Parts Manual Owner manual

ManualsBrandsJLG ManualsSpecial machinery800A_AJ

Illustrated Parts Manual

Models

800A

800AJ

S/N 0300069000

to S/N 0300140000

P/N

3121854

April 30, 2014

Summary of content (350 pages)

PAGE 1
Illustrated Parts Manual Models 800A 800AJ S/N 0300069000 to S/N 0300140000 P/N 3121854 April 30, 2014
PAGE 2
PAGE 3
REVISION LOG GROUND MODULE MODULE IDENTIFICATION MODULE ON MACHINES “WITHOUT UGM” (UNIVERSAL GROUND MODULE) MODULE ON MACHINES “WITH UGM” (UNIVERSAL GROUND MODULE) September 30, 2002 - Original Issue Of Manual (Manual edited to 0010580 Revision 21) February 7, 2003 - Revised (Manual edited to 0010580 Revision 30) June 30, 2003 - Revised (Manual edited to 0010580 Revision 45) October 14, 2003 - Revised (Manual edited to 0010580 Revision 49) February 10, 2004 - Revised (Manual edited to 0010580 Revision 4
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REVISION LOG July 31, 2012 - Revised Manual December 14, 2012 - Revised Manual March 26, 2013 - Revised Manual June 20, 2013 - Revised Manual September 16, 2013 - Revised Manual December 30, 2013 - Revised Manual April 30, 2014 - Revised Manual B 800A 800AJ 3121854
PAGE 5
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE AND WHEEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) . . . . . . . . 4-2 PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM) . . . . . . . . . . 4-6 PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM) . . . . . 4-10 PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) . . . . . . . .
PAGE 7
SECTION 1 FRAME 3121854 800A 800AJ 1-1
PAGE 8
SECTION 1 FRAME FIGURE 1-1.
PAGE 9
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NUMBER QTY.
PAGE 10
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 11
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED) ITEM # PART NUMBER 205 QTY.
PAGE 12
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED) ITEM # 301 302 to 303 304 305 306 307 to 309 310 311 to 314 315 401 402 403 404 405 406 407 408 409 410 411 412 PART NUMBER QTY.
PAGE 13
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 14
SECTION 1 FRAME FIGURE 1-2.
PAGE 15
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS ITEM # PART NUMBER QTY. Ref 0270209 0270210 0270211 1 to 2 3 4 Not Used 0682016 Use 0920119 7018612 7000731 7007990 5 6 7 2780227 2780228 Not Used 3160204 8 9 10 11 to 12 13 14 15 3300007 Not Used 4300097 Not Used 4891800 4892000 3311801 Ref Ref Ref Ref 16 4 1 2 1 Ref 2 2 DESCRIPTION WHEEL DRIVE INSTALLATIONS (SN 0300069000 TO SN 0300083332) 2WD/2WS 4WD/2WS 4WD/4WS Note: 2WD Qty Shown For 4WD, Double Qty Shown.
PAGE 16
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 17
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED) ITEM # 301 302 303 3121854 PART NUMBER QTY. 0256196 Ref 1670776 0641550 0100011 4 20 AR DESCRIPTION WHEEL COVER INSTALLATION (OPTIONAL) REV.
PAGE 18
SECTION 1 FRAME FIGURE 1-3.
PAGE 19
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) ITEM # PART NUMBER QTY.
PAGE 20
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) (CONTINUED) ITEM # PART NUMBER 12 QTY.
PAGE 21
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 22
SECTION 1 FRAME FIGURE 1-4.
PAGE 23
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 24
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 25
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 127 128 7024193 7024197 1 1 3121854 DESCRIPTION REV.
PAGE 26
SECTION 1 FRAME FIGURE 1-5.
PAGE 27
SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY (SN 0300069000 TO SN 0300083332) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 to 29 30 31 3121854 PART NUMBER QTY.
PAGE 28
SECTION 1 FRAME FIGURE 1-6.
PAGE 29
SECTION 1 FRAME FIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN 0300140000) (4 BOLT ASSEMBLY) ITEM # 1 2 3 4 5 6 7 8 PART NUMBER QTY. DESCRIPTION 3160308 3160266 Ref Ref Ref Ref DRIVE MOTOR ASSEMBLY 2WD 4WD Note: Original Equipment Motor p/n 3160308 & p/n 3160266 uses 4 bolts to assemble the motor. Service Replacement Motor p/n 3160347 & p/n 3160348 motors use 5 bolts to assemble the motor. Visually identify component before ordering parts.
PAGE 30
SECTION 1 FRAME FIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN 0300140000) (4 BOLT ASSEMBLY) (CONTINUED) ITEM # PART NUMBER 22 23 24 25 26 27 28 29 30 31 QTY.
PAGE 31
SECTION 1 FRAME FIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN 0300140000) (4 BOLT ASSEMBLY) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 32
SECTION 1 FRAME FIGURE 1-7.
PAGE 33
SECTION 1 FRAME FIGURE 1-7. DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO SN 0300140000) (5 BOLT ASSEMBLY) ITEM # 1 2 3 4 5 6 7 7A PART NUMBER QTY.
PAGE 34
SECTION 1 FRAME FIGURE 1-7. DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO SN 0300140000) (5 BOLT ASSEMBLY) (CONTINUED) ITEM # PART NUMBER QTY. 24 25 26 27 28 29 Use 7022328 2220883 Use 7022328 2220888 Use 7022328 1 1 1 2 2 1 30 31 32 33 34 35 36 37 38 39 40 41 42 to 49 50 1-28 7027741 7022372 See Note 2220883 Use 7022328 2220886 Use 7022328 Use 7022328 Use 7022328 7024871 7024854 7007437 7022326 Use 7022328 7022371 Not Used 7022328 DESCRIPTION REV.
PAGE 35
SECTION 1 FRAME FIGURE 1-7. DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO SN 0300140000) (5 BOLT ASSEMBLY) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 36
SECTION 1 FRAME FIGURE 1-8.
PAGE 37
SECTION 1 FRAME FIGURE 1-8. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300069000 TO SN 0300083332) ITEM # 1 2 3 to 10 11 11A 11B 11C 12 PART NUMBER QTY.
PAGE 38
SECTION 1 FRAME FIGURE 1-9.
PAGE 39
SECTION 1 FRAME FIGURE 1-9. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO SN 0300140000) ITEM # 1 2 3 to 10 11 12 12A 12B PART NUMBER QTY.
PAGE 40
SECTION 1 FRAME FIGURE 1-9. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO SN 0300140000) (CONTINUED) ITEM # 201 202 203 204 205 1-34 PART NUMBER QTY. 0274267 0274266 Ref Ref Ref FRAME SHIELDS INSTALLATIONS 2WS 4WS AR AR 1 1 Compound, Locking Bolt, 3/8in - 16NC x 1in Plate, Cover Front Plate, Cover Rear Options: 2WS 4WS Flatwasher, 3/8in 0100011 0641608 3575718 Not Required 3570690 4751600 AR DESCRIPTION 800A 800AJ REV.
PAGE 41
SECTION 1 FRAME FIGURE 1-9. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO SN 0300140000) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 42
SECTION 1 FRAME FIGURE 1-10.
PAGE 43
SECTION 1 FRAME FIGURE 1-10. TOW PACKAGE INSTALLATION (2WS ONLY) ITEM # PART NUMBER QTY.
PAGE 44
SECTION 1 FRAME FIGURE 1-10. TOW PACKAGE INSTALLATION (2WS ONLY) (CONTINUED) ITEM # PART NUMBER QTY. 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 1704578 1705090 Not Used 3250872 3311401 3420292 3539662 3820001 4420051 4640261 4711500 4751400 4846507 4846508 3570686 2 1 1 2 2 1 4 2ft/0.
PAGE 45
SECTION 2 TURNTABLE 3121854 800A 800AJ 2-1
PAGE 46
SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 47
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS ITEM # PART NUMBER 0258454 0273789 0274640 0258455 0273790 0274641 0258456 0273791 0274642 0258457 0273792 0274643 1 2 0100011 QTY.
