Clamp, Hose

71 88521205 2 Locknut, Nylon Insert 5/16in-18NC

72 91401281 1 Hold-down, Battery

73 1001093382 2 Bolt, Battery Hold-down

74 1 Valve, Oil Drain Options:

Use 4640750 USA Built Machines SN 0300140000 to SN 0300141103 Only

4640750 USA Built Machines SN 0300141103 to SN 0300182743 Only &

75 1001109595 1 Plate, Radiator Mounting

76 1001112077 1 Caterpillar Tier IVi Engine Assembly

77 1001107705 1 Hose, Radiator (Top)

78 4791400 4 Starwasher 1/4in

79 0100020 AR Sealant, Pipe (USA Built Machines SN 0300141103 to

2ft/0.7mm

Flex-Trim 1/4in

(was p/n 1001105833)

China Built Machines SN B300000100 to Present Only

SN 0300182743 Only & China Built Machines SN B300000100 to Present Only)

3121270 800S 860SJ 2-17

Page 50

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref CATERPILLAR TIER IVi ENGINE INSTALLATIONS 1001110212 Ref Machines Without Arctic Package D 1001110213 Ref Machines With Arctic Package C

101 0100011 AR Compound, Locking 102 0100020 AR Sealant, Thread 103 0641608 2 Bolt 3/8in-16NC x 1in 104 0641610 1 Bolt 3/8in-16NC x 1-1/4in 105 0641808 1 Bolt 1/2in-13NC x 1in 106 0642010 1 Bolt 5/8in-11NC x 1-1/4in 107 1320022 7 Clamp, Hose 108 1320176 1 Clamp 109 1701505 1 Decal - Diesel (Not Shown - Located on Hood) 110 2180348 1 Fitting, Barbed 111 2200222 1 Plug, Pipe (Not Shown - Located in Bottom of Fuel Tank) 112 2220313 1 Fitting, Elbow 113 2221176 1 Fitting, Elbow 114

2300004 Without Arctic Package

2300041 With Arctic Package 115 2720058 116 2750532 117 3422446 1 Pin, Pivot 118 3460544 1 Pipe, Exhaust 119 3841143 1 Keeper, Pin 120 4711600 2 Flatwasher 3/8in Thin 121 4752000 1 Flatwasher 5/8in Regular 122 Not Used

123 1060625 1 Cable, Immersion Heater (Located on bottom of Hydraulic Oil

124 1320223 1 Clamp 125 1702943 1 Decal - Hydraulic Tank Heater (Located on bottom of Hydraulic

126 2580050 1 Heater, Hydraulic Tank (Located on bottom of Hydraulic Oil

2.63gl/9.96Li

30ft/9.1m

6ft./1.8m

Ref Note: Arctic Package Items 123 - 126 Not Shown - Used on

Anti-Freeze Options (Not Shown):

Hose Hose 3/8in

Arctic Machines Only

Ta n k)

Oil Tank)

Ta n k)

Ref CATERPILLAR TIER IVi ENGINE W/PUMPS ASSEMBLIES 1001110206 Ref Machines Without Arctic Package B 1001110205 Ref Machines With Arctic Package C

201 0100011 AR Compound, Locking 202 0641407 1 Bolt 1/4in-20NC x 7/8in 203 0641812 4 Bolt 1/2in-13NC x 1-1/2in 204

3020016 Without Arctic Package - Motor Oil 15W-40

3020044 With Arctic Package - Motor Oil 0W-40 205 3311405 1 Locknut 1/4in-20NC 206 3422532 1 Pin, Hitch

2.5gal/9.4Li

Motor Oil Options (Not Shown):

2-18 800S 860SJ 3121270

Page 51

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

207 3600410 1 Piston Pump Assembly (See PUMP ASSEMBLY (SAUER-

DANFOSS) PUMP) for Breakdown)

208 3600411 1 Load Sensing Pump Assembly with Fittings

(See LOAD SENSING PUMP ASSEMBLY for Breakdown) 209 3790044 1 O-Ring 210 3960548 211 3960549 212 4751400 1 Flatwasher 1/4in Regular 213 4891800 2 Flatwasher 1/2in Hardened 214 Not Used 215 1001112762 1 Battery Cable Kit B

215A 7027028 1 Cable, Battery (Red) 215B 7027029 1 Cable, Battery (Black) 215C 7027030 1 Cable (Red) 215D 7027031 1 Cable (Black)

216 0641608 2 Bolt 3/8in-16NC x 1in 217 1060626 1 Cord, 3-Way Extension (Located on Left Front of Engine) 218 1320223 2 Clamp 219 1702941 1 Decal - Battery Heater (Located on Battery Heater) 220 1702942 1 Decal - Engine Block Heater (Located on Right Side of Engine) 221 1702944 1 Decal - Heater Cord (Located on Left Front of Engine) 222 2580024 1 Heater, Battery (Located on Battery) 223 2580055 1 Heater, Block (Located on Left Side of Engine) 224 3311605 2 Locknut 3/8in-16NC 225 3980007 1 Seat, Battery (Located Under Battery) 226 4751600 2 Flatwasher 3/8in Regular

42in/1m

1ft/0.3mm

Ref Note: Arctic Package Items 216 - 226 Not Shown - Used on

Seal, Hood

Seal

Arctic Machines Only

1001112077 Ref CATERPILLAR TIER IVi ENGINE W/ECM ASSEMBLY E

301 0100011 AR Compound, Locking 302 0100020 AR Sealant, Thread 303 0700620 1 Bolt M6 x 60mm 304 0700808 5 Bolt M8 x 16mm 305 0701010 2 Bolt M10 x 20mm 306 0760606 2 Bolt M6 x 12mm 307 0760610 2 Bolt M6 x 20mm 308 3 Bolt M6 x 25mm Options:

0760612 USA Built Machines SN 0300140000 to SN 0300141319 Only 4031709 USA Built Machines SN 0300141319 to SN 0300182743 Only &

China Built Machines SN B300000100 to Present Only 309 8303541 1 Screw M6 x 35mm 310 0700616 2 Bolt M6 x 40mm 311 0761210 2 Bolt M12 x 20mm 312 8406009 1 Clamp, Cable 313 1320224 1 Clamp, Cable 314 8406105 2 Clip, Tube 315 3290507 1 Locknut M5 316 4811700 12 Flatwasher M6

3121270 800S 860SJ 2-19

Page 52

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

317 4811900 5 Flatwasher M8 318 4812000 2 Flatwasher M10 319 4812100 2 Flatwasher M12 320 4811600 1 Flatwasher M5 321 1001097553 1 Washer, Coolant Sensor 322 1001109064 1 Caterpillar Tier IVi Engine Assembly 323 1001112057 1 Bracket 324 1001112059 5 Bumper 325 1001112067 1 Module, ECM 326 1001112068 1 Sensor, Speed 327 1001112069 1 Sensor, Temperature 328 1001112070 1 Switch, Oil Pressure 329 1001112071 1 Harness, Engine (Not Shown - See ELECTRICAL SECTION for

Breakdown) 330 1001112072 1 Bracket 331 1001112073 1 Actuator

1001112849 1 Linkage Assy 332 1001112570 1 Spacer 333 Not Used 334 1320263 1 Clamp, Cable 335 1001112075 1 Bolt 336 1001112592 1 Bearing 337 1001116595 1 Spacer 338 8406109 1 Clip, Tube

1001109064 Ref ENGINE COMPONENTS B

401 70001051 1 Valve, Crankcase Actuator Shut-Off 402 70001120 1 Pump, Water

70001742 1 Pulley, Water Pump 70002765 1 Hose, By-Pass (Not Shown)

403 See Note Head, Cylinder (Note: Not Available for Purchase.)

7026801 1 Gasket, Valve Cover 70002764 1 Gasket, Rear Head 70002762 15 Seat, Valve 70002761 17 Bolt, Head

404 7026839 1 Pump, Fuel Supply

7026830 1 Element, Fuel Filter 70002834 1 Bowl, Water Collection 70002835 1 Seal Kit - Water Separator 70002833 1 Ring, Fuel Pump Retaining

405 70002844 1 Dipstick Oil Level

70002843 1 Seal, Dipstick Tube

406 70002845 1 Pump, Oil (Not Shown)

70002846 1 O-Ring, Oil Pump (Not Shown)

407 70002849 1 Pump, Fuel Injection

70002847 1 O-Ring, Fuel Injection Pump Flange 70002848 1 Gasket, Fuel Injection Pump 70002850 1 Solenoid, Fuel Shut-Off

408 Not Used

2-20 800S 860SJ 3121270

Page 53

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

409 7026802 1 Flywheel

7026803 1 Gear, Flywheel 7026804 1 Gasket (Not Shown - Between Flywheel Housing & Engine Block) 7026805 1 Seal, Rear Main (Not Shown - Rear of Flywheel Housing)

7026807 1 Seal, Front Main (Located in Front Housing) 410 7026800 1 Cap Oil Filler (Top of Valve Cover) 411 7026806 1 Cap, Filler (Front Side of Engine) 412 7026810 1 V-Belt 413 7026811 1 Filter, Oil

7026812 1 O-Ring (Between Bolt & Oil Filter Bracket)

7026813 1 O-Ring (Between Oil Filter Bracket & Engine Block) 414 7026819 1 Engine Cooler Assembly (Not Shown)

7026816 2 O-Ring (Between Cover & Cooler)

7026817 4 O-Ring (Between Cover & Cooler) 415 7026822 1 Thermostat

7026821 1 Gasket (Between Regulator & Thermostat Housing)

7026820 1 Gasket (Between Regulator & Engine Head) 416 7026814 1 Relief Valve, Oil Pressure (Not Shown)

