JLG 860SJ Parts Manual

Illustrated Parts Manual

Models

800S

860SJ

Prior to

SN 0300140000

3121140

January 17, 2014

NOTES:

MODULE ON MACHINES

“WITHOUT UGM”

(UNIVERSAL

GROUND MODULE)

MODULE ON MACHINES

“WITH UGM” (UNIVERSAL

GROUND MODULE)

GROUND MODULE MODULE IDENTIFICATION

REVISION LOG

REVISION LOG:

October 15, 2001 - Original Issue Of Manual (Edited to B/M 0010575 Revision 3)

December 15, 2001 - Revised Manual (Edited to B/M 0010575 Revision 7)

April 25, 2002 - Revised Manual (Edited to B/M 0010575 Revision 14)

November 19, 2002 - Revised Manual (Edited to B/M 0010575 Revision 22)

April 9, 2003 - Revised Manual (Edited to B/M 0010575 Revision 23)

September 5, 2003 - Revised Manual (Edited to B/M 0010575 Revision 36)

December 18, 2003 - Revised Manual (Edited to B/M 0010575 Revision 37)

March 5, 2004 - Revised Manual (Edited to B/M 0010575 Revision 37)

August 2, 2004 - Revised Manual (Edited to B/M 0010575 Revision 42)

November 1, 2004 - Revised Manual (Edited to B/M 0010575 Revision 42)

March 15, 2005 - Revised Manual (Edited to B/M 0010575 Revision 50)

September 16, 2005 - Revised Manual (Edited to B/M 0010575 Revision 61)

March 10, 2006 - Revised Manual (Edited to B/M 0010575 Revision 67)

June 5, 2006 - Revised Manual (Edited to B/M 0010575 Revision 67)

October 5, 2006 - Revised Manual (Edited to B/M 0010575 Revision 70)

March 1, 2007 - Revised Manual (Edited to B/M 0010575 Revision 73)

June 14, 2007 - Revised Manual (Edited to B/M 0010575 Revision 79)

October 5, 2007 - Revised Manual (Edited to B/M 0010575 Revision 81)

March 1, 2008 - Revised Manual (Edited to B/M 0010575 Revision 81)

August 22, 2008 - Revised Manual (Edited to B/M 0010575 Revision 96)

January 1, 2009 - Revised Manual (Edited to B/M 0010575 Revision 96)

June 15, 2009 - Revised Manual (Edited to B/M 0010575 Revision 104)

3121140 800S 860SJ A

REVISION LOG

November 4, 2009 - Revised Manual (Edited to B/M 0010575 Revision 104)

May 3, 2010 - Revised Manual (Edited to B/M 0010575 Revision 110)

November 30, 2010 - Revised Manual (Edited to B/M 0010575 Revision 119)

April 21, 2011 - Revised Manual

July 22, 2011 - Revised Manual

October 14, 2011 - Revised Manual

January 10, 2012 - Revised Manual

June 15, 2012 - Revised Manual

August 2, 2012 - Revised Manual

January 4, 2013 - Revised Manual

April 2, 2013 - Revised Manual

June 28, 2013 - Revised Manual

September 23, 2013 - Revised Manual

January 17, 2014 - Revised Manual

B 800S 860SJ 3121140

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 ASSEMBLY (2WD PRIOR TO SN 0300083331) . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) . . . . . . . . . . . . 1-18

1-6 DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000) . . . . . . . . . 1-22

1-7 DRIVE MOTOR ASSEMBLY (2WD PRIOR TO SN 0300083331) . . . . . . . . . . . . . . . . 1-26

1-8 DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 &

ALL 4WD MACHINES) (4 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1-9 DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-10 FRAME VALVES & SHIELDS INSTALLATIONS (PRIOR TO SN 0300083331) . . . . . 1-36

1-11 FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO

SN 0300140000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-12 TOW PACKAGE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

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 HUB ASSEMBLY (PRIOR TO SN 0300066417) . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 SWING MOTOR ASSEMBLY (PRIOR TO SN 0300066417) . . . . . . . . . . . . . . . . . . . . 2-14