PAGE 48
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 49
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY. 27 4420060 2in/5cm 28 29 0140001 0641408 1 1 0258670 Ref Ref AUXILIARY PUMP INSTALLATION Note: Original Equipment pump may have been replaced with Service Replacement pump. Identify component before ordering parts.
PAGE 50
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 51
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20A 21 21A 3121854 PART NUMBER QTY.
PAGE 52
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 53
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY. 33 7021310 7018945 7017478 7017477 7012941 7010543 7012944 7017428 7012998 7018942 7018951 7021311 3931048 AR 2 1 1 1 1 1 1 1 28 4 4 4 34 35 36 37 38 39 40 3121854 DESCRIPTION REV.
PAGE 54
SECTION 2 TURNTABLE FIGURE 2-3. ACCESSORY VALVE ASSEMBLY 7 2 2A 2B 2C 6 1 4 3 8 NOTE: TORQUE ITEMS 6, 7,103 &104 TO 60 IN/LBS.
PAGE 55
SECTION 2 TURNTABLE FIGURE 2-3. ACCESSORY VALVE ASSEMBLY ITEM # PART NUMBER QTY. Ref 4640921 Ref 5 6 7012965 7012953 Use 70001976 7012773 7018945 7018912 7012772 7017421 7012998 7017422 7012998 4460499 7012777 1 1 1 1 4 2 2 1 1 1 1 2 4 7 8 7018942 7012776 4 2 4640922 Ref 102A 102B 102C 103 7017420 7012998 7012774 7012773 7018945 7018912 7012772 7018946 1 1 1 1 4 2 2 4 104 105 106 7018942 7018948 7018947 4 4 1 1 2 2A 2B 2C 3 4 101 102 3121854 DESCRIPTION REV.
PAGE 56
SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 57
SECTION 2 TURNTABLE FIGURE 2-4. AUXILIARY PUMP ASSEMBLY (SN 0300109067 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 58
SECTION 2 TURNTABLE FIGURE 2-4. AUXILIARY PUMP ASSEMBLY (SN 0300109067 TO SN 0300140000) ITEM # PART NUMBER QTY. 135 136 137 to 139 140 141 142 See Note See Note Not Used 70001069 70001068 7010944 1 2 Label (Note: Not Available for Purchase.) Pin, Shear (Note: Not Available for Purchase.
PAGE 59
SECTION 2 TURNTABLE FIGURE 2-4. AUXILIARY PUMP ASSEMBLY (SN 0300109067 TO SN 0300140000) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 60
SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 61
SECTION 2 TURNTABLE FIGURE 2-5. TURNTABLE BEARING AND SWING DRIVE INSTALLATION ITEM # 1 2 3 4 PART NUMBER QTY.
PAGE 62
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 63
SECTION 2 TURNTABLE 27 220 101 121 208 213 214 51 126 226 227A 227B 227C 227D 102 104 207 105 217 218 103 106 104 209 107 215 104 216 108 201 104 206 109 203 36 110 31 104 206 112 203 29 113 115 204 28 222 223 32 114 116 117 29 23 28 219 221 21 202 22 118 30 119 120 212 210 211 3121854 800A 800AJ 35 19 205 2-19
PAGE 64
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353) ITEM # 1 1A 1B 1C 1D 1E 1F 1G 1H 1I 1J 2 3 3A 3B 3C 3D 3E 3F 3G 4 5 5A 6 7 8 9 10 11 12 13 14 to 18 19 20 21 22 23 24 2-20 PART NUMBER QTY.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353) ITEM # PART NUMBER QTY. 25 26 27 28 29 30 31 32 33 to 34 35 36 37 to 50 51 7000281 7024705 7017082 See Note 7024185 7017085 7024707 7024784 Not Used 7024706 7024702 Not Used 7024100 2 1 1 2 2 2 1 1 Screw, Drive O-Ring Plug, Pipe Lug, Lifting (Note: Not Available for Purchase.
PAGE 66
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353) ITEM # PART NUMBER QTY. 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 to 225 226 227 227A 227B 227C 227D 7024191 7024192 Use 7024197 Use 7024197 Use 7024197 See Note See Note Use 7024194 Use 7024194 Use 7024194 Use 7024194 7024190 See Note See Note Use 7024195 Use 7024196 Not Used 7024194 1 1 1 1 1 6 6 1 1 1 1 2 1 1 AR AR 2-22 7024195 7024196 7024193 7024197 1 1 DESCRIPTION REV.
PAGE 67
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 68
SECTION 2 TURNTABLE FIGURE 2-7.
PAGE 69
SECTION 2 TURNTABLE 200A 200B 200C 201 101 26 102 104 8L 105 8A 103 106 104 107 8E 8D 104 8F 108 8H 104 8K 109 8J 110 31 104 8K 112 8J 113 29 115 8K 28 8J 32 114 116 125 117 118 29 23 8K 8J 21 28 22 119 120 30 8K 35 3121854 800A 800AJ 2-25
PAGE 70
SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134353 TO SN 0300140000) ITEM # 1 1A 1B 1C 1D 1E 1F 1G 1H 1I 1J 2 3 4 5 5A 6 7 8 8A 8B to 8C 8D 8E 8F 8G 8H 8I 8J 8K 8L 9 to 10 11 12 13 14 to 19 20 21 22 23 24 25 26 27 28 2-26 PART NUMBER QTY.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134353 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 72
67 2-28 144 10 30 28 32 46 67 68 28 51 34 55 38 48 800A 800AJ 3 23 93 92 40 55A 18 66 43 73 50 55B 19 228 213 219 48 68 14 203 2 41 30 85 86 29 67 43 66 50 14 205 68 48 212 54 222 28 38 220 4 52 37 218 39 46 3 21 22 18 42 33 71 210 20 4 1 64 68 206 70 19 35 207 202 236 63 215 204 229 234 214 36 30 211 208B 208 208A 225 3 59 15 30 68 58 53 14 68 48 66 50 43 13 121 145 102 65 68 3 22 47 3 93 69 96 148 31 45 149 6 70 12 232 67 18
PAGE 73
3121854 800A 800AJ 95 9 110 111 5 8 GRD. 107E AUX.PWR. START RELAY RELAY 107A AUX.PWR. PUMP GLOW PLUG RELAY AUX.PWR. START RELAY RELAY 107B GRD. 113 107B GRD.
PAGE 74
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 2-30 PART NUMBER QTY.
PAGE 75
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # PART NUMBER QTY.
PAGE 76
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # PART NUMBER QTY. 68 69 70 71 72 73 74 4751600 4751800 4811900 4832000 4846790 4846805 4922737 AR 1 AR 8 1 1 1 75 to 84 85 86 Not Used 2180798 4360392 1 1 87 88 89 90 91 92 3311005 3740080 4751000 3020016 2300004 93 94 4751800 4812100 0100019 AR 1 AR 2.50gal. 2.63gal.
PAGE 77
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # PART NUMBER QTY.
PAGE 78
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # PART NUMBER QTY. DESCRIPTION 119 120 121 122 123 124 125 126 127 128 129 130 3380429 3539957 0100011 0100020 2220273 2180536 2220313 2750532 2220250 2220459 2720271 2220794 2180348 2720058 4751400 0641608 3311405 0641507 3311505 0641407 0641808 1320022 1701505 0641610 0641514 4751500 3960389 0641812 3841340 0641608 1320176 3460544 2221176 1 2 AR AR 2 2 1 6ft./1.8m 1 1 15ft./4.6m AR 2 1 30ft/9.
PAGE 79
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # PART NUMBER QTY.
PAGE 80
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # PART NUMBER QTY.