7026815 Gasket, Relief Valve 417 See Note 4 Injector, Fuel (Not Shown) (Note: Not Available for Purchase.)

70002763 4 Gasket, Fuel Line (Not Shown) 418 7026831 1 Alternator 419 7026832 1 Plug, Glow (Not Shown) 420 7026833 1 Starter (Not Shown - Located on other side of engine) 421 7026826 1 Gasket, Exhaust Manifold to Cylinder Head (Not Shown)

7026827 1 Gasket, Exhaust Manifold to Exhaust Pipe (Not Shown)

70002852 4 Stud, Exhaust Manifold (Not Shown) 422 7026829 1 Gasket, Intake Manifold to Cylinder Head (Not Shown)

7026828 1 Gasket, Intake Manifold to Intake Tube (Not Shown)

423 7026808 1 Plug, Oil Pan (Not Shown)

7026809 1 Gasket, Oil Plug 424 70002851 1 Gasket Kit (Not Shown) 425 4569371 1 Tube, Intake

3121270 800S 860SJ 2-21

Page 54

SECTION 2 TURNTABLE

208

256

240

247

109

243

223

256

237

226

227

225

223

215

259

262

209

256

237

254

238

232

211

256

209

232

241

254

238

237

256

211

259

215

412

239

210

301

233

209

256

237

254

238

242

533531031

06108112107

201

411

409

265

256

237

249

405

402

401

109

110

10325

420

424

423

101101352

201

212

351

205

255

235

204

222

219

228

430

236

213

260

245

206

224

215

114

115119116120101117101

11211

810

116

303

30330

FIGURE 2-6. DEUTZ ENGINE INSTALLATION

2-22 800S 860SJ 3121270

Page 55

SECTION 2 TURNTABLE

ENTRETURN

FUE

L PUMPSUPPL

EDW

THE

GIN

256

209

237

256

209

237

257

216

246

217

248

161412159916179

111

104

102

105

230

251

258

235

205

416

406

404

415

250

402

403

414

417

407

419

248

244

421

263

SUPPL

266

201

266

GLOW PLUGS

ON ENGINE

STARTER

BATTE

AUX PWR PUMP

AUX.PWR.

RELAY

GLOW

PLUG

RELAY

START

RELAY

GRD.

265

18D

18C

18A

GRD

18B69112220122120725226

218

3121270 800S 860SJ 2-23

Page 56

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref DEUTZ ENGINE INSTALLATION Ref Tier III/Tier IVi Engines

1001099829 Ref Without Arctic Package (USA Built Machines

SN 0300140000 to SN 0300170337 & China Built Machines SN B300000100 to SN B300000753)

1001100382 Ref With Arctic Package (USA Built Machines SN 0300170337

to SN 0300182743 & China Built Machines SN B300000753 to Present)

Ref Tier IVi-Flex Engines

1001137740 Ref Without Arctic Package (ANSI, CE & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001137743 Ref With Arctic Package (ANSI & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001144323 Ref Tier IVi-PRE Engines (CE Spec Only USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1 0100011 AR Compound, Locking 2 0100020 AR Sealant, Pipe 3 0400075 1 Battery 4 0641412 4 Bolt 1/4in-20NC x 1-1/2in 5 0641610 1 Bolt 3/8in-16NC x 1-1/4in 6 0641808 2 Bolt 1/2in-13NC x 1in 7 0642010 1 Bolt 5/8in-11NC x 1-1/4in 8 1060637 1 Cable, Lanyard

9 1320022 5 Clamp, Hose 10 1320223 1 Clamp (Not Shown - Located on Turntable to clamp fuel line) 11 1701505 1 Decal - Diesel (Not Shown - Located on Hood) 12 2180348 1 Fitting, Straight Barbed 13 2200222 1 Fitting, Plug (Not Shown - Located on Fuel Tank for Drain) 14 2220313 1 Fitting, Elbow 15 2221176 1 Fitting, Elbow Barbed 16 2720058 30ft/9.2m Hose 17 2750532 7ft/2.1m Hose 18 2902401 Battery Cable Kit C

18A 1001116288 1 Cable, Battery (Red)

18B 7027004 1 Cable, Battery (Black) 18C 7016824 1 Cable (Red) 18D 7016825 1 Cable (Black)

19 3311801 1 Nut 1/2in-13NC 20 3422446 1 Pin, Pivot 21 3841143 1 Pin, Keeper 22 4711400 4 Flatwasher 1/4in Thin 23 4751500 2 Flatwasher 5/16in Regular 24 4751800 1 Flatwasher 1/2in Regular 25 4752000 1 Flatwasher 5/8in Regular 26 4922737 1 Harness, Engine Grounding (Not Shown) 27 88521205 2 Locknut, Nylon Insert 5/16in-18NC 28 91401281 1 Hold-down, Battery

2-24 800S 860SJ 3121270

Page 57

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

29 1001093382 2 Bolt, Battery Hold-down 30 Not Used 31 1320176 1 Clamp 32 1001101948 1 Tube, Exhaust 33 1 Decal - Warning Explosion/Fire

1704972 ANSI Spec 1706098 Australian & CE Spec 1706059 Brazilian Spec 1706060 Chinese Spec 1706064 CSA Spec 1706062 Japanese Spec 1706061 Korean Spec 1706063 Spanish Language

Ref Note: Arctic Package Items 34 - 43 Not Shown - Used on

Arctic Machines Only

34 1060626 1 Cord, 3 Way Extension (Located on Left Front of Engine) 35 1702941 1 Decal - Battery Heater (Located on Battery Heater) 36 1702942 1 Decal - Engine Block Heater (Located on Right Side of

Engine)

37 1702943 1 Decal - Hydraulic Tank Heater (Located on bottom of Hydrau-

lic Oil Tank) 38 1702944 1 Decal - Heater Cord (Located on Left Front of Engine) 39 2580024 1 Heater, Battery (Located on Battery) 40 2580050 1 Heater, Hydraulic Tank (Located on bottom of Hydraulic Oil

Tank) 41 0641608 1 Bolt 3/8in-16NC x 1in 42 1060625 1 Cable, Immersion Heater (Located on bottom of Hydraulic Oil

Tank) 43 1320223 2 Clamp

Ref ENGINE AND PUMP ASSEMBLIES Ref Tier III/Tier IVi Engines

1001099828 Ref Without Arctic Package (USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001100381 Ref With Arctic Package (USA Built Machines SN 030014000 to

SN 0300170337 & China Built Machines SN B300000100 to SN B300000753)

Ref Tier IVi-Flex Engines

1001137739 Ref Without Arctic Package (ANSI, CE & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001137742 Ref With Arctic Package (ANSI & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001144321 Ref Tier IVi-PRE Engines (CE Spec Only USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

Ref Note: See SPECIAL OPTIONS SECTION for machines not

equipped with Pump Mounting Bracket Kit, Deutz Engine with Sauer Danfoss drive and load sensing pump combination.

3121270 800S 860SJ 2-25

Page 58

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

101 0100011 AR Compound, Locking 102 0641407 1 Bolt 1/4in-20NC x 7/8in 103 0641812 2 Bolt 1/2in-13NC x 1-1/2in 104 3311405 1 Locknut 1/4in-20NC 105 3422532 1 Pin, Hitch 106 1 Piston Pump Assembly with Fittings Options:

3600410 S/N 0300140000 to SN 0300180778 (See PUMP

ASSEMBLY (SAUER-DANFOSS) for Breakdown)

1001152522 SN 0300180778 to 0300182115 (See PUMP ASSEMBLY

(EATON) for Breakdown)

3600410 S/N 0300182116 to SN 0300182141 (See PUMP

ASSEMBLY (SAUER-DANFOSS) for Breakdown)

1001152522 SN 0300182142 to 03001822743 (See PUMP ASSEMBLY

(EATON) for Breakdown)

107 3600411 1 Load Sensing Pump Assembly with Fittings (See LOAD

SENSING PUMP ASSEMBLY for Breakdown) 108 3790044 1 O-Ring 109 3960548 110 3960549 1ft/0.3m Seal, Hood 111 4751400 2 Flatwasher 1/4in Regular 112 4891800 4 Flatwasher 1/2in Hardened 113 Not Used 114 1001137898 1 Bracket, Support (USA Built Machines SN 0300161434 to

115 1001137899 1 Plate, Mounting (USA Built Machines SN 0300161434 to

116 4891600 7 Flatwasher 3/8in Hardened (USA Built Machines

117 2 Bolt Options:

0641812 Bolt 1/2in-13NC x 1-1/2in (SN 0300140000 to

0641814 Bolt 1/2in-13NC x 1-3/4in (USA Built Machines

118 0711025 4 Bolt M10 x 85mm (USA Built Machines SN 0300161434 to

119 0791608 3 Bolt 3/8in-16NC x 1in (USA Built Machines SN 0300161434

120 3311605 3 Locknut 3/8in-16NC (USA Built Machines SN 0300161434 to

3.66ft/1.1m

Seal, Hood

SN 0300174936 & China Built Machines B300000100 to

SN B300000804)

SN 0300174936 & China Built Machines B300000100 to

SN B300000804)

SN 0300161434 to SN 0300174936 & China Built Machines

B300000100 to SN B300000804)

SN 0300161434)

SN 0300161434 to SN 0300174936 & China Built Machines B300000100 to SN B300000804)

SN 0300174936 & China Built Machines B300000100 to

SN B300000804)

SN 0300174936 & China Built Machines B300000100 to

SN B300000804)

SN 0300174936 & China Built Machines B300000100 to

SN B300000804)

2-26 800S 860SJ 3121270

Page 59

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref ENGINE AND PUMP ASSEMBLIES Ref Tier III/Tier IVi Engines