2-6 SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) . . . . . . . . 2-16

2-7 SWING MOTOR/HUB ASSEMBLY (SN 0300134352 TO SN 0300140000) . . . . . . . . 2-22

2-8 CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) . . . . . . . . . . 2-26

2-9 CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) . . . 2-36

2-10 DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586). . . . . . . . . . . . . . . . . 2-44

2-11 DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) . . . . . . . . . 2-50

2-12 FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612). . . . . . . . . . . . . . . . . . 2-62

2-13 FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) . . . . . . . . . . 2-68

2-14 DUAL FUEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

2-15 GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) . . . . . . . . . . . . . . . . . . . 2-80

2-16 GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) . . . . . . . . . . . . 2-86

2-17 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

2-18 LOAD SENSING PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

2-19 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

2-20 ROTARY COUPLING INSTALLATION (PRIOR TO SN 0300083331). . . . . . . . . . . . . 2-104

2-21 ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) . . . . . 2-106

2-22 GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . 2-110

2-23 GROUND CONTROL BOX ASSEMBLY (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . 2-116

2-24 LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 2-120

2-25 HOODS INSTALLATION (PRIOR TO SN 0300089982) . . . . . . . . . . . . . . . . . . . . . . . 2-124

2-26 HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) . . . . . . . . . . . . . . . . 2-130

2-27 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

2-28 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-138

2-29 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-142

2-30 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO

SN 03000079612) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-148

2-31 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO

SN 0300140000) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152

2-32 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) . . . . . . . . . . . 2-156

3121140 800S 860SJ i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

2-33 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR &

DEUTZ ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160

2-34 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES. . . . . . . . . . .2-168

2-35 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES . . . . . . . . . . . . .2-172

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 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5 ROTATOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-6 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS. . . . . . . . . . . . . . . .3-22

3-7 BOOM CABLE CLAMPS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

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

4-1 PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORM . . . . . . . . . . . . . . . . . . . . .4-2

4-2 PLATFORM ASSEMBLIES - SIDE ENTRY (SN 0300067916 TO SN 0300140000) . .4-6

4-3 PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM). . . . . .4-10

4-4 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-5 CONTROLLER ASSEMBLY (LIFT AND SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-6 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-7 SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL) . . . . . . .4-26

4-8 SOFT TOUCH SYSTEM INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) .4-30 4-9 PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) . .4-32

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 LEVEL CYLINDER ASSEMBLY - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-5 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-6 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2 DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331) . . . . . . . . . . . . .6-4

6-3 DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000). . . . . .6-8

6-4 DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331) . . . . . . . . . . . . .6-12

6-5 DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300083331 TO SN 0300140000). . . . . .6-16

6-6 MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL) . . . . . . . . . . . . . . . . . . . .6-20

6-7 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-8 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

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

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

7-2 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM)

(PRIOR TO SN 0300085332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-3 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM)

(SN 0300085332 TO SN 0300140000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7-4 HARNESS COMPONENTS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . .7-38

ii 800S 860SJ 3121140

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

8-1 DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) . . . . . 8-6

8-3 DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) . . . . . . . . 8-10

8-4 DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) . 8-16

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

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

10-1 SPECIAL OPTIONS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 SKY WELDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3121140 800S 860SJ iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 800S 860SJ 3121140

SECTION 1

FRAME

3121140 800S 860SJ 1-1

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

501

107

103

113

111

109

206

217

216

102

201

101

201

105

201

204

201

304

219

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

1-2 800S 860SJ 3121140

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

Ref OSCILLATING AXLE INSTALLATION 0271135 Ref Prior to SN 0300083331 B 0274571 Ref SN 0300083331 to SN 0300140000 A

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

3121140 800S 860SJ 1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0272003 Ref STEERING INSTALLATIONS (2WS) B

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 0962448 4 Bearing 207 1683740 2 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 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 (SN 0300134352 to SN 0300140000)

Ref HUB INSTALLATION (2WD ONLY) 0271341 Ref Prior to SN 0300083331 E 0273378 Ref SN 0300083331 to SN 0300140000 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