PAGE 81
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 82
2-38 800A 800AJ 315 316 320 335 336 337 312 210 210 31 48 33 48B 69 69 432 411 301 303 310 316 60 7 48A 211 75 70 301 304 308 317 331 316 338 330 40 60 29 210 42 62 13 3 52 2 402 76 322 321 422 327 415 77 32 301 304 414 317 334 412 70 70 62 18 20 1 66 30 34 26 40 60 16 37 59 44 424 45 417 416 301 305 418 314 318 421 12 62 42 326 36 323 425 413 301 304 428 317 301 309 313 316 324 325 332 302 44 328 304 68 317 301 307 434 316 324 404 65 406 21 301 37 301 311 12 3
PAGE 83
3121854 800A 800AJ 67 106 ENGINE TRAY KEEPER PIN BOLT 6 + INCLUDES ITEMS 215A THRU 215D ENGINE MOUNTING BOLT 215B ITEM 215 - BATTERY CABLE KIT - BATTERY MTG BOLT FOR GLOW PLUG RELAY GLOW PLUG RELAY 215A 121 215C STARTER AUX PWR RELAY AUX POWER PUMP 215D 14 42 62 14 42 62 61 71 73 72 58 27 215B 206 205 212 3 11 125 123 124 101 105 202 102 112 107 126 53 53 24 15 63 43 114 25 124 127 102 110 107 102 107 111 RETURN 126 24 49 VENT 101 104 115 116 118 49 5
PAGE 84
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 2-40 PART NUMBER QTY.
PAGE 85
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 86
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000) ITEM # PART NUMBER QTY. 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 1320022 1320176 1701505 2180348 2220313 2221176 2300004 2720058 2750532 3422446 3460544 3841143 3841340 4711600 4752000 Not Used 0641508 3311505 3380429 3539957 3900272 7 1 1 1 1 1 2.6gal. 30ft/9.1m 6ft./1.
PAGE 87
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 88
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 89
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000) ITEM # PART NUMBER QTY. 431 7026808 7026809 70002849 70002850 70002848 7026827 7026814 7026815 70002851 1 1 1 1 1 1 1 432 433 434 435 3121854 DESCRIPTION REV.
PAGE 90
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 91
SECTION 2 TURNTABLE FIGURE 2-10. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # 1 2 PART NUMBER QTY. 0273518 0274081 No Longer Avail.
PAGE 92
SECTION 2 TURNTABLE FIGURE 2-10. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # PART NUMBER 2B QTY.
PAGE 93
SECTION 2 TURNTABLE FIGURE 2-10. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # PART NUMBER QTY.
PAGE 94
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 95
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) ITEM # PART NUMBER QTY.
PAGE 96
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) ITEM # PART NUMBER QTY.
PAGE 97
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) ITEM # PART NUMBER QTY.
PAGE 98
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) ITEM # PART NUMBER QTY. 305 312 7020479 See Note 7026608 70001498 7026631 70001002 7020168 7020480 7020408 7020458 7026607 7020462 7026522 7024413 7020411 See Note 1 1 2 1 1 1 1 1 1 1 1 4 4 1 1 1 313 7024579 7024565 1 314 315 70001423 7020431 306 307 308 309 310 311 316 317 318 319 320 401 402 403 404 405 406 407 2-54 1 1 1 DESCRIPTION REV. Starter Relay (Note: Not Available for Purchase.
PAGE 99
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 100
2-56 800A 800AJ 210 257 236 201 254 216 236 262 257 257 210 257 46 223 111 243 274 255 237 257 210 231 212 240 231 412 226 238 210 257 236 254 212 223 401 224 247 234 255 257 237 210 236 257 233 410 256 409 411 225 227 201 213 226 257 236 257 236 239 205 227 232 201 216 279 402 204 237 255 211 13 48 47 219 228 301 307 351 405 228 222 19 245 OR 241 101 103 201 214 354 253 306 355 253 254 306 235 207 209 219 202 271 270 219 229 304 303 3
PAGE 101
3121854 31 800A 800AJ 261 31 6 11 3 4 4 5 201 217 SN 0300077500 TO SN 0300110581 AUX PWR PUMP 21E GLOW PLUGS ON ENGINE GLOW PLUG RELAY STARTER 21D + 107 102 106 112 22 7 248 248 218 26 275 27 9 273 21E 21D 275 GLOW PLUG RELAY AUX.PWR. START RELAY RELAY BATTERY + 420 12 GRD.
PAGE 102
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21A 21B 2-58 PART NUMBER QTY. 0273709 0274301 1001095348 1001098506 Ref Ref Ref Ref Ref 0100011 0100020 Not Used AR AR 1 0181727 91401281 0400075 1 2 0630498 1001093382 0641508 0641608 0641610 0641808 0642010 1060637 1320022 1701505 Not Used 2180348 2220313 2221176 2720058 2750532 1 1 1 30ft/9.2m 6ft/1.
PAGE 103
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 104
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY. 106 107 108 3311405 3422532 3600400 1 1 1 3600401 2220415 2220374 3600278 7018995 7024918 7024930 1001095354 AR 1 1 1 1 1 1 1 1 2220415 1001094595 7023967 7023956 3790044 3960389 4751400 4891600 4891800 1 1 1 1 1 5ft/1.
PAGE 105
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 106
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # 242 243 244 245 246 247 248 249 PART NUMBER 3574978 1001093943 Not Used 3620033 3740067 3960407 3960468 3960469 4060805 QTY.
PAGE 107
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 108
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 109
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 110
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY. 70003003 1 70002415 70002416 70002417 426 1 70000800 See Note 427 428 2-66 1 Not Available 7027794 7001872 7027793 70001847 1 1 70001126 1 DESCRIPTION REV. 3 Notches Gasket (SN 0300129456 to SN 0300140000): 1 Notch 2 Notches 3 Notches Timing Belt/Idler Kit Options (Not Shown): SN 0300077500 to SN 0300085331 SN 0300085331 to SN 0300140000 (Note: Not Available for Purchase.
PAGE 111
SECTION 2 TURNTABLE FIGURE 2-12. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 112
SECTION 2 TURNTABLE FIGURE 2-13.
PAGE 113
SECTION 2 TURNTABLE FIGURE 2-13. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER 0272482 0274090 1001100308 1001115410 0272481 0274086 1001099868 1001115409 1 2 3580158 QTY.
PAGE 114
SECTION 2 TURNTABLE FIGURE 2-13. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER QTY.
PAGE 115
SECTION 2 TURNTABLE FIGURE 2-13. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. 36 37 38 39 40 41 4420060 4460968 4811600 1001099869 Not Used 1 4 1 1 Tape, Double Coated Acrylic Foam Connector, Strain Relief Flatwasher 5mm Box, Junction 1 Light Red Options: 125 Vac 250 Vac Bushing 42 3121854 1001100233 1001100234 0962449 1 DESCRIPTION 800A 800AJ REV.
PAGE 116
2-72 800A 800AJ 1203 1201A 1201 2001 802 1502 806 805 1509 1204 1508 1511 1510 1103 155 110 1220 111 106 165 604 1002 1003 1001 2005 1104 304 1220 2004 1401 OR OR 603 605 110 105 104 103 101 102 166 142 2004 141 1503 165 106 166 115 1404 902 114 158 909 910 911 919 1403 906 2003 107 140 2002 916 918 168 121 168 918 916 167 119 118 137 501 120 2007 150 129 107 2006 907 905 908 123 108 160 401 111 130 127 201 126 135 136 138 134 1
PAGE 117
SECTION 2 TURNTABLE FIGURE 2-14. PISTON PUMP ASSEMBLY ITEM # 1 to 100 101 102 103 104 105 106 107 108 109 110 111 112 to 113 114 115 116 to117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 to 149 150 151 to 154 155 156 to 157 158 3121854 PART NUMBER QTY.
PAGE 118
SECTION 2 TURNTABLE FIGURE 2-14. PISTON PUMP ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 119
SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 120
SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 121
SECTION 2 TURNTABLE FIGURE 2-15. TANK INSTALLATIONS ITEM # PART NUMBER QTY. 0258382 Ref 1 1 4845928 1001091928 2 1 4400410 4400452 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 101 102 103 104 105 106 201 202 203 204 205 206 207 208 3121854 4400400 7019658 4240112 4240113 4360436 2200222 4280295 4420038 0641614 3311601 4751600 0100011 0100079 0641607 1 1 4 1 1 1 25in/44cm 70in/1.
PAGE 122
SECTION 2 TURNTABLE FIGURE 2-15. TANK INSTALLATIONS (CONTINUED) ITEM # PART NUMBER Ref 1 301 7016314 1120487 2-78 QTY. DESCRIPTION REV.