1001098508 Ref Without Arctic Package (USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001099640 Ref With Arctic Package (AUSA Built Machines SN 0300170337

to SN 0300182743 & China Built Machines SN B300000753 to Present)

Ref Tier IVi-Flex Engines

1001137738 Ref Without Arctic Package (ANSI, CE & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001137741 Ref With Arctic Package (ANSI & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001144320 Ref Tier IVi-PRE Engines (CE Spec Only USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

201 0100011 AR Compound, Locking

202 to 203 Not Used

204 0340041 2 Band, Air Cleaner 205 0641407 10 Bolt 1/4in-20NC x 7/8in 206 0641510 2 Bolt 5/16in-18NC x 1-1/4in 207 0641606 2 Bolt 3/8in-16NC x 3/4in 208 0641609 6 Bolt 3/8in-16NC x 1-1/8in 209 0641610 16 Bolt 3/8in-16NC x 1-1/4in 210 0641818 2 Bolt 1/2in-13NC x 2-1/4in 211 0641826 2 Bolt 1/2in-13NC x 3-1/4in 212 0700808 4 Bolt M8 x 16mm 213 0641512 1 Bolt 5/16in-18NC x 1-1/2in 214 Not Used 215 0771414 10 Bolt M14 x 30mm Grade 10.9 216 0940070 1 Bumper 217 0961986 2 Bushing, Flanged 218 1060904 1 Cable, Jumper (USA Built Machines SN 0300140000 to

SN 0300140567 Only) 219 1320016 2 Clamp 220 Not Used 221 1320223 4 J-Clip 222 1340060 1 Air Cleaner Assembly Including Filter Element

7012664 1 Element, FIlter (Not Shown) 223 1703162 2 Decal - Caution Fan Blade 224 1703162 2 Plug, Hole 225 2060025 1 Fan 226 2220451 2 Fitting, Straight 227 2720398 2 Hose, Oil Cooler 228 1001091179 1 Elbow, Rubber 229 Not Used

3121270 800S 860SJ 2-27

Page 60

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

230 AR Hose, Oil Drain Options:

1001091892 6in/15cm USA Built Machines SN 0300140000 to SN 0300141456

Only

2750532 1ft/0.3m USA Built Machines SN 0300141456 to SN 0300182743

Only & China Built Machines SN B300000100 to Present Only

231 3.75gal Oil, Motor Options (Not Shown):

3020016 Without Arctic Package

3020044 With Arctic Package 232 3200362 2 Mount, Motor 233 3200406 2 Mount, Motor 234 Not Used 235 3311405 10 Locknut 1/4in-20NC 236 3311505 3 Locknut 5/16in-18NC 237 3311605 22 Locknut 3/8in-16NC 238 3311805 4 Locknut 1/2in-13NC 239 3537416 1 Plate, Engine Mounting (Front Right Side) 240 3539872 1 Plate, Radiator Mounting 241 3539971 1 Plate, Engine Mounting (Front Bottom) 242 1001093943 1 Plate, Engine Mounting (Rear) 243 Use 1001150998 1 Radiator (was p/n 3620033) 244 3740067 3 Relay 245 3960407 1 Gasket, Air Intake 246 3960468 1 Seal 247 3960469 1 Seal 248 4060805 37in/1m Flex-Trim 249 1 Engine, Deutz Options:

1001094101 Tier III/Tier IVi Engines (All Specs USA Built Machines

SN 030014000 to SN 0300170337 & China Built Machines SN B300000100 to SN B300000753)

1001094101 Tier III/Tier IVi Engines (All Specs Except ANSI, CE & CSA

Specs USA Built Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001137737 Tier IVi-Flex Engines (ANSI, CE & CSA Specs USA Built

Machines SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001144319 Tier IVi-PRE Engines (CE Spec Only USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present

250 1 Valve, Oil Drain Options:

Use 4640751 USA Built Machines SN 0300140000 to SN 0300141456

Only (was p/n 1001104308)

4640751 USA Built Machines SN 0300141456 to SN 0300182743

Only & China Built Machines SN B300000100 to Present

Only 251 4711400 6 Flatwasher 1/4in Thin 252 4711600 3 Flatwasher 3/8in Thin 253 Not Used 254 4740274 4 Washer, Snubbing 255 4751400 8 Flatwasher 1/4in Regular 256 4751600 44 Flatwasher 3/8in Regular

2-28 800S 860SJ 3121270

Page 61

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

257 1001094321 1 Tray, Engine 258 4791400 6 Starwasher 1/4in 259 4812200 10 Flatwasher M14 260 4845395 1 Adapter, Air Intake 261 Not Used 262 4846566 1 Plate, Engine Mounting (Front Left Side) 263 4923379 1 Harness, Glowplug 264 Not Used 265 1 Muffler Options:

1001099051 Spark Arresting (Standard) 1001101241 Catalytic (Optional)

Muffler Components:

1320176 Saddle Clamp Used on Spark Arresting

70001017 Band Clamp Used on Catalytic

7024560 1 Plug, Brass 266 3740080 1 Relay 267 1320022 1 Clamp (USA Built Machines SN 0300141456 to

SN 0300182743 Only & China Built Machines SN B300000100 to Present Only)

Ref Note: Arctic Package Item 268 Not Shown - Used on

Arctic Machines Only

268 2580062 1 Heater, Engine Block

2902065 Ref KIT PUMP COUPLING AND MOUNTING PLATE

(USA Built Machines SN 0300140000 to SN 0300174936 & China Built Machines SN B300000100 to SN B300000804)

301 70000793 1 Coupling, Hayes 302 See Note 1 Plate, Pump Adapter (Note: Not Available - Purchase p/n

2902065)

303 See Note 18 Capscrew M10 (Note: Not Available - Purchase p/n 2902065) 304 See Note 12 Flatwasher M10 (Note: Not Available - Purchase p/n

2902065)

1001153282 Ref KIT PUMP COUPLING AND MOUNTING PLATE

(USA Built Machines SN 0300174936 to SN 0300182743 & China Built Machines SN B300000804 to Present)

351 70004183 1 Coupling, Guardian 352 Use 1001153282 1 Plate, Pump Adapter (Note: Not Available for Purchase.) 353 Use 1001153282 20 Capscrew M10 (Note: Not Available for Purchase.)

Ref ENGINE COMPONENTS

1001094101 Ref Tier IVi Engines Without Arctic Package ( USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present)

1001137737 Ref Tier IVi-Flex Engines (ANSI,CE & CSA Specs USA Built

Machines SN 0300170338 to SN 0300182743 & China Built Machines SN B300000752 to Present)

1001144319 Ref Tier IVi-PRE Engines (CE Spec Only USA Built Machines

SN 0300170337 to SN 0300182743 & China Built Machines SN B300000753 to Present

3121270 800S 860SJ 2-29

Page 62

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

401 7026631 1 Dipstick

7020487 1 O-Ring, Dipstick 402 7020465 1 Cap, Filler 403 70001850 1 Pump, Oil Lube

7020468 1 Seal Between Oil Pump & Engine Block (Not Shown) 404 7016331 1 Filter, Oil

70001848 1 Sensor at Oil Filter 70001132 1 Seal, Sensor at Oil Filter

405 4 Pump, Injector Options:

70000912 Series A Injector 70000913 Series B Injector 70000914 Series C Injector

70000915 Series D Injector 406 8320270 1 Filter, Fuel 407 70000916 1 Pump, Fuel Supply

70001435 1 Kit, Repair

70000919 1 Hand Pump

70000918 1 Seal, Hand Pump

70000917 1 O-Seal Between Fuel Pump & Engine Block (Not Shown) 408 7020449 4 Gasket, Intake Manifold (Not Shown) 409 7020408 1 V-Belt 410 7020471 4 Gasket, Exhaust Manifold to Engine Block (Not Shown)

70001835 1 Gasket, Exhaust (Header to EGR Valve Block) (Not Shown)

70001836 1 Gasket, Exhaust (Engine Head to Header) (Not Shown)

70001837 1 Gasket, Exhaust (Exhaust Tube to Muffler) (Not Shown)

70001838 2 Gasket, Exhaust (EGR Valve Block to Exhaust Tube) (Not

Shown) 70001874 1 Plate Choke (Between 70001838 Gaskets) (Not Shown) 70001839 1 Flange, Sealing (Near Front of Header) (includes Seal & Pin)

(Not Shown) 70001841 1 Valve, EGR (Not Shown)

411 7000663 1 Alternator

70001868 1 Regulator, Voltage (Not Shown) 70001866 1 Gasket, Regulator (Not Shown) 70002234 1 Bracket, Adjusting (Not Shown)

412 7020479 1 Starter

7026608 1 Solenoid

413 See Note 2

414 7027791 1 Transmitter, Temperature

See Note 1 Ring, Sealing (Note: Not Available for Purchase.) 415 7027790 1 Sensor, Oil Pressure 416 7024565 1 Sensor, Speed 417 7027792 1 Actuator, Throttle 418 Not Used 419 7027795 1 Module, EMR2 Controller

7027796 1 Harness. EMR2 Module

420 70000345 4 Plug, Glow

Plug- In Connector (Not Shown) (Note: Not Available for

Purchase.)

2-30 800S 860SJ 3121270

Page 63

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

421 7020459 1 Thermostat 422 Not Used 423 70001870 1 Flywheel 424 7024579 1 Rim, Gear

425 to 426 Not Used

427 70001847 1 Breather Valve (Not Shown)

70001126 1 Seal, Breather Valve (Not Shown)

428 1 Gasket, Cylinder Head Options (Not Shown):

70002415 1 Notch 70002416 2 Notches

70002417 3 Notches 429 Not Used 430 70002200 8 Stud (Used to attach muffler) 431 70001872 1 Harness. Engine (Not Shown)

7027793 1 Plug, Connector

3121270 800S 860SJ 2-31

Page 64

SECTION 2 TURNTABLE

219

228

204

216

226

256

244

216

113

114

216

215

(NOT SHOWN)

215

221

227

237

217 225

205

250

232

240

208

251

233

235

217

258

220

205

247

232

216

201

115

NOTE: SEE GM ENGINE

SUPPLEMENT P/N 3121245

FOR DETAILED ENGINE

BREAKDOWN.