2780229 Ref HUB ASSEMBLY (2WD ONLY) A

1-4 800S 860SJ 3121140

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

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)

501 Ref FRAME WELDMENT OPTIONS

1 800S Options: 2360568 2WD Prior to SN 0300083331 2360687 2WD SN 0300083331 to SN 0300140000 2360555 4WD Prior to SN 0300083331 2360688 4WD SN 0300083331 to SN 0300140000

1 860SJ Options: 2360566 2WD Prior to SN 0300083331 2360689 2WD SN 0300083331 to SN 0300140000 2360568 4WD Prior to SN 0300083331 2360687 4WD SN 0300083331 to SN 0300140000

3121140 800S 860SJ 1-5

SECTION 1 FRAME

106

110

106

114

102

118

501

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

405

406

410

411

412

409

219

204

202

206

224

214

221

204

218

209

223

209

217

216

207

221

226

207

222

208

215

204

203

218

104

201

218

201

101

201

101

301

316

304

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

1-6 800S 860SJ 3121140

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref OSCILLATING AXLE INSTALLATION 0271353 Ref Prior to SN 0300083331 A 0274572 Ref SN 0300083331 to SN 0300140000 A

0271352 Ref STEERING INSTALLATION 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 0641508 1 Bolt 5/16in- 18NC x 1in 204 0641608 7 Bolt 3/8in-16NC x 1in 205 0962152 2 Bearing, Garmax 206 0962448 4 Bearing, Garmax 207 0962292 2 Bearing, Garmax 208 0962348 1 Bearing, Garmax 209 1683740 2 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 210 3422567 1 Pin, Steer Spindle Attach (RH) 211 3422701 1 Pin, Steer Spindle Attach (LH) 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

3121140 800S 860SJ 1-7

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

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 1 Bar, Pivot Options:

4846414 Prior to SN 0300074135

4846935 SN 0300074135 to SN 0300140000 227 0641810 16 Bolt 1/2in-13NC x 1-1/4in 228 4 Screw Options:

0741607 Screw 3/8in-16NC x 3/4in (SN 0300070782 to

SN 0300074135)

0741609 Screw 3/8in-16NC x 1-1/4in (SN 0300074135 to

SN 0300140000) 229 3340966 2 Pad, Stop (SN 0300070782 to SN 0300140000) 230 4071059 4 Shim (SN 0300070782 to SN 0300140000)

Ref HUB INSTALLATION (2WD ONLY) 0271341 Ref Prior to SN 0300083331 E 0273378 Ref SN 0300083331 to SN 0300140000 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

2780229 Ref HUB ASSEMBLY (2WD ONLY) A

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

1-8 800S 860SJ 3121140

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

501 Ref FRAME WELDMENT OPTIONS

1 800S Options: 2360568 2WD Prior to SN 0300083331 2360687 2WD SN 0300083331 to SN 0300140000 2360555 4WD Prior to SN 0300083331 2360688 4WD SN 0300083331 to SN 0300140000

1 860SJ Options: 2360566 2WD Prior to SN 0300083331 2360689 2WD SN 0300083331 to SN 0300140000 2360568 4WD Prior to SN 0300083331 2360687 4WD SN 0300083331 to SN 0300140000

3121140 800S 860SJ 1-9

SECTION 1 FRAME

2WD

PRIOR TO

SN 0300083331

105

113

108

106

107

112

104

114

4WD

PRIOR TO

SN 0300083331

302

304

307

303 306

305

301

DETAIL OF

VALVE STEM

206

214

204

208

213

203

2WD & 4WD

SN 0300083331 TO

SN 0300140000

209

101

201

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

1-10 800S 860SJ 3121140

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref WHEEL DRIVE INSTALLATIONS

0271341 Ref 2WD (PRIOR TO SN 0300083331) E

1 0100011 AR Compound, Locking

2 to 3 Not Used

4 0682016 16 Bolt 5/8in-11NC x 2in (Grade 8) 5Use 0920119 2 Drive Brake Assembly (was p/n 0920117)