PAGE 123
SECTION 2 TURNTABLE FIGURE 2-15. TANK INSTALLATIONS (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 124
SECTION 2 TURNTABLE FIGURE 2-16.
PAGE 125
SECTION 2 TURNTABLE FIGURE 2-16. ROTARY COUPLING INSTALLATION (SN 0300069000 TO SN 0300083332) ITEM # 1 2 3 4 5 6 7 8 3121854 PART NUMBER QTY. DESCRIPTION 0272354 0272355 Ref Ref Ref ROTARY COUPLING INSTALLATIONS 2WS 4WS 0641820 4751800 3311805 0641611 4751600 0100011 0902846 2 4 2 4 4 AR 2 AR 1660219 7013187 1660219RR 1 1 1 1660223 7016342 1660223RR 1 1 1 REV.
PAGE 126
SECTION 2 TURNTABLE FIGURE 2-17.
PAGE 127
SECTION 2 TURNTABLE FIGURE 2-17. ROTARY COUPLING INSTALLATION (SN 0300083332 TO SN 0300137975) ITEM # 1 2 3 4 5 6 7 8 9 10 101 102 PART NUMBER QTY.
PAGE 128
SECTION 2 TURNTABLE FIGURE 2-17. ROTARY COUPLING INSTALLATION (SN 0300083332 TO SN 0300137975) ITEM # PART NUMBER QTY.
PAGE 129
SECTION 2 TURNTABLE FIGURE 2-17. ROTARY COUPLING INSTALLATION (SN 0300083332 TO SN 0300137975) ITEM # PART NUMBER 126B 7026512 QTY. 1 126C 126D 3121854 70001248 70001249 DESCRIPTION REV.
PAGE 130
SECTION 2 TURNTABLE FIGURE 2-18.
PAGE 131
SECTION 2 TURNTABLE FIGURE 2-18. ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 PART NUMBER QTY.
PAGE 132
SECTION 2 TURNTABLE FIGURE 2-18. ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000) ITEM # PART NUMBER QTY. 116 117 118 119 120 121 122 7024404 7026505 7026506 7026507 Use p/n 7024404 7026509 See Note 1 1 1 1 1 1 AR 123 124 125 126 127 128 129 to 199 200 200A 200B 2-88 1 Use 70001248 Use 70002212 See Note See Note See Note 70003454 4360517 Not Used 4 2 4 1 1 1 70001248 70002212 DESCRIPTION REV.
PAGE 133
SECTION 2 TURNTABLE FIGURE 2-18. ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 134
SECTION 2 TURNTABLE FIGURE 2-19.
PAGE 135
SECTION 2 TURNTABLE FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) ITEM # PART NUMBER 0861623 0861758 1810092 0861624 0861757 1810097 0861504 0861714 1810090 1001102238 0861505 0861715 1810095 1001102239 1 2 3 4 5 6 6A 7 8 9 0100011 0100048 0630518 0630548 0641506 0861407 1001097164 7020246 QTY.
PAGE 136
SECTION 2 TURNTABLE FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 137
SECTION 2 TURNTABLE FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED) ITEM # PART NUMBER QTY. 40 4922666 1 41 1 4922675 4923282 4922675 4923223 4923575 1001096458 42 1 4922933 4923280 4923585 4922549 4923238 1001102150 43 1 4923296 4923338 4933373 44 45 46 47 3121854 4933232 4933321 4933372 0641410 3311405 1001094484 4711400 2 2 1 4 DESCRIPTION REV.
PAGE 138
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 139
SECTION 2 TURNTABLE FIGURE 2-20. GROUND CONTROL BOX ASSEMBLY (WITH UGM) ITEM # 1 2 3 4 5 5A 6 7 8 9 PART NUMBER QTY.
PAGE 140
SECTION 2 TURNTABLE FIGURE 2-20. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY. 34 4922557 1 35 36 1 1001110324 1001110222 1001110225 37 38 39 40 41 42 2-96 1 1 1001110323 1001110322 4460496 4460497 0641407 1001106736 0641506 1 1 1 1 4 DESCRIPTION REV.
PAGE 141
SECTION 2 TURNTABLE FIGURE 2-20. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 142
SECTION 2 TURNTABLE 10 17 31 33 34 32 30 2 4 3 35 5 1 29 27 15 25 28 25 26 18 26 16A 11 14 16 12 13 14 FIGURE 2-21.
PAGE 143
SECTION 2 TURNTABLE FIGURE 2-21. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # PART NUMBER QTY. Ref 1 2 3 4 5 6 to 9 10 11 0258674 Ref 0257887 0140032 2820035 4460424 4460268 0641508 4711500 0100011 0100048 Not Used 1 1 6in/15cm 1 2 2 2 AR AR 0271422 Ref Ref 4220162 1 1 1 1 1 1 12 13 0630491 0080241 3539281 0741606 14 15 16 0100011 4240032 Use 0272507 AR 1 1 1 7016380 70001941 16A 17 18 25 26 27 28 29 30 31 32 3121854 1 DESCRIPTION REV.
PAGE 144
SECTION 2 TURNTABLE FIGURE 2-21. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # PART NUMBER QTY.
PAGE 145
SECTION 2 TURNTABLE FIGURE 2-21. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 146
2-102 800A 800AJ 109 42 43 41 302 13 32 34 35 36 51 52 34 44 21 34 36 51 13 105 26 32 30 16 34 35 51 303 35 105 301 304 5 31 34 35 25 106 107 108 1 101 305 47 46 45 18 17 24 34 32 51 40 102 110 3 306 307 308 4 10 42 41 14 31 34 51 23 34 37 21 34 36 51 27 47 46 205 45 44 7 39 28 37 50 49 48 9 22 40 40 19 39 28 32 51 34 38 15 39 39 40 34 33 32 51 28 33 11 30 33 32 51 3B 8 32 34 51 23 104 29 103 34 35 3A 210 28 29 32 47 46 35 34 22 40 32
PAGE 147
SECTION 2 TURNTABLE FIGURE 2-22. HOODS INSTALLATION (SN 0300069000 TO SN 0300089982) ITEM # PART NUMBER QTY.
PAGE 148
SECTION 2 TURNTABLE FIGURE 2-22. HOODS INSTALLATION (SN 0300069000 TO SN 0300089982) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 149
SECTION 2 TURNTABLE FIGURE 2-22. HOODS INSTALLATION (SN 0300069000 TO SN 0300089982) (CONTINUED) ITEM # PART NUMBER QTY. 306 307 308 0641506 4751500 0100011 2 2 AR 3121854 DESCRIPTION REV.
PAGE 150
2-106 800A 800AJ 121 42 43 41 102 103 118 119 25 114 115 116 104 13 21 32 34 35 36 51 52 53 34 35 301 57 113 31 44 34 35 21 34 36 51 13 5 113 32 30 34 35 107 51 110 105 106 108 109 101 112 1 111 305 24 17 47 46 45 18 40 120 32 51 117 34 109 122 3 39 306 307 308 4 14 39 37 31 34 51 10 29 32 34 51 23 23 33 32 51 37 19 39 40 37 38 15 39 39 40 34 33 32 51 28 34 11 30 34 33 35 32 3B 51 3A 21 34 36 51 37 39 28 47 46 57 203 45 44 9 22 27 39 40 56 28 34 50
PAGE 151
SECTION 2 TURNTABLE FIGURE 2-23. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) ITEM # PART NUMBER 0274759 0274759 1001099137 1 QTY. DESCRIPTION Ref Ref Ref Ref Ref HOODS INSTALLATIONS Caterpillar Engine Machines Deutz Engine Machines SN 0300089982 to SN 0300129456 SN 0300129456 to SN 0300140000 1 1 1 1 1 Hood Assembly - Engine Side Options (See Items 101-122 for Breakdown): Note: Replacement decals must be ordered separately - See DECAL SECTION.