209 210 233 251

209 233 248

206 202

218

213

239

241

238

214

241

230 255

236

243

221

209

248

233

231

242

3 4

1 9

1 8

105

103

116

108

109

102

107

212

254

223

246

229

203

207 248

248

233

231

257

(REAR)

211

(FRONT)

249

252

234

205 247 253 232

203A

203C

110

210

233

248

245

248

112

104

101

111

117

104

4529434329

222

259

FIGURE 2-7. GM ENGINE INSTALLATION

2-32 800S 860SJ 3121270

Page 65

203B

RETURN ON FUEL TANK

TO ENGINE

106

FRONT ENGINE

MTG BOLT

AUX RELAY

MTG BOLT

BATTERY

AUX POWER

PUMP

STARTER

AUX POWER

RELAY

106E

106C

106B

106A

106D

NOTE: SEE GM ENGINE

SUPPLEMENT P/N 3121245

FOR PART NUMBER.

ENGINE TRAY

KEEPER PIN

MTG BOLT

106A

TO LP FUEL

SHUT-OFF

35 1 5

NOTE: SEE GM ENGINE

SUPPLEMENT P/N 3121245

FOR PART NUMBER.

20240

SECTION 2 TURNTABLE

3121270 800S 860SJ 2-33

Page 66

SECTION 2 TURNTABLE

FIGURE 2-7. GM ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001114634 Ref GM 3.0L TIER III/iV ENGINE INSTALLATION C

1 0100011 AR Compound, Locking 2 0100020 AR Sealant, Pipe 3 0100048 AR Grease, Dielectric 4 0400075 1 Battery (Wet) 5 0641412 2 Bolt 1/4in-20NC x 1-1/2in 6 0641422 2 Bolt 1/4in-20NC x 2-3/4in 7 0641511 2 Bolt 5/16in-18NC x 1-3/8in 8 0641608 1 Bolt 3/8in-16NC x 1in

9 0641808 1 Bolt 1/2in-13NC x 1in 10 0642010 1 Bolt 5/8in-11NC x 1-1/4in 11 1320022 4 Clamp, Fuel Line 12 1320323 1 Clamp 13 1700818 2 Decal - LP Gas (Liquid) (Not Shown) 14 1701542 1 Decal, Gas (Not Shown) 15 1701543 2 Decal, LPG (Not Shown) 16 2180348 1 Fitting, Barbed 17 2180418 1 Fitting, Straight 18 2200222 1 Fitting, Plug 19 2220005 1 Fitting, Straight 20 2221176 1 Fitting, Elbow 21 2300004 2.63gal. Fluid, Anti-Freeze (Not Shown) 22 2720392 1 Hose, LP 23

2720566 SN 0300140000 to SN 0300181850

1001156823 SN 0300181850 to SN 0300182743

24 1 Hose, Hi Pressure Fuel Line (4ft/1.2m Length) Options:

2720567 SN 0300140000 to SN 0300181850

1001156824 SN 0300181850 to SN 0300182743

25 1 Hose Options:

2720580 SN 0300140000 to SN 0300181850

1001156825 SN 0300181850 to SN 0300182743 26 3290405 1 Locknut M4 x 0.7 27 3290505 1 Locknut M5 x 0.8 28 3311405 4 Locknut 1/4in x 20NC 29 3311505 AR Locknut 5/16in-18NC 30 3422446 1 Pin 31 3790012 1 O-Ring (Not Shown - Located in Console Box) 32 3841143 1 Keeper 33 4360336 1 Switch, Toggle (Not Shown - Located in Console Box) 34 4711500 4 Flatwasher 5/16in Thin 35 4751400 8 Flatwasher 1/4in Regular 36 4751500 2 Flatwasher 5/16in Regular 37 4752000 1 Flatwasher 5/8in Regular 38 88521205 2 Locknut, Nylon Insert 5/16in-18NC 39 91401281 1 Angle, Battery Hold Down

Hose, Hi Pressure Fuel Line (6in/15cm Length) Options:

2-34 800S 860SJ 3121270

Page 67

SECTION 2 TURNTABLE

FIGURE 2-7. GM ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001091587 SN 0300140000 to SN 0300181850

1001156819 SN 0300181850 to SN 0300182743 41 1001093382 2 Bolt, Battery Hold-down 42 Not Used 43 0641508 7 Bolt 5/16in-18NC x 1in 44 4240018 1 Strap, Cable Tie (Not Shown) 45 4740508 4 Washer 46 1001121891 1 Panel, Rubber (USA Built Machines SN 0300143288 to

47 1001125468 1 Bracket, Air Baffle (USA Built Machines SN 0300143288 to

1001114633 Ref GM ENGINE AND PUMP SUB-ASSEMBLIES D

101 0100011 AR Compound, Locking 102 0641406 1 Bolt 1/4in-20NC x 3/4in 103 0641808 1 Bolt 1/2in-13NC x 1in 104 0641812 4 Bolt 1/2in-13NC x 1-1/2in 105 1060637 1 Cable, Lanyard

106 2902533 1 Battery Cable Kit B 106A 7027018 1 Cable (Battery - to Ground) 106B 7027015 1 Cable (Battery + to Auxiliary Relay) 106C 7027017 1 Cable (Auxiliary Relay to Starter) 106D 7016824 1 Cable (Auxiliary Relay to Auxiliary Pump) 106E 7016825 1 Cable (Ground to Auxiliary Pump)

107 3311405 1 Locknut 1/4in-20NC

108 3311805 1 Locknut 1/2in-13NC

109 3422532 1 Pin, Hitch

110 1 Piston Pump Assembly with Fittings Options):

3600410 S/N 0300140000 to SN 0300180778 (See PUMP

1001152522 SN 0300180778 to 0300182115 (See PUMP ASSEMBLY

3600410 S/N 0300182116 to SN 0300182141 (See PUMP

1001152522 SN 0300182142 to 03001822743 (See PUMP ASSEMBLY

111 3600411 1 Load Sensing Pump Assembly with Fittings (See LOAD SENSING

112 3790044 1 O-Ring

113 3960548

114 3960549 1ft/0.3m Seal

115 4711400 1 Flatwasher 1/4in Thin

116 4751800 1 Flatwasher 1/2in Regular

117 4891800 4 Flatwasher, 1/2in Hardened

8.5ft/2.6m

3.66ft/1.1m

Hose, Fuel Line Options:

SN 0300182743 Only & China Built Machines SN B300000143 to Present Only)

ASSEMBLY (SAUER-DANFOSS) for Breakdown)

(EATON) for Breakdown)

ASSEMBLY (SAUER-DANFOSS) for Breakdown)

(EATON) for Breakdown)

PUMP ASSEMBLY for Breakdown)

Seal

1001114632 Ref GM ENGINE ASSEMBLY D

3121270 800S 860SJ 2-35

Page 68

SECTION 2 TURNTABLE

FIGURE 2-7. GM ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

201 0080201 1 Adapter, Elbow 202 0100011 AR Compound, Locking 203 1001114595 1 Engine, GM 3.0L (See GM Engine Supplement P/N 3121245 for

Breakdown of Additional Components) 203A 7027965 1 Filter, Oil 203B 7027972 1 Filter, Fuel 203C 70002895 1 Module, Control (ECU) 203D 70000164 4 Sparkplug (Not Shown)

204 0340041 2 Band, Mounting 205 0641406 10 Bolt 1/4in-20NC x 3/4in 206 0641606 3 Bolt 3/8in-16NC x 3/4in 207 0641608 8 Bolt 3/8in-16NC x 1in 208 0641609 4 Bolt 3/8in-16NC x 1-1/8in 209 0641610 10 Bolt 3/8in-16NC x 1-1/4in 210 0641612 4 Bolt 3/8in-16NC x 1-1/2in 211 0641828 2 Bolt 1/2in-13NC x 3-1/2in 212 0700810 4 Bolt M8 x 20mm 213 0940070 1 Bumper 214 0961986 2 Bearing, Flanged 215 1320012 3 Clamp 216 1320016 5 Clamp 217 1320022 AR Clamp 218 1320223 3 Clamp 219 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner 220 1580011 1 Container, Coolant Overflow 221 1703162 2 Decal - Caution Fan 222 0100020 AR Locking Compound 223 2060025 1 Fan 224 Not Used 225 2720058 226 1001116544 1 Duct 227 2720563 1 Hose, Radiator (Top) 228 2720564 1 Hose, Radiator (Bottom) 229

1001091892

2750532

230 1001091794 1 Insulation, Muffler 231 3200362 4 Mount, Engine 232 3311405 12 Locknut 1/4in-20NC 233 3311605 26 Locknut 3/8in-16NC 234 3311805 4 Locknut 1/2in-13NC 235 3539872 1 Plate, Radiator Mounting 236 3572280 1 Plate, Engine Mount 237 3620040 1 Radiator

Use 8180311 1 Cap, Radiator (was p/n 7019656) 238 3740067 1 Relay 239 3960468 1 Seal 240 3960469 1 Seal

5.5in/14cm

6in/15.2cm

1ft/0.3m

Hose

Hose Options:

USA Built Machines SN 0300140000 to SN 0300140809 Only USA Built Machines SN 0300140809 to SN 0300182743 Only &