7018612 1 Kit, Repair 7000731 2 Gasket (Between Components)

6 2780227 2 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for

Breakdown) 7Not Used 8 3160268 2 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for

Breakdown) 9 3300007 20 Nut, Wheel

10 3311801 4 Nut 1/2in - 13 NC 11 3790045 4 O-Ring 12 4300097 4 Stud

13 to 15 Not Used

16 4892000 16 Flatwasher 5/8in Hardened

0271349 Ref 4WD (PRIOR TO SN 0300083331) E

101 0100011 AR Compound, Locking

102 to 103 Not Used

104 0681810 8 Bolt 1/2in-13NC x 1-1/4in (Grade 8) 105 0682016 32 Bolt 5/8in-11NC x 2in (Grade 8) 106 2780259 4 Drive Hub/Brake Assembly (See DRIVE HUB/BRAKE

ASSEMBLY for Breakdown)

107 3160266 4 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for

Breakdown)

108 3790045 4 O-Ring

109 to 111 Not Used

112 4891800 4 Flatwasher 1/2in Hardened 113 4892000 32 Flatwasher 5/8in Hardened 114 3300007 40 Nut, Wheel

Ref WHEEL DRIVE INSTALLATION (SN 0300083331 TO

SN 0300140000)

0273378 Ref 2WD E 0273704 Ref 4WD D

Ref Note: 2WD Qty Shown. For 4WD, Double Qty Shown.

201 0100011 AR Compound, Locking 202 Not Used 203 3311801 4 Nut 1/2in-13 NC 204 0682016 16 Bolt 5/8in-11NC x 2in (Grade 8) 205 2300016 AR Fluid, Hydraulic (Not Shown) 206 2780272 2 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for

Breakdown)

3121140 800S 860SJ 1-11

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

207 3020008 AR Lubricant (Not Shown) 208 AR Drive Motor Assembly Options (See DRIVE MOTOR

ASSEMBLY for Breakdown) 3160308 2 2WD Rear (Prior to SN 0300098924) 3160347 2 2WD Rear (SN 0300098924 to SN 0300140000) 3160266 4 4WD Front & Rear (Prior to SN 0300098641) 3160348 4 4WD Front & Rear (SN 0300098641 to SN 0300140000)

209 3300007 20 Nut, Wheel

210 to 212 Not Used

213 4891800 4 Flatwasher, 1/2in Hardened 214 4892000 16 Flatwasher 5/8in Hardened

Ref TIRE AND WHEEL INSTALLATIONS 0270885 Ref 15-625 NHS Pneumatic A 0272322 Ref 15-625 NHS Pneumatic W/Sealant 1 0270886 Ref 15-625 NHS Foam-Filled A 0270888 Ref 18-625 NHS Foam-Filled A 0271419 Ref 41/18LLx22.5 Sand & Turf Foam-Filled B

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 0271419 4 41/18LLx22.5 Sand & Turf Foam-Filled

Ref Note: Assemblies may require ballast/foam filling to

manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

301 1 Decal Options (Pneumatic Only):

1702701 95 PSI/6.5 Bar (15-625 Tires)

302 1 Tire Options:

4520252 15-625 Tire 4520253 18-625 Tire 4520256 41/18LLx22.5 Sand & Turf Tire

303 4640113 1 Valve, Air 304 1 Rim, Wheel Options:

4860224 13 x 24.5 Rim (Use with 15-625 Tires) 4860225 15 x 24.5 Rim (Use with 18-625 Tires) 4860230 22.5 x 14 (41/18LLx22.5 Sand & Turf Tires)

305 1705364 AR Decal - Tire Sealant (W/Sealant Only) 306 1300019 AR Chemical, Tire Sealant (Green) (W/Sealant Only) 307 1120552 AR Cap, Valve Stem (Green) (W/Sealant Only)

1-12 800S 860SJ 3121140

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 1-13

SECTION 1 FRAME

1A1B1C

1N1G1F1E1H

1616151515

151213

3C3D3C

3A33E

1J1J100

FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331)

1-14 800S 860SJ 3121140

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780227 Ref DRIVE HUB ASSEMBLY (2WD) A

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

Components.)