PAGE 152
SECTION 2 TURNTABLE FIGURE 2-23. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 153
SECTION 2 TURNTABLE FIGURE 2-23. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 107 QTY. 1 4061010 1001101392 108 109 110 1001101392 1001101623 4740500 4751600 AR AR 1 4845411 4845411 1001099121 111 1 Ref 1001097965 1001097965 1001099139 112 113 114 115 116 117 118 119 120 121 122 201 202 203 204 205 206 207 208 209 210 211 212 213 3121854 1671230 2940088 0721008 4751000 3311005 0641608 1321384 0641606 2600209 3960464 3960462 1 1 2 2 2 AR 4 4 1 65in/1.
PAGE 154
SECTION 2 TURNTABLE FIGURE 2-23. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # 301 302 to 304 305 306 307 308 2-110 PART NUMBER QTY. 0256823 Ref 2820078 Not Used 3539955 0641506 4751500 0100011 1 1 2 2 AR DESCRIPTION NOISE REDUCTION INSTALLATION (CATERPILLAR/DEUTZ ENGINE MACHINES) REV.
PAGE 155
SECTION 2 TURNTABLE FIGURE 2-23. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 156
SECTION 2 TURNTABLE FIGURE 2-24.
PAGE 157
SECTION 2 TURNTABLE FIGURE 2-24. ENGINE TRAY JACK INSTALLATION (OPTIONAL) ITEM # 1 2 3 3A 3B 3C 3D 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3121854 PART NUMBER QTY.
PAGE 158
SECTION 2 TURNTABLE FIGURE 2-24. ENGINE TRAY JACK INSTALLATION (OPTIONAL) (CONTINUED) ITEM # 2-114 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 159
SECTION 3 BOOM 3121854 800A 800AJ 3-1
PAGE 160
3-2 800A 800AJ 15 209 202 4 203 40 206 207 28 24 50 9 25 38 25 37 21 25 33 27 23 25 26 33 206 206 41 31 3 209 202 205 210 201 204 208 25 31 31 11 SIDE ENTRY PLATFORM 5 25 44 45 26 46 33 47 43 26 35 25 33 14 10 25 32 39 11 25 27 37 20 31 26 20 25 33 27 18 8 7 30 22 25 37 12 25 34 19 2 25 32 17 25 37 6 110 27 16 37 27 25 1 16 102 108 105 113 101 44 45 109 115 114 102 104 115 102 104 112 25 36 29 119 117 116 106 118 103 111 102 102 107 41 31 F
PAGE 161
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A ITEM # PART NUMBER QTY.
PAGE 162
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A (CONTINUED) ITEM # PART NUMBER QTY. 36 37 38 39 40 41 42 43 44 0641820 0642214 0642620 3841340 1120510 1670864 Not Used 0961951 3 5 1 AR 1 1 2 1 DESCRIPTION REV.
PAGE 163
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 164
3-6 37 47 39 17 800A 800AJ 37 55 39 30 37 54 44 17 44 37 54 29 44 9 41 15 29 37 54 3 39 26 27 39 18 37 49 28 (TOWER BOOM) 37 45 32 37 38 47 LIFT CYLINDER 42 10 11 31 37 54 34 33 61 14 2 37 47 38 37 54 1 39 26 57 25 38 46 20 23 59 46 38 46 38 23 6A 65 13 51 21 64 51 59 38 7 6A 65 36 20 37 47 50 6 6A 64 65 35 37 53 8 12 19 40 45 21 16 58 43 4 19 101 36 22 102 105 109 4 206 209 202 206 206 207 FRONT ENTRY PLATFORM 111 110 107
PAGE 165
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ ITEM # PART NUMBER QTY.
PAGE 166
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 167
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ (CONTINUED) ITEM # PART NUMBER QTY. 110 111 4711800 4844790 8 1 Ref 201 202 203 204 205 206 207 208 209 210 3121854 0272070 See Note Ref Ref See Note Ref See Note Ref 0100011 0641812 0642684 0681608 3272605 3311805 4846573 4891600 4891800 4892600 AR 8 1 8 1 8 1 8 8 1 DESCRIPTION REV.
PAGE 168
SECTION 3 BOOM FIGURE 3-3.
PAGE 169
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 170
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY. 111 112 113 114 115 116 117 3311602 3311605 3841340 3900262 4711600 0641624 0259420 3340859 3340859 2 4 2 4 AR 2 1 2 2 118 3-12 DESCRIPTION REV.
PAGE 171
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 172
101B 3-14 8 101C 16 110 111 121 GEMCO 101A 101E 7 17 23 117 800A 800AJ 17 21 104 101 17 20 110 109 111 14 13 12 110 109 111 GORTRAC 101D 101F 17 18 13 11 12 9 10 5 17 6 20 123 124 103 3 1 102 109 118 110 113 119 124 114 122 109 110 24 2 106 800AJ 15 4 106 2 17 22 24 12 14 14 107 111 116 108 105 25 12 17 18 112 17 18 11 10 122 115 120 124 113 800A 14 17 19 17 19 9 SECTION 3 BOOM FIGURE 3-4.
PAGE 173
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES ITEM # PART NUMBER QTY.
PAGE 174
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 175
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) ITEM # PART NUMBER 121 QTY. 2 3900232 3900283 122 123 124 3121854 3311605 4071052 0100081 2 2 AR DESCRIPTION REV.
PAGE 176
SECTION 3 BOOM FIGURE 3-5.
PAGE 177
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) ITEM # PART NUMBER 0060041 0060077 0060031 1001103095 QTY. DESCRIPTION Ref Ref ROTATOR ASSEMBLIES Note: See ROTATOR ASSEMBLY (SIDE ENTRY PLATFROM) for Machines equipped with Fall Arrest Platforms.
PAGE 178
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) (CONTINUED) ITEM # PART NUMBER 17 QTY. 1 Use 7017183 7017183 17A 2 7011331 7017193 2900770 See Note 2 2 7011332 See Note AR 2 1 7011311 See Note 2 1 18 19 7017118 See Note 2 3 20 3790110 3 21 to 24 25 Not Used 17B 1 7017157 7017158 70000342 26 3-20 1 27 7017156 7017159 7017142 1 27A 70001697 6 DESCRIPTION REV.
PAGE 179
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 180
SECTION 3 BOOM FIGURE 3-6.
PAGE 181
SECTION 3 BOOM FIGURE 3-6. ROTATOR ASSEMBLY (SIDE ENTRY PLATFORM) ITEM # PART NUMBER QTY. 0060069 0060066 Ref Ref Ref 1 See Note 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7017162 7017163 7017164 See Note Use 7017159 Use 7017159 See Note See Note See Note See Note See Note Use 7017159 70001697 See Note 1 1 1 2 1 2 2 1 1 1 1 1 6 3 16 7017183 7017193 See Note 1 2 2 See Note 1 See Note 1 17 to 24 25 26 3121854 DESCRIPTION ROTATOR ASSEMBLIES 800A 800AJ REV.
PAGE 182
SECTION 3 BOOM FIGURE 3-7.
PAGE 183
SECTION 3 BOOM FIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14A 14B 15 16 17 18 19 20 21 22 101 102 103 104 3121854 PART NUMBER QTY.
PAGE 184
SECTION 3 BOOM FIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED) ITEM # 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 PART NUMBER QTY.
PAGE 185
SECTION 3 BOOM FIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED) ITEM # PART NUMBER 308 309 310 311 312 QTY. 1 Use 4360578 Use 4360578 4360578 4420060 Not Used 4751400 AR 501 502 503 504 505 506 507 508 3121854 REV.
PAGE 186
SECTION 3 BOOM FIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED) ITEM # 3-28 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 187
SECTION 4 PLATFORM 3121854 800A 800AJ 4-1
PAGE 188
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 189
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) ITEM # PART NUMBER QTY. DESCRIPTION 3510760 3510728 3510542 3510565 3510543 3510566 Ref Ref Ref Ref Ref Ref Ref Ref AUSTRALIAN SPEC PLATFORM ASSEMBLIES: 4ft (1.22m) with Self-Closing Gate 5ft (1.52m) Self-Closing Gate (Without Mesh) 6ft (1.83m) Self-Closing Gate (Without Mesh) 6ft (1.83m) with Mesh to Top Rail 8ft (2.44m) Self-Closing Gate (without Mesh) 8ft (2.