China Built Machines SN B300000100 to Present Only

2-36 800S 860SJ 3121270

Page 69

SECTION 2 TURNTABLE

FIGURE 2-7. GM ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

241 4060805 3ft/0.9m Flex-Trim 242 4341239 1 Tray, Engine 243 4341241 1 Mount, Engine (Front) 244 1001116545 1 Tube, Intake 245 4569394 1 Pipe, Exhaust 246 1 Valve, Oil Drain Options:

Use 4640952 USA Built Machines SN 0300140000 to SN 0300141456 Only

(was p/n 1001105872)

4640952 USA Built Machines SN 0300141456 to SN 0300182743 Only &

China Built Machines SN B300000100 to Present Only 247 4711400 12 Flatwasher 1/4in Thin 248 4711600 36 Flatwasher 3/8in Thin 249 4740274 4 Flatwasher, Snubbing 250 4751400 8 Flatwasher 1/4in Regular 251 4751600 16 Flatwasher 3/8in Regular 252 4751800 4 Flatwasher 1/2in Regular 253 4791400 2 Starwasher 1/4in 254 4831900 4 Lockwasher M8 255 4920385 10ft/3m Wire, Safety 256 2180877 1 Fitting Elbow 257 0641826 2 Bolt 1/2in-13NC x 3-1/4in 258 2720271 259 0100062 AR Adhesive (SN 0300173554 to SN 0300182743)

18in/46cm

Hose

3121270 800S 860SJ 2-37

Page 70

SECTION 2 TURNTABLE

1502

1510

1509

1511

1503

155

604

1204

1203

1201

1220

304

1104

165

106

166

111

115

902

114

1404

107

140

501

120

119

121123160124125128127126136201134202134

138135

40115913013313113313230113216

118

137

129

2001

806

802

805

1401

142

141

603 605

1103

165

106

166

102

103

101

104

105

1001

1002

1003

919

911

910

909

906

907

905

908

916

918

168

167

168

918

916

114

901

111

920

108

158

1403

150

3000A

3000B

3001

2004

200

2002

2006

110

2005

2007

FIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS)

2-38 800S 860SJ 3121270

Page 71

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600295 Ref PUMP ASSEMBLIES B

1 to 100 Not Used

101 7007413 1 Shim Kit 102 7007414 1 Plug 103 Use 2900752 1 O-Ring 104 7021200 1 Spring, Relief Valve 105 7007417 1 Valve, Relief 106 Use 2900752 2 O-Ring (Part of Items 1103 & 1104) 107 7007419 2 Plug 108 7021201 1 Bracket, Lifting 109 Not Used 110 7007470 2 Plug 111 7007470 2 Plug

112 to 113 Not Used

114 Use 2900752 2 Gasket, Servo Cover 115 7007423 1 Nut, Special

116 to117 Not Used

118 7007425 1 Bearing, Needle 119 Use 7010116 1 Ring, Retaining 120 Use 7010116 1 Washer 121 Use 7010116 1 Spring 122 Not Used 123 Use 7010116 1 Washer 124 Use 7010116 1 Retainer 125 Use 7010116 3 Pin, Slipper Holddown 126 Use 7010116 7 Piston Assembly 127 Use 7010116 1 Retainer, Slipper 128 Use 7010116 1 Guide, Retainer 129 7007435 1 Pin, Spring 130 7021202 1 Screw, 12 Point Head 131 7007437 1 Bearing, Ball 132 7007438 2 Ring, Retainer 133 7007439 2 Ring 134 7021203 2 Pin, Spring 135 7007441 1 Handle, Pin (Part of Item 201) 136 7007442 1 Sleeve, Bearing 137 Use 2900752 1 Gasket, Front Cover 138 7021205 1 Pin (Part of Item 201) 139 Not Used 140 7007446 1 Pin 141 Use 2900752 1 O-RIng 142 Use 2900752 1 Ring, Load Temper

143 to 149 Not Used

150 7023977 1 Housing, Pump

151 to 154 Not Used

155 7007452 1 Cover, Gerotor

156 to 157 Not Used

158 7007208 1 Plug

3121270 800S 860SJ 2-39

Page 72

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

159 7007454 1 Cover, Front

160 to 162 Not Used

163 7021207 6 Screw 164 Not Used 165 7021208 2 Spring (Part of Items 1103 & 1104) 166 7021209 2 Plug, SCR (Part of Items 1103 & 1104) 167 7007494 1 Piston, Servo 168 Use 2900752 2 Bearing

169 to 200 Not Used

201 7007457 1 Swashplate Assembly (Includes Items 135 & 138) 202 7021212 2 Journal, Bearing

203 to 300 Not Used

301 Use 2900752 1 Seal, Lip

302 to 303 Not Used

304 Use 2900752 1 O-Ring

305 to 400 Not Used

401 7021213 1 Shaft, Main Pump

402 to 500 Not Used

501 7021214 1 Plate, Valve

502 to 602 Not Used

603 7007463 1 Gerotor Assembly 604 7007464 1 Pin 605 7007465 1 Key, Woodruff

606 to 801 Not Used

802 7007466 1 Adaptor, Remote Filtration

803 to 804 Not Used

805 Use 2900752 1 Seal, Filter Adapter 806 7021218 3 Screw

807 to 900 Not Used

901 7021219 1 Cover, Servo 902 7021220 1 Cover, Servo

903 to 904 Not Used

905 7007483 1 Guide, Spring 906 7007484 1 Stop, Servo 907 7007485 1 Spring 908 7021221 1 Screw 909 7007487 1 Guide, Spring 910 7007488 1 Ring, Retaining 911 7021222 1 Nut

912 to 915 Not Used

916 See Note 2 Ring, Piston (Note: Use Items 3000A & 3000B) 917 Not Used 918 See Note 2 O-Ring (Note: Use Items 3000A & 3000B) 919 7021206 1 Nut 920 7021223 10 Screw

921 to 1000 Not Used

1001 7007472 1 Valve, Bypass 1002 Use 2900752 1 Ring, Back-up 1003 Use 2900752 1 O-Ring

2-40 800S 860SJ 3121270

Page 73

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1004to1102

1103 7010122 1 SCR Kit (Includes items 166, 106 & 165) 1104 7010122 1 SCR Kit (Includes items 166, 106 & 165)

1105to1200

1201 7007474 1 Control, Dual Oil-Filled

1201A 7024828 1 Gasket

1202 Not Used 1203 7007478 2 Screw 1204 7001498 2 Screw

1205to1219

1220 Use 2900752 2 O-Ring

1221to1400

1401 7007475 1 Plug, Orifice/Screen (.156) 1402 Not Used 1403 7021226 1 Plug, Orifice 1404 7021226 1 Plug, Orifice

1402to1501

1502 7007453 3 Screw 1503 7021227 1 Adapter, Flange

1504to1507

1508 7021228 1 O-Ring 1509 7021229 1 Plate, Cover 1510 7021230 2 Screw 1511 7021231 1 O-Ring

Not Used

7007496 1 Coil Assembly (Pilot) 7007497 1 Plug (Pump) 7007498 1 Plug (Valve Harness)

Not Used

3600410 Ref PUMP AND FITTING ASSEMBLY B

2001 2111010 2 Fitting, Straight 2002 2111616 1 Fitting, Straight 2003 2131212 1 Fitting, Elbow 2004 2131616 1 Fitting, Elbow 2005 2110408 1 Fitting, Straight 2006 3600295 1 Pump Options (Includes Items 1 - 1511) 2007 2220811 1 Fitting, Reducer

Ref KIT OPTIONS:

3000 AR Seal Kit Options:

3000A 7021232 1 Seal Kit - Complete (Includes Items 103, 106, 114, 137, 141,

142, 168, 301, 304, 805, 916, 918, 1002, 1003 &1220)

3000B 7007412 1 Seal Kit - Servo Piston (Includes Items 916 and 918)

3001 7010116 1 Cylinder Block Kit (Includes Items 119-128)

3121270 800S 860SJ 2-41

Page 74

SECTION 2 TURNTABLE

FIGURE 2-9. PUMP ASSEMBLY (EATON)

2-42 800S 860SJ 3121270

Page 75

SECTION 2 TURNTABLE

FIGURE 2-9. PUMP ASSEMBLY (EATON)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001142522 Ref PUMP ASSEMBLY B

1Not Used 2 Use 70004352 1 Nut 3 Use 70004352 1 Ring, Retaining 4 Use 70004352 2 Ring, Retaining 5Not Used 6 Use 70004352 1 Washer, Seal 7 70004330 8 Capscrew 8 70004331 1 Cylinder Block Assembly

9 70004332 1 Servo Piston Assembly 10 70004333 1 Follower, Servo Piston 11 70004334 1 Cover 12 Use 70004352 2 Gasket, Cover 13 Not Used 14 Use 70004352 1 Gasket, Housing 15 Not Used 16 Use 70004352 1 Gasket, Control Housing 17 70004335 1 Cover 18 70004336 1 Camplate Assembly 19 7004907 2 Race, Thrust 20 7004908 1 Bearing, Thrust 21 70004337 1 Relief Valve Assembly 22 70004337 1 Relief Valve Assembly 23 Not Used 24 70004338 2 Capscrew 25 70004338 2 Capscrew 26 70004339 6 Capscrew 27 70004340 1 Plate, Valve 28 See Note 1 Housing (Note: Not Available for Purchase) 29 70004341 1 End Cover Assembly 30 Not Used 31 70004342 1 Shaft, Drive 32 Not Used 33 Use 70004352 1 O-Ring

34 to 36 Not Used

37 7004906 1 Washer 38 See Note 1 Plug (Note: Not Available for Purchase) 39 See Note 1 Plug (Note: Not Available for Purchase)