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

4 7017035 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 7017042 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 7017027 1 Ring, Retaining 11 7017039 1 Shaft, Input 12 7017041 1 Spacer, Input 13 7017038 1 Gear, Sun 14 Not Used 15 7000287 4 Thrustwasher

3121140 800S 860SJ 1-15

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

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 AR Thrustwasher

Ref KIT OPTIONS:

100 7017068 1 Seal Kit - Hub (Includes Items 1B,1I, 5, 6F, 6G, 15 & 16)

1-16 800S 860SJ 3121140

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 1-17

SECTION 1 FRAME

16 2

3D3E3G1766A6C6B6D

1J520

1A 22

101A

103

104

105

101F

102

106

107

101B

101D

101C

101E

149238201D

201C

201B

201A

200

FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331)

1-18 800S 860SJ 3121140

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780259 Ref DRIVE HUB ASSEMBLY (2WD) A

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

Individual Components.)

1A 7024139 1 Spindle 1B 7024140 1 Seal 1C 7024144 2 Cone, Bearing 1D 7024143 2 Cup, Bearing

1E to 1F Not Used

1G 7024142 1 Housing 1H 7024137 1 Thrustwasher

1I 7024141 1 Ring, Retaining

1J 7001928 1 Plug, Pipe

1K Not Used

1L Not Used

1M Not Used 1N 7000265 10 Stud, Wheel

2 7024150 1 Gear, Internal

3 7024145 1 Carrier Assembly

3A 7024147 1 Carrier 3B 7001901 6 Thrustwasher, Tanged 3C 7001902 84 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, Ring

5 7000224 2 O-Ring

6 See Note 1 Cover Assembly (Note: Not Available - Purchase Individual

Components.)

6A 7024155 1 Cover 6B 7024156 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 7024106 1 Brake Assembly (See Items 101A - 108)

8 7000283 1 Spring

9 7000284 1 Ring, Retaining 10 7017027 1 Ring, Retaining 11 7024152 1 Shaft, Input 12 7024154 1 Spacer, Input 13 7024149 1 Gear, Sun 14 7017050 1 Thrustwasher 15 7000287 4 Thrustwasher 16 7000288 2 Thrustwasher 17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)

3121140 800S 860SJ 1-19

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

18 7024108 1 Plug, Pressure 19 7024153 1 Coupling 20 7017047 2 Pin, Dowel 21 7017082 1 Plug, O-Ring 22 7024138 1 Coupling 23 7000282 1 Thrustwasher

7024106 Ref BRAKE ASSEMBLY

101A Use 7024719 1 Internal Circlip 101B Use 7024709 1 O-Ring 101C Use 7024709 1 Back-Up Ring 101D Use 7024709 1 O-Ring 101E Use 7024709 1 Back-Up Ring 101F Use 7024719 1 Internal Circlip

102 Use 7024719 1 Plate. End 103 See Note 1 Piston (Note: Not Available - Purchase Complete Assy.) 104 Use 7024710 8 Plate, Outer 105 Use 7024719 1 Spacer 106 See Note 6 Screw (Note: Not Available for Purchase.) 107 Use 7024710 7 Plate, Inner 108 Use 7024711 10 Spring, Compression

Ref KIT OPTIONS:

200 7024720 1 Seal Kit - Hub (Includes Items 1B, 1I & 5)

201 AR Repair Kit Options: 201A 7024719 1 Hardware 201B 7024710 1 Lining 201C 7024709 1 O-Ring 201D 7024711 1 Spring

1-20 800S 860SJ 3121140

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 1-21

SECTION 1 FRAME

10531111

110

112

121

102

119

122

123

104

103

101

109

107

108

114 113

116

115

118

117

120

27191A

1B1C1D

1N1G1F1E1H

151515

151213

3F3C3D

106

1061J1J

201D

201C

201B

201A

200A

200B

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000)

1-22 800S 860SJ 3121140

+ 416 hidden pages