PAGE 190
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) ITEM # PART NUMBER QTY. 17 18 19 20 21 22 2080040 4761000 Not Used 3539685 4220165 4060803 13 4 1 1 6ft/1.
PAGE 191
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) ITEM # 101 102 103 104 105 106 107 108 109 110 PART NUMBER QTY.
PAGE 192
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 193
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM) ITEM # PART NUMBER QTY. DESCRIPTION Use 1001144023 Use 1001144024 Use 1001144027 Ref Ref Ref Ref Ref PLATFORM ASSEMBLIES: 8ft (2.44m) with No Mesh (was p/n 3510822) 6ft (1.83m) with No Mesh (was p/n 3510833) 4ft (1.22m) with No Mesh (was p/n 3510830) Note: Original Equipment platform may have been replaced with Service Replacement platform. Identify platform before ordering parts.
PAGE 194
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM) ITEM # PART NUMBER 104 QTY. 1 0861517 1001108735 1001114448 104A Use 0272970 1 Ref 1 4360031 1001117320 104B 104C 105 106 107 108 109 110 111 112 7000625 70003483 1060918 4460071 Not Used 3311405 3311605 3380434 Not Used 4740362 4751400 4751600 0270814 0273484 0273485 201 202 3536089 AR 2 1 7ft/2.
PAGE 195
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM) ITEM # PART NUMBER 209 QTY. 1 4460598 4460426 Ref 301 302 1580012 1580013 0272482 0274090 0272481 0274086 Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref 4360336 4740397 4060802 3251102 1 1 1 1 0273538 0274091 0273539 0274087 401 3121854 1 1 DESCRIPTION REV.
PAGE 196
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 197
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3121854 PART NUMBER QTY. 3510877 Ref Ref 0681814 0681822 0962270 1702773 1706501 2410014 3271805 3311605 See Note 3520072 3890040 3900054 4711800 4751800 1706493 2 6 2 1 1 1 8 1 1 1 1 1 2 6 1 DESCRIPTION PLATFORM ASSEMBLY (FALL ARREST) Note: Replacement Decals Must be purchased separately See DECAL SECTION. REV.
PAGE 198
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 199
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) ITEM # 1 2 3 4 5 6 7 8 9 PART NUMBER QTY. 0861517 Ref 0100009 0100020 0100035 0100048 0100081 0140011 0630464 0641406 AR AR AR AR AR 1 2 4 4 0641416 0641414 10 11 12 0861537 0902751 1060918 13 1 4 7ft/2.
PAGE 200
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) ITEM # PART NUMBER QTY.
PAGE 201
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) ITEM # PART NUMBER QTY.
PAGE 202
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) ITEM # PART NUMBER QTY. 3790012 1 Ref Ref Ref 0275805 0275804 901 1 1707113 1707111 Ref 4-16 DESCRIPTION O-Ring LIGHT PANEL DECAL INSTALLATION OPTIONS: CE Spec Australian Spec REV. B B Decal - Light Panel Display Options: CE Spec Australian Spec Note: Machines should have been updated to this light panel installation.
PAGE 203
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 204
SECTION 4 PLATFORM FIGURE 4-5.
PAGE 205
SECTION 4 PLATFORM FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY (SN 0300137975 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 206
SECTION 4 PLATFORM FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY (SN 0300137975 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 207
SECTION 4 PLATFORM FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY (SN 0300137975 TO SN 0300140000) ITEM # PART NUMBER QTY. 403 404 405 4460425 2920028 2920029 1 1 1 0273484 0273485 Ref Ref Ref Not Used 4460426 1 1 0271340 Ref 4360328 3790012 1 1 0258945 Ref 4360331 3790012 1 1 1001108736 Ref 501 to 504 505 601 701 801 to 803 804 805 to 807 808 901 3121854 DESCRIPTION REV.
PAGE 208
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 209
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (SWING & LIFT) ITEM # PART NUMBER QTY.
PAGE 210
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (SWING & LIFT) (CONTINUED) ITEM # PART NUMBER QTY. 108 109 110 111 70002734 70002735 70002906 Use 1001129555 4 1 1 1 112 7022819 4460871 1 6 4-24 DESCRIPTION REV. Screw Can, Enclosure Cap Mechanical Assembly (Note: Not Available for Purchase.
PAGE 211
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (SWING & LIFT) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 212
SECTION 4 PLATFORM FIGURE 4-7.
PAGE 213
SECTION 4 PLATFORM FIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER) ITEM # PART NUMBER QTY.
PAGE 214
SECTION 4 PLATFORM FIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED) ITEM # PART NUMBER QTY. 109 Use 1001113961 4460871 1 7 7022812 70002727 Ref Ref Ref 201 202 203 204 205 206 207 208 209 210 4-28 7003972 7003973 7003980 7019167 7019164 7019165 7019196 7019166 70002729 7003982 7003983 7019194 7003989 1 2 4 4 1 1 AR 1 2 1 2 2 1 2 DESCRIPTION REV.
PAGE 215
SECTION 4 PLATFORM FIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 216
SECTION 4 PLATFORM FIGURE 4-8.
PAGE 217
SECTION 4 PLATFORM FIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3121854 PART NUMBER QTY. 0273824 0272427 0273706 Ref Ref Ref Ref 0100011 0200048 0630462 0641414 0731005 AR 2 8 8 4 1 0940134 0940103 0940133 1060341 1060903 Not Used 3311401 3311501 AR 4 3575359 3574091 4240099 4360057 Not Used 4420068 7 2 8 8 2 SOFT TOUCH SYSTEM INSTALLATIONS OPTIONS: 6Ft/1.8m Platforms 8Ft/2.4m Platforms 8Ft/2.
PAGE 218
SECTION 4 PLATFORM FIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (CONTINUED) ITEM # 4-32 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 219
SECTION 5 CYLINDER 3121854 800A 800AJ 5-1
PAGE 220
SECTION 5 CYLINDER 20 19 17 30 3 18 17 2A 5 11 2 9 7 21 22 25 12 13 1 23 8 10 4 11 14 15 16 FIGURE 5-1.
PAGE 221
SECTION 5 CYLINDER FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY ITEM # 1 1A 2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 to 29 30 3121854 PART NUMBER QTY.
PAGE 222
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 223
SECTION 5 CYLINDER FIGURE 5-2. UPRIGHT LEVEL CYLINDER ASSEMBLY ITEM # PART NUMBER 1683546 1684497 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 to 29 30 3121854 1683544 Use 0370034 1683071 3760374 3932240 3480237 0961901 4640509 2900792 4640605 2900792 2220883 2220888 0962102 Not Used Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 0100011 0100038 0100063 0630537 Not Used 2901526 QTY.
PAGE 224
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 225
SECTION 5 CYLINDER FIGURE 5-3. LIFT CYLINDER ASSEMBLY - JIB (800AJ ONLY) ITEM # 1 1A 2 3 4 5 5A 6 7 8 9 10 11 12 PART NUMBER QTY.
PAGE 226
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 227
SECTION 5 CYLINDER FIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 to 28 29 30 31 32 to 39 40 3121854 PART NUMBER QTY.
PAGE 228
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 229
SECTION 5 CYLINDER FIGURE 5-5. LIFT CYLINDER ASSEMBLY - TOWER BOOM ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 to 29 30 3121854 PART NUMBER QTY.
PAGE 230
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 231
SECTION 5 CYLINDER FIGURE 5-6. MASTER CYLINDER ASSEMBLY - 800A ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 to 29 30 3121854 PART NUMBER QTY.
PAGE 232
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 233
SECTION 5 CYLINDER FIGURE 5-7. MASTER CYLINDER ASSEMBLY - 800AJ ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 to 29 30 3121854 PART NUMBER QTY.
PAGE 234
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 235
SECTION 5 CYLINDER FIGURE 5-8. SLAVE CYLINDER ASSEMBLIES ITEM # PART NUMBER 1683610 1684408 1683677 1684228 1 2 3 4 0100011 0100038 0630535 QTY. DESCRIPTION Ref Note: Original Equipment Cylinder may have been replaced with Service Replacement Cylinder. Identify p/n stamped on cylinder before ordering parts.