40 to 42 Not used

43 Use 70004352 1 Seal, Shaft

44 to 45 Not Used

46 70004343 1 Adapter, Charge Pump 47 Not Used 48 70004344 1 Servo Control Assembly 49 Not Used 50 70004345 1 Gerotor 51 70004346 1 Orifice 52 70004346 1 Orifice

3121270 800S 860SJ 2-43

Page 76

SECTION 2 TURNTABLE

FIGURE 2-9. PUMP ASSEMBLY (EATON) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

53 70004346 1 Orifice 54 Not Used 55 70004347 1 Coupler 56 Not Used 57 See Note 2 Plug (Note: Not Available for Purchase)

58 to 59 Not Used

60 70004348 1 Washer 61 70004349 8 Washer 62 70004350 4 Washer

63 to 72 Not Used

73 70004351 1 Ring, Retaining

— — — — — — — — —

100 70004352 1 Seal Kit - Pump (Includes Items 3,4,6,12,14,16,33 & 43 and Valve

& Plug O-Rings & Seals)

1001152522 Ref PUMP AND FITTING ASSEMBLY B

101 2110408 1 Fitting, Straight 102 2110810 1 Fitting, Straight 103 2111016 1 Fitting, Straight 104 2131212 1 Fitting, Elbow 105 2131616 2 Fitting, Elbow 106 2132016 1 Fitting, Elbow 107 2220811 1 Fitting, Reducer 108 1001142522 1 Pump Assembly (Includes Items 1 - 73)

2-44 800S 860SJ 3121270

Page 77

SECTION 2 TURNTABLE

FIGURE 2-9. PUMP ASSEMBLY (EATON) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 2-45

Page 78

SECTION 2 TURNTABLE

FIGURE 2-10. LOAD SENSING PUMP ASSEMBLY

2-46 800S 860SJ 3121270

Page 79

SECTION 2 TURNTABLE

FIGURE 2-10. LOAD SENSING PUMP ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600324 Ref LOAD SENSING PUMP ASSEMBLY D

1 7023947 1 Bearing, Front (Includes Cup and Cone)

2 7023948 1 Bearings, Swashplate (Includes Both Sides and Pins)

3 7023949 1 Servo Piston Assembly

4 7023950 1 Bearing, Rear (Includes Cup and Cone)

5 7023951 1 Spring, Bias

6 7023952 1 Swashplate

7 Use 7023967 1 O-Ring

8 Use 7023967 1 O-Ring

9 7023953 1 Plate, Valve 10 7023954 1 Spring, Check Valve 11 7023955 1 Poppet, Check Valve

— — — — — — — — — — 100 7023956 1 Control Assembly 101 Not Used 102See Note 2Setscrew (Note: Not Available for Purchase.) 103See Note 1Plug (Note: Not Available for Purchase.)

103A Use 7023967 1 O-Ring

104 to 105 Not Used

106See Note 1Plug (Note: Not Available for Purchase.)

106A Use 7023967 1 O-Ring

107See Note 1Plug (Note: Not Available for Purchase.)

107A Use 7023967 1 O-Ring

108 to 111 Not Used

112 See Note 1 Spool, Control (Note: Not Available for Purchase.) 113 See Note 1 Guide, Spring (Note: Not Available for Purchase.) 114 See Note 1 Spring (Note: Not Available for Purchase.) 115 See Note 1 Spring (Note: Not Available for Purchase.) 116 Use 7023967 1 O-Ring 117 Use 7023967 2 Ring, Back-up 118 See Note 1 Plug, Adjusting (Note: Not Available for Purchase.)

119 to 131 Not Used

132 See Note 1 Spool, Control (Note: Not Available for Purchase.) 133 See Note 1 Guide, Spring (Note: Not Available for Purchase.) 134 See Note 1 Spring (Note: Not Available for Purchase.) 135 See Note 1 Spring (Note: Not Available for Purchase.) 136 Use 7023967 1 O-Ring 137 Not Used 138 See Note 1 Plug, PC Adjusting (Note: Not Available for Purchase.)

— — — — — — — — — — 200 Use 7023967 3 Ring, Seal

— — — — — — — — — — 300 7023957 4 Screw

1 — — — — — — — — — — 401 7023958 1 Shaft 402 7023959 1 Cap, End 403 7023960 4 Screw

3121270 800S 860SJ 2-47

Page 80

SECTION 2 TURNTABLE

FIGURE 2-10. LOAD SENSING PUMP ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

404 7022318 1 Plug

404A Use 7023967 1 O-Ring

405 7023961 1 Pin

— — — — — — — — — — 501 7023962 1 Ring, Retaining 502 Use 7023967 1 Seal, Lip 503 7023963 1 Housing 504 7023964 1 Plug

504A 7007415 1 O-Ring

505 7023964 1 Plug

505A 7007415 1 O-Ring

— — — — — — — — — — 601 7023965 1 Cylinder Block Assembly

602 to 640 Not Used

641 Use 7023965 1 Block, Cylinder (Note: Not Available - Purchase Complete

Cylinder Block Assy.)

642 See Note 1 Washer (Note: Not Available for Purchase.) 643 See Note 1 Spring (Note: Not Available for Purchase.) 644 See Note 1 Retainer, Spring (Note: Not Available for Purchase.) 645 See Note 1 Ring, Retaining (Note: Not Available for Purchase.) 646 7021275 3 Pin, Slipper 647 See Note 1 Guide, Slipper (Note: Not Available for Purchase.) 648 Not Used 649 See Note 1 Retainer, Slipper (Note: Not Available for Purchase.) 650 7023966 9 Piston Assembly

3600411 Ref LOAD SENSING PUMP AND FITTING ASSEMBLY B

1001 2112424 1 Fitting, Straight 1002 2130404 1 Fitting, Elbow 1003 2130810 1 Fitting, Elbow 1004 2131216 1 Fitting, Elbow 1005 3600324 1 Pump Options (Includes Items 1 - 650):

Ref KIT OPTIONS:

2000 7023967 1 Seal Kit - Complete (Includes Items 7,8,103A,106A,107A,

116,117,136,200,404A & 502)

2-48 800S 860SJ 3121270

Page 81

SECTION 2 TURNTABLE

FIGURE 2-10. LOAD SENSING PUMP ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 2-49

Page 82

SECTION 2 TURNTABLE

201

106

107A

107

104

105

108

109

103

101

STANDARD

MACHINES

ONLY

HOSTILE

ENVIRONMENT

MACHINES

ONLY

181712415

614

FIGURE 2-11. TANK INSTALLATIONS

2-50 800S 860SJ 3121270

Page 83

SECTION 2 TURNTABLE

FIGURE 2-11. TANK INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TANKS INSTALLATION

0270881 Ref Diesel Machines F 1001125354 Ref Diesel Machines (Hostile Environment Machines) B 1001091568 Ref GM Machines A

1 0100011 AR Compound, Locking 2 0731007 5 Capscrew #10-32NF x 7/8in 3 1 Gauge, Fuel Level Options:

2420191 Standard Machines 1001109048 Hostile Environment Machines

4 3311601 AR Nut 3/8in-16NC 5Not Used 6 1 Strap, Tank Mounting Options:

4240139 Standard Machines 1001110059 Hostile Environment Machines

4280295

Not Required

8 4400453 1 Hydraulic Oil Tank Assembly (See Items 101-109 for

9 1 Fuel Tank Assembly Options:

4400439 Diesel Machines 1001108579 Diesel Machines (Hostile Environment Machines Only) 1001091563 GM Machines

10 4420038 AR Tape, Rubber 11 4751000 5 Flatwasher #10 Regular 12 4751600 AR Flatwasher 3/8in Regular 13 0641614 4 Bolt 3/8in-16NC x 1-3/4in

14 0641615 1 Bolt 3/8in-16NC x 1-7/8in 15 1001125344 1 Support, Tank 16 1001125345 1 Bracket, Tank 17 2180467 2 Fitting, Barb 18 8405009 2 Clamp, Gear 19 1001113103 1 Tube, Fuel Sight

30in/76cm

Ref Note: Items 14-19 Used on Hostile Environment Machines

Strip, Protector Options:

Standard Machines Hostile Environment Machines

Breakdown)

Only.

4400453 Ref HYDRAULIC TANK ASSEMBLY E

101 7024481 1 Strainer 1-1/2inNPT 102 7024442 1 Strainer 1-1/4inNPT 103 7024441 1 Gauge, Sight 104 7024444 1 Breather/Fill Cap 105 7024443 1 Neck, Fill

7024445 1 Screen

106 7024446 1 Plug, Magnetic 107 7024374 1 Filter Assembly

107A 7024375 1 Element, Filter

108 7024439 1 Cover

3121270 800S 860SJ 2-51

Page 84

SECTION 2 TURNTABLE

FIGURE 2-11. TANK INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

109 7024440 1 Gasket

Ref FUEL TANK CAP INSTALLATION

201 1 Cap Options:

7016314 Standard Non-Locking (Part of Item 3) (Used with p/n 4400439)

70001103 Standard Non-Locking (Used with p/n 1001091563)

1120487 Optional Lockable (Diesel Machines)

2-52 800S 860SJ 3121270

Page 85

SECTION 2 TURNTABLE

FIGURE 2-11. TANK INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 2-53

Page 86

SECTION 2 TURNTABLE

54142210

33333

FIGURE 2-12. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY)

2-54 800S 860SJ 3121270

Page 87

SECTION 2 TURNTABLE

FIGURE 2-12. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0255524 Ref LP TANK AND BRACKETS INSTALLATION 9/F

1 1320220 2 Clamp Kit - LP

1320127 2 Clamp, Toggle (1 Per Clamp)

2 2720144 2 Hose 3 0100020 AR Sealant, Pipe 4 2221197 1 Fitting, Reducer 5 2180125 1 Fitting - Elbow 6 2220261 1 Fitting, Nipple 7 2180388 1 Filter, Bulkhead 8 2180389 1 Valve, Relief

9 2220418 1 Fitting, Tee 10 2180387 2 Fitting, LP Tank 11 0641606 8 Bolt 3/8in-16NC x 3/4in 12 4751600 8 Flatwasher 3/8in Regular 13 2180418 2 Fitting, Straight 14 2220261 1 Fitting, Nipple 15 1320218 2 Clamp, Spring 16 3910808 2 Screw, Machine #8-32NC x 1/2in 17 4750800 4 Flatwasher #8 Regular 18 3310805 2 Locknut #8-32NC 19 0181949 2 Support, Angle 20 2221024 2 Fitting, Ball Check 21 0362519 4 Bar, Clamp 22 1 LP Tank Options:

4400275 Aluminum 4400420 Steel

3121270 800S 860SJ 2-55

Page 88

SECTION 2 TURNTABLE

117

126

126 127

125

123

124

118

116

119

121

120

113

114

104

110

109

101

108

107

102

103

115

106

105

115

103

122

107

108

COMPLETE VALVE BLOCK ASSEMBLY

200

FIGURE 2-13. ROTARY COUPLING INSTALLATION

2-56 800S 860SJ 3121270

Page 89

SECTION 2 TURNTABLE

FIGURE 2-13. ROTARY COUPLING INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001107531 Ref ROTARY COUPLING INSTALLATION A

1 0100011 AR Compound, Locking

2 0641611 2 Bolt 3/8in-16NC x 1-3/8in

3 0641812 1 Bolt 1/2in-13NC x 1-1/2in

4 0641820 2 Bolt 1/2in-13NC x 2-1/2in

5 0903242 1 Bracket

6Not Used

7 3271805 2 Locknut 1/2in-13NC

8 4751800 5 Flatwasher 1/2in Regular

9 4891600 2 Flatwasher 3/8in Hardened 10 3322201 2 Locknut 3/4in x 16NF 11 1001106974 1 Coupling, Rotary (See Items 101-128 for Breakdown)

1001106974 Ref ROTARY COUPLING ASSEMBLY B

101 Use 1001106974 1 Body (Note: Not Available - Purchase Complete Assy.) 102 Use 70001248 1 Seal, Poly 103 Use 70001248 2 O-Ring/Seal 104 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.) 105 Use 70001248 6 Seal, Cap 106 Use 70001248 6 O-Ring 107 7026503 2 Ring, Thrust 108 7026504 2 Ring, Retaining 109 80934561 2 Plug 110 See Note 1 Lug, Torque (Note: Not Available for Purchase.) 111 Not Used 112 7026197 4 Capscrew 113 Use 70001248 3 O-Ring 114 Use 70001248 1 O-Ring 115 Use 70001248 2 Bearing 116 7024404 1 Block Valve Assembly 117 7026505 1 Plug 118 7026506 1 Valve, Check 119 7026507 1 Plug 120 Use 7024404 1 Plunger, Valve (Note: Not Available for Purchase.) 121 7026509 1 Spring 122 Use 70001248 1 Seal, Oil 123 70003454 1 Bracket, Switch Mounting 124 4711000 4 Flatwasher #10 Thin 125 See Note 2 Locknut 1/4in-24NF (Note: Not Available for Purchase.) 126 See Note 4 Capscrew 1/4in-24NF (Note: Not Available for Purchase.) 127 4360517 1 Switch, Proximity 128 See Note AR Protective Netting (Not Shown) (Note: Not Available for

Purchase.)

200 70001248 Ref Seal Kit - (Includes Items 102,103,105,106,113, 114, 115 & 122)

3121270 800S 860SJ 2-57

Page 90

SECTION 2 TURNTABLE

3030192423

18223137

12 33

6124143132

FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY

2-58 800S 860SJ 3121270

Page 91

SECTION 2 TURNTABLE

FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref GROUND CONTROL BOX ASSEMBLIES Ref USA Built Machines SN 0300140000 to SN 0300149140 &

China Built Machines SN B300000100 to SN B300000310

Ref 800S with Caterpillar Engine 1001110333 Ref All Specs Except Australian & CE Specs A 1001110335 Ref Australian & CE Specs Only A

Ref 860SJ with Caterpillar Engine 1001110334 Ref All Specs Except Australian & CE Specs A 1001110336 Ref Australian & CE Specs Only A

Ref 800S with Deutz Engine 1001110329 Ref All Specs Except Australian & CE Specs B 1001110331 Ref Australian & CE Specs Only B

Ref 860SJ with Deutz Engine 1001110330 Ref All Specs Except Australian & CE Specs B 1001110332 Ref Australian & CE Specs Only B 1001110327 Ref 800S with GM Engine (All Specs Except Australian & CE

Specs)

1001110328 Ref 860SJ with GM Engine (All Specs Except Australian & CE

Specs)

Ref USA Built Machines SN 0300149140 to SN 0300182743 &

China Built Machines SN B300000310 to Present

Ref 800S with Caterpillar Engine 1001110333 Ref All Specs Except CE Specs A 1001110335 Ref CE Specs Only A

Ref 860SJ with Caterpillar Engine 1001110334 Ref All Specs Except CE Specs A 1001110336 Ref CE Specs Only A

Ref 800S with Deutz Engine 1001110329 Ref All Specs Except CE Specs B 1001110331 Ref CE Specs Only B

Ref 860SJ with Deutz Engine 1001110330 Ref All Specs Except CE Specs B 1001110332 Ref CE Specs Only B 1001110327 Ref 800S with GM Engine (All Specs Except Australian & CE

Specs)

1001110328 Ref 860SJ with GM Engine (All Specs Except Australian & CE

Specs)

1 0100011 AR Compound, Locking 2 0100048 AR Grease, Dielectric 3 0630518 2 Capscrew, Button Head 4 0630548 5 Bolt, 2-1/2in Tap 5 1001111017 1 Box, Fiberglass

5A 7020246 2 Latch

6 1001103667 1 Module, Ground Control 7 1670829 1 Bezel 8 1706712 1 Decal - Ground Control Display 9 1 Decal - Faceplate Options:

1001102601 800S 1001102602 860SJ

3121270 800S 860SJ 2-59

Page 92

SECTION 2 TURNTABLE

FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

10 2420172 1 Gauge, Hourmeter 11 2760105 1 Housing, Display Light 12 3300205 4 Nut, Retainer 13 3300408 AR Locknut, Plastic Insert 14 77143013 11 Nut 1/4in-20NC 15 3539219 1 Plate, Reinforcement 16 3740049 AR Relay Options:

3 Caterpillar Engine Machines

2 Deutz & GM Engine Machines 17 3900268 3 Screw, Flange #10 x 1/2in 18 3910804 6 Screw #8-32NC x 1/4in 19 4060906 1 Shield, Toggle Switch 20 4070987 1 Shim (.015in) 21 4360328 AR Switch, Toggle

6 800S

7 860SJ 22 1 Switch, Key Options:

4360469 All Specs Except CE Specs 4360470 CE Specs Only

Australian Specs Only

4360470 USA Built Machines SN 0300140000 to

SN 0300149140 & China Built Machines SN B300000100 to SN B300000310

4360469 USA Built Machines SN 0300149140 to SN 0300182743

& China Built Machines SN B300000310 to Present

2860030 1 Key Replacement

23 4360475 1 Switch, Emergency Stop

7020175 1 Cap, Mushroom

7020176 1 Block, Contact 24 4360476 1 Switch, Contact Block 25 4460426 1 Connector, Strain Relief 26 4460470 1 Nut, Terminal 27 4460471 1 Lockwasher, Terminal 28 4460488 6 Mounting Base, Terminal 29 4460526 1 Connector, Strain Relief 30 4740444 6 Washer, Special 31 4751400 12 Flatwasher 1/4in Regular 32 4761400 6 Lockwasher 1/4in 33 0641506 4 Bolt 5/16in-18NC x 3/4in 34 4922594 1 Harness, Valve (Not Shown - See ELECTRICAL SECTION

for Breakdown)

35 1 Harness, Engine Options (Not Shown - See ELECTRICAL

SECTION for Breakdown): 1001110341 Caterpillar Engine Machines 1001110340 Deutz Engine Machines 1001110338 GM Engine Machines

36 1001110339 1 Harness, Ground Control Box (Not Shown - See

ELECTRICAL SECTION for Breakdown)

2-60 800S 860SJ 3121270

Page 93

SECTION 2 TURNTABLE

FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

37 1 Ground Control Box Wiring Diagram (Not Shown - See

ELECTRICAL SECTION for Breakdown) 1001110344 Caterpillar Engine Machines 1001110343 Deutz Engine Machines 1001110342 GM Engine Machines

38 4460496 1 Lockwasher, Terminal 39 4460497 1 Nut, Terminal 40 0641407 1 Bolt 1/4in-20NC x 7/8in 41 1001106736 1 Cap, Dust

3121270 800S 860SJ 2-61

Page 94

SECTION 2 TURNTABLE

800S

256

257

258

259

260

201

202

204

203

860SJ

16 17

251

252

255

254

EFGCBDA

216A

216

217

218

214

211

251

252

227

226

230

228

225

229

FIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS

2-62 800S 860SJ 3121270

Page 95

SECTION 2 TURNTABLE

FIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref ELECTRICAL OPTIONS INSTALLATIONS (TURNTABLE

MOUNTED)

Ref LIMIT SWITCHES INSTALLATION

0271360 Ref 800S (All Specs Except Australian & CE Specs) J

1001091187 Ref 800S (Australian & CE Specs Only) D

0271362 Ref 860SJ (All Specs Except Australian & CE Specs) J

1001091188 Ref 860SJ (Australian & CE Specs Only) D

1 0100011 AR Compound, Locking 2 0100035 AR Compound, Locking 3 1001106480 AR Bar, Fiberglass (Top)