PAGE 236
SECTION 5 CYLINDER FIGURE 5-8. SLAVE CYLINDER ASSEMBLIES (CONTINUED) ITEM # PART NUMBER QTY. 19 20 21 22 23 3931620 See Note See Note See Note 8 2 1 1 1 24 25 26 27 to 29 30 4567434 4566468 4640605 2900792 4640932 7011112 0100063 Not Used 1 2901556 2901301 5-18 1 1 1 1 AR DESCRIPTION REV.
PAGE 237
SECTION 5 CYLINDER FIGURE 5-8. SLAVE CYLINDER ASSEMBLIES (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 238
SECTION 5 CYLINDER FIGURE 5-9.
PAGE 239
SECTION 5 CYLINDER FIGURE 5-9. STEER CYLINDER ASSEMBLY ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 to 19 20 3121854 PART NUMBER QTY.
PAGE 240
SECTION 5 CYLINDER FIGURE 5-10.
PAGE 241
SECTION 5 CYLINDER FIGURE 5-10. TELESCOPE CYLINDER ASSEMBLY - MAIN ITEM # 1 2 3 4 5 PART NUMBER QTY.
PAGE 242
SECTION 5 CYLINDER FIGURE 5-11.
PAGE 243
SECTION 5 CYLINDER FIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY - TOWER ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32A 33 34 35 36 37 to 39 40 3121854 PART NUMBER QTY.
PAGE 244
SECTION 5 CYLINDER FIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY - TOWER (CONTINUED) ITEM # 5-26 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 245
SECTION 6 HYDRAULIC 3121854 800A 800AJ 6-1
PAGE 246
SECTION 6 HYDRAULIC 101 109 102 101 109 108 104 103 107 OSC AXLE PORT P 105 PORT #7 CASE DRAIN 106 110 102 V P FIGURE 6-1.
PAGE 247
SECTION 6 HYDRAULIC FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 101 102 103 104 105 106 107 108 109 110 3121854 PART NUMBER QTY.
PAGE 248
6-4 3 38 77 3 800A 800AJ 3 7 3 12 13 40 3 27 26 11 25 44 6 RIGHT REAR DRIVE MOTOR 10 5 6 24 40 44 41 3 REF. HYD. LOCKOUT DIA.
PAGE 249
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 3121854 PART NUMBER QTY.
PAGE 250
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332) 6-6 ITEM # PART NUMBER QTY.
PAGE 251
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 252
6-8 39 52 49 52 39 48 44 58 49 58 44 40 45 45 51 45 45 50 51 40 57 59 60 59 42 60 21 46 61 800A 800AJ 24 22 14 47 53 4 17 12 20 54 14 46 13 19 15 56 45 45 38 43 41 5 23 43 11 8 62 7 9 25 43 26 3 11 63 2 1 6 7 18 43 1 32 43 69 36 37 27 28 34 43 30 33 31 66 68 31 29 31 35 32 68 66 67 67 64 65 65 64 10 SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 253
3121854 39 52 49 52 39 48 44 58 49 58 44 40 45 45 51 45 45 50 51 40 59 60 57 59 42 60 800A 800AJ 72 21 46 61 22 14 47 53 4 17 12 20 54 14 46 13 19 15 56 45 45 38 43 41 5 23 43 11 8 62 7 9 25 43 26 3 11 63 2 1 4 70 43 1 32 43 69 27 28 34 71 43 30 33 31 66 68 31 29 31 36 37 32 68 66 67 67 35 64 65 65 64 10 SECTION 6 HYDRAULIC (SN 0300121643 TO SN 0300140000 W/SAUER DANFOSS LOAD SENSING PUMP) 6-9
PAGE 254
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000) ITEM # 1 2 3 PART NUMBER QTY.
PAGE 255
SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 256
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY. 64 65 66 67 68 69 70 71 72 2130606 2150606 2170506 2753625 2753626 2753627 2220221 2220385 2752934 5 2 2 2 2 2 1 1 1 6-12 DESCRIPTION REV.
PAGE 257
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 258
BRAKE 800A 800AJ 3 X B A 39 40 39 A B 6 3 26 27 11 25 2-SPEED VALVE REF. HYD. LOCKOUT DIA.
PAGE 259
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 3121854 PART NUMBER QTY.
PAGE 260
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332) ITEM # PART NUMBER QTY.
PAGE 261
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 262
6-18 800A 800AJ 18 68 64 19 70 78 47 30 47 78 19 51 74 51 48 20 69 20 17 77 45 30 45 17 54 71 31 72 71 66 73 54 73 46 66 72 73 41 15 59 67 65 65 67 34 13 21 3 27 55 38 11 40 27 13 21 19 19 14 24 39 12 76 16 50 19 4 6 8 7 39 33 29 25 42 2 23 18 44 23 32 75 61 5 1 10 29 55 23 62 23 6 53 61 61 56 35 28 82 82 28 53 36 37 23 26 43 30 43 28 28 49 22 22 57 60 58 23 30 52 26 9 SECTION 6 HYDRAULIC FIGUR
PAGE 263
3121854 800A 800AJ 18 68 64 19 70 78 47 30 47 78 19 51 74 51 48 20 69 20 17 77 45 30 45 17 54 71 31 72 71 66 73 54 73 46 66 72 73 41 67 65 65 67 34 13 21 3 27 55 11 40 27 13 21 19 80 19 14 24 39 12 76 16 50 19 4 6 8 7 39 33 29 25 42 2 23 18 44 23 32 75 61 3 81 10 29 55 23 62 23 53 61 61 53 28 37 23 26 43 30 43 28 28 28 36 35 56 57 60 79 58 23 30 52 26 22 49 22 9 SECTION 6 HYDRAULIC (SN 0300121643
PAGE 264
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000) ITEM # 1 2 PART NUMBER QTY.
PAGE 265
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 266
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 267
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 268
SECTION 6 HYDRAULIC FIGURE 6-6.
PAGE 269
SECTION 6 HYDRAULIC FIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 3121854 PART NUMBER QTY.
PAGE 270
SECTION 6 HYDRAULIC FIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 271
SECTION 6 HYDRAULIC FIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) (CONTINUED) ITEM # PART NUMBER 81 82 83 84 85 86 87 QTY. 2 Not Required 2753128 4100062 2220873 2220947 2221036 2220950 4 1 1 1 1 2 2220371 2220603 88 89 90 to 91 92 93 94 1 2220371 2220501 2220655 Not Used 2180724 2180380 0100019 1 1 1 AR 1 2902456 2902457 2902459 2902457 3121854 DESCRIPTION REV.
PAGE 272
6-28 800A 800AJ 2 P1 X V1 4 35 41 X V2 P1 30 85 65 V1 23 V2 P2 32 34 X X 2 31 49 Port Block on Upright Lift Cylinder X 4 70 LIFT UP V2 V1 62 LIFT DOWN 60 B BRAKE A X C V 5 SWING MOTOR X 59 23 22 1 2 71 68 66 30 72 V2 T V1 ROTATOR ACTUATOR R E PORT BLOCK ON TOWER TELE CYL.
PAGE 273
SECTION 6 HYDRAULIC FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 3121854 PART NUMBER QTY.
PAGE 274
SECTION 6 HYDRAULIC FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) ITEM # PART NUMBER QTY.
PAGE 275
SECTION 6 HYDRAULIC FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) ITEM # PART NUMBER QTY.
PAGE 276
SECTION 6 HYDRAULIC FIGURE 6-8. HYDRAULIC DIAGRAM LIST ITEM # 6-32 PART NUMBER QTY. DESCRIPTION Ref Note: Diagrams with asterisk (*) are shown in the preceding pages. Information on diagrams not shown is available from JLG Service/Parts Departments.
PAGE 277
SECTION 7 ELECTRICAL 3121854 800A 800AJ 7-1
PAGE 278
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST ITEM # 7-2 PART NUMBER QTY.