1 All Specs Except Australian & CE Specs

Not Required 0 Australian & CE Specs Only 4 0641403 4 Bolt 1/4in-20NC x 3/8in 5 1671022 1 Cover, Limit Switch 6 3310805 AR Locknut #8-32NC 7 3930816 AR Capscrew, Socket Head #8-32NC x 1in 8 3930828 AR Capscrew, Socket Head #8-32NC x 1-3/4in 9 4360578 AR Switch, Limit Options: (Note: P/N 4360578 does not include

#19 Connector - Purchase Separately)

4 All Specs Except Australian & CE Specs 2 Australian & CE Specs Only

10 4420060 AR Tape, Double Sided Options:

31.2ft/9.5m

12.3ft/3.8m

11 4751400 6 Flatwasher 1/4in Regular 12 1001106449 1 Bar, Fiberglass (Bottom) 13 0641406 2 Bolt 1/4in-20NC x 3/4in 14 Not Used 15 1671059 1 Cover, Proximity Switch 16 4071043 1 Shim 17 4360517 1 Switch, Proximity 18 1001097942 4 Flatwasher #8 19 4460968 AR Connector, Strain Relief Options:

4 All Specs Except Australian & CE Specs

2 Australian & CE Specs Only 20 1001097939 2 Capscrew, Socket Head #8-32NC x 1-3/4in 21 1001097945 2 Locknut #8-32NC

All Specs Except Australian & CE Specs Australian & CE Specs Only

0271999 Ref ALARM INSTALLATION 1

201 0257887 1 Alarm/Harness Assembly

0140032 1 Alarm 2820035 6in/15cm Loom 4460424 1 Plug

4460268 2 Socket 202 0641410 2 Bolt 1/4in-20NC x 1-1/4in 203 3311405 2 Locknut 1/4in-20NC

3121270 800S 860SJ 2-63

Page 96

SECTION 2 TURNTABLE

FIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

204 4711400 4 Flatwasher 1/4in Thin

205 to 210 Not Used

0270805 Ref STROBE LIGHT INSTALLATION (AMBER) (OPTIONAL)

(USA BUILT MACHINES SN 0300140000 TO SN 0300171628 & CHINA BUILT MACHINES SN B300000100 TO SN B300000767)

Ref Note: If machine is equipped with BLUE Strobe Light, see

SPECIAL OPTIONS SECTION SkyGuard Kit.

211 1 Adapter Options:

0630491 Adapter used with ECCO Model 6640 0080241 Adapter used with ECCO Model 6650

212 to 213 Not Used

214 0100011 AR Compound, Locking 215 4240032 1 Wire-Tie (Not Shown) 216 Use 0272507 1 Strobe Light/Guard/Harness Assembly (Includes Items 211 &

216A)

1 Bulb, Replacement

7016380 Bulb for ECCO Model 6640

70001941 Bulb for ECCO Model 6650

216A 1 Guard Options:

4060907 Guard used with ECCO Model 6640

2920215 Guard used with ECCO Model 6650 217 4460234 1 Clamp 218 0100048 AR Sealant, Silicone

219 to 224 Not Used

1001150406 Ref STROBE LIGHT INSTALLATION (AMBER) (OPTIONAL)

(USA BUILT MACHINES SN 0300171628 TO SN 0300182743 & CHINA BUILT MACHINES SN B300000767 TO PRESENT)

Ref Note: If machine is equipped with BLUE Strobe Light, see

SPECIAL OPTIONS SECTION SkyGuard Kit.

225 0100035 AR Compound, Locking 226 2920161 1 Strobe Light/Harness Assembly

7016319 1 Bulb

7016372 1 Lens 227 3312602 1 Nut, Jam 1in-8NC 228 3900085 2 Screw #10-32 x 1/2in 229 4751000 2 Flatwasher 1/4in Thin 230 1001149994 1 Mount Strobe

231 to 250 Not Used

Ref LIGHTS INSTALLATIONS (OPTIONAL) 0271552 Ref Headlights and Taillights C 0272057 Ref Floodlights (Not Shown) B

251 2 Light Options:

2920110 Headlight 2920157 Floodlight (Not Shown)

2-64 800S 860SJ 3121270

Page 97

SECTION 2 TURNTABLE

FIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

252 0902206 2 Bracket, Mounting 253 0642612 1 Bolt 1in-8NC x 1-1/2in 254 4220162 2 Spacer 255 0100011 AR Compound, Locking 256 2 Light Options:

2920113 Taillight 2920157 Floodlight (Not Shown)

257 3911040 4 Screw, Machine #10-24NC x 2-1/2in (0271552 Installation

Only) 258 3311005 4 Nut #10-24NC (0271552 Installation Only) 259 4751000 4 Flatwasher #10 Regular (0271552 Installation Only) 260 4740362 4 Washer, Fender (0271552 Installation Only) 261 3960461 2 Gasket (0271552 Installation Only) 262 Not Used 263 4240032 AR Tie-Strap (Not Shown) 264 4460234 AR Mount, Tie-Strap (Not Shown) 265 1 Switch Options (Not Shown - Located on Console):

4360336 1 Switch, Toggle 4360522 1 Switch, Push Button

266 3790012 1 O-Ring (Used with Toggle Switch) (Not Shown - Located on

Console) 267 3820001 11 Rivet, Pop (Not Shown) 268 1705170 1 Decal - Lights (Used with Push Button Switch) (Not Shown -

Located on Console)

3121270 800S 860SJ 2-65

Page 98

SECTION 2 TURNTABLE

312031454843283128

434831133148312020

7488

4835482722

201

203

205

206

204

205

206

204

209

208

210

202

211

207

210

209

212

213

104552

203

104552

203

811171717

NOTE: REPLACEMENT DECALS MUST BE PURCHASED SEPARATELY.

FIGURE 2-16. HOODS INSTALLATION (ABS)

2-66 800S 860SJ 3121270

Page 99

48203148311232

3948164028

45732

748110

106

109

108

107

109

105

120

117

109

121

122

121

111

109

118

119

112

102

123

101

104

301

116

115

114

113

124

113

103

126

125

NOTE: REPLACEMENT DECALS MUST BE PURCHASED SEPARATELY.

SECTION 2 TURNTABLE

3121270 800S 860SJ 2-67

Page 100

SECTION 2 TURNTABLE

FIGURE 2-16. HOODS INSTALLATION (ABS)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref HOODS INSTALLATIONS

0274762 Ref CATERPILLAR ENGINES E

1001100386 Ref DEUTZ ENGINES A

0275547 Ref GM ENGINES (USA Built Machines SN 0300140000 to

SN 0300143045 Only & China Built Machines SN B300000100 to SN B300000135)

1 0100011 AR Compound, Locking 2 0182077 1 Angle, Hood Support 3 0362770 1 Bar, Panel Mounting 4 0630507 8 Bolt, Carriage 1/2in-13NC x 1-1/4in 5 0641406 4 Bolt 1/4in-20NC x 3/4in 6 0641508 9 Bolt 5/16in-18NC x 1in 7 0641608 33 Bolt 3/8in-16NC x 1in 8 0641610 3 Bolt 3/8in-16NC x 1-1/4in

9 0641616 6 Bolt 3/8in-16NC x 2in 10 0721006 6 Screw #10-24NC x 3/4in 11 0901921 3 Bracket, Hood Mounting 12 0902219 2 Bracket, Bumper 13 0902223 2 Bracket, Latch 14 0902351 1 Bracket, Hood Mounting 15 0902412 1 Bracket, Hood Mounting 16 0902491 1 Bracket, Latch 17 0902673 1 Bracket, Support (Front Cover) 18 0902674 1 Bracket, Support (Front Cover) 19 0902769 1 Bracket, Bumper Support 20 0940071 4 Bumper 21 1671201 1 Cover 22 1671228 1 Hood Assembly (See Items 201-213 for Breakdown) 23 1 Hood Assembly (See Items 101-126 for Breakdown)

1671248 Caterpillar Engines 1001099138 Deutz Engines 1001117045 GM Engines

24 2540035 3 Grommet 25 Not Used 26 2600244 1 Hinge, Adapter Panel 27 2680490 1 Hood, Right Cover 28 3311005 6 Locknut #10-24NC 29 3311405 4 Locknut 1/4in-20NC 30 3311505 12 Locknut 5/16in-18NC 31 3311601 8 Nut 3/8inin-16NC 32 3311605 15 Locknut 3/8in-16NC 33 3311805 8 Locknut 1/2in-13NC 34 3380444 1 Panel, Adapter 35 3380461 1 Cover, Top (Tank Side) 36 3380575 1 Panel, Cover 37 3380580 1 Panel, Storage Box (Top) 38 3571712 1 Plate, Seal 39 3960389 3.5ft/1.1m Seal 40 3960470 1 Seal, Latch

2-68 800S 860SJ 3121270

JLG 860SJ Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)

FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS

FIGURE 1-7. TOW PACKAGE INSTALLATION

FIGURE 2-1. CONTROL VALVES INSTALLATIONS

FIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION

FIGURE 2-6. DEUTZ ENGINE INSTALLATION

FIGURE 2-7. GM ENGINE INSTALLATION

FIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS)

FIGURE 2-9. PUMP ASSEMBLY (EATON)

FIGURE 2-10. LOAD SENSING PUMP ASSEMBLY

FIGURE 2-11. TANK INSTALLATIONS

FIGURE 2-12. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY)

FIGURE 2-13. ROTARY COUPLING INSTALLATION

FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY

FIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS

FIGURE 2-16. HOODS INSTALLATION (ABS)