PAGE 279
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 280
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 281
SECTION 7 ELECTRICAL 3121854 800A 800AJ 7-5
PAGE 282
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM ITEM # 1 to 18 19 20 21 22 23 24 25 26 27 to 29 30 31 32 33 34 35 36 37 38 to 40 41 42 43 44 PART NUMBER QTY.
PAGE 283
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 284
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY. 202D 202E 203 4460473 4460466 2 8 1 203A Not Required 4922579 1060902 4460465 4460891 204 Not Required 4922580 4922868 1060902 204A 4460464 4460897 205 206 207 Use 4922578 4922578 4922578 39ft/11.9m 2 1 1 AR 27ft/8.2m 30ft/9.
PAGE 285
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY. 213K 213L 213M 213N 213P 213Q 213R 213S 4923613 1060978 1001097051 1001097082 4460464 4460466 1001094400 4461077 See Note 1 2ft/0.
PAGE 286
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 287
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 288
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER 441 QTY.
PAGE 289
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 290
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 291
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 292
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 293
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER 805A (cont’d) See Note QTY. 0861731 1001141967 805B 1 See Note 4461198 4461201 Use 1001100343 Use 1001100344 4461244 4461245 4461246 1001141968 1001141969 805C 1 See Note 4461198 4461201 Use 1001100343 Use 1001100344 4461244 4461245 4461246 1001141968 1001141969 805D 1 4460051 4460968 1001101191 4460968 4460662 3121854 DESCRIPTION REV.
PAGE 294
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER 805D (cont’d) 1001101191 QTY. Not Required AR 0 1001101196 1 Not Required 0 1001101197 1 805E 1 See Note 4461196 4461199 4461202 4461205 4461249 Not Required 805F 0903484 1 805G 0903697 1 805H AR 1001109654 1001109654 1001109648 1 See Note Ref 7-18 1001109475 1001109482 1 1 1001109475 1001109482 1 1 1001109477 1001109482 0861880 4460956 1 1 1 1 DESCRIPTION REV.
PAGE 295
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY. 805J 805K 805L 805M 805N 805P 4460957 1060908 1001097150 1001101191 4460709 4460710 1 12ft/3.6m 1 1 1 1 0275216 0275217 Use 1001100343 Use 1001100344 0275452 0275453 0275454 1001100341 1001100342 1001100343 1001100344 1001100345 1001100347 1001100346 806 AR 4933215 4933216 3121854 DESCRIPTION REV.
PAGE 296
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER 806 (cont’d) 4933300 QTY. 4933300 1001100027 806A 806B 806C 3990010 4922641 4460226 1 1 2 1 806D 4922482 4922970 4460027 1 806E 4460961 1 806F 4460705 4460321 4 1 806G 4460906 1001100305 4 1 806H 807 7020193 4921957 1 1 Ref 807A 807B 808 809 1060461 Not Required Not Required Not Used 6ft/1.
PAGE 297
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # PART NUMBER QTY. 810 810A 0861567 See Note Ref 2ft/.6m 810B See Note 2.5ft/.76m 810C 810D 810E Not Required 4460425 810F 811 4460426 3520189 Not Required 4933264 811A 811B 811C 811D 811E 811F 812 812A 812B 813 813A 4922757 4460374 4460375 4460967 4460465 2400060 2400064 4922641 4460226 See Note 1060341 3740049 4922643 2920140 813B 813C 813D 813E 2 AR 1 1 Ref Ref 1 2 7 1 3 1 1 1 2 1 48ft/14.
PAGE 298
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 299
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 300
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 301
SECTION 7 ELECTRICAL 208 OR 704G 704P 208 208 704F 704E 207 707B 704M 704N 704L 704J 706D 706G 704K 707A 704D 704B 2500W 704C GENERATOR 706C 706C RELAY 707 706F 706J 709J 706H 711B 7500W GENERATOR CONTROL BOX 211B 2500W GENERATOR 713G TO ALTERNATOR (CAT) 602E FUEL PUMP (CAT) 706E 547 553 DIAGNOSTIC CONNECTOR (CAT) EGR RELAY (DEUTZ) 602F ENGINE HARNESS (DEUTZ) 604B THROTTLE ACTUATOR (CAT) 602 HYDRAULIC PUMPS DRIVE ORIENTATION SWITCH 334B 334E 334B 606A 606 FUEL LEVEL SENSOR – 601A 603
PAGE 302
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM ITEM # 1 to2 3 4 to 5 6 6A 6B 6C 7 to 12 13 13A 14 14A 15 to 30 31 31A 32 to 35 36 37 38 39 40 41 to 42 43 43A 44 45 101 to 118 119 120 121 7-26 PART NUMBER QTY. 1001114448 Ref Not Used 0100048 Not Used AR 1060918 4460042 4460226 4460464 4460071 Not Used See Note AR 7ft/2.
PAGE 303
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 304
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY. 201D 4923613 1060978 1001097051 1001097082 4460466 4460464 4922576 1060896 1 2ft/0.6m 1 3 1 3 1 201E 201F 202 202A 202B 203 203A 4460865 4460465 4460509 4460466 4460473 Not Required 4922579 1060902 4460465 4460891 204 204A 205 206 207 Not Required 4922868 1060902 4460464 4460897 4922578 4922578 44ft/13.4m 2 22 8 8 2 1 39ft/11.9m 2 1 1 30ft/9.
PAGE 305
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 306
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 307
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 308
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 309
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 310
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY. Continued 1001100328 Ref 1001100329 Ref 1001100331 Ref 1001100333 Ref 1001100337 Ref 1001109558 Ref 1 704A 0860038 0861781 See Note 0861731 1001141967 704B 1 See Note 4461198 4461201 Use 1001100343 Use 1001100344 4461244 4461245 4461246 1001141968 1001141969 704C 1 See Note 4461198 4461201 Use 1001100343 Use 1001100344 4461244 4461245 4461246 7-34 DESCRIPTION REV.
PAGE 311
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER 704C (cont’d) 1001141968 QTY. 1 4460051 4460968 1001101191 4460968 4460662 1001101191 704E 704F 704G Not Required AR 0 1001101196 1 Not Required 0 1001101197 1 4460709 4460710 1 1 1 See Note 4461196 4461199 4461202 4461205 4461249 Not Required 704H 0903484 1 704J 0903697 1 704K 3121854 REV.
PAGE 312
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER 704K (cont’d) 1001109654 QTY. 1 See Note Ref 1001109475 1001109482 1 1 1001109475 1001109482 1 1 1001109477 1001109482 0861880 4460956 4460957 1060908 1001097150 1001101191 1 1 1 1 1 12ft/3.6m 1 1 0275216 0275217 Use 1001100343 Use 1001100344 0275452 0275453 0275454 1001100341 1001100342 7-36 REV.
PAGE 313
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 314
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER QTY. 710B 710C 710D 710E See Note Not Required 4460425 2.5ft/.
PAGE 315
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # PART NUMBER 714B QTY. 1 4460425 4460049 4460226 2 801 802 7002821 7002823 Ref 1 1 803 4460467 1 4460510 1 7002828 1600244 1060633 4460321 4460226 1 1 1 2 8 714C 804 805 805A 805B 3121854 DESCRIPTION REV.
PAGE 316
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM (CONTINUED) ITEM # 7-40 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 317
SECTION 8 DECALS 3121854 800A 800AJ 8-1
PAGE 318
8-2 800A 800AJ 31 44 30 15 9 48 31 4 9 13 48 12 7 34 26 22 20 24 21 23 44 11 8 205 1 206 5 11 10 12 4 27 24 25 35 SN 0300069205 TO SN 0300078346 101 23 27 4 32 4 24 24 25 101 23 40 203 17 16 18 26 7 SN 0300069000 TO SN 0300069205 29 14 23 2 4 31 30 13 36 44 SECTION 8 DECALS FIGURE 8-1.
PAGE 319
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (SN 0300069000 TO SN 0300078346) ITEM # PART NUMBER QTY.
PAGE 320
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (SN 0300069000 TO SN 0300078346) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 321
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (SN 0300069000 TO SN 0300078346) (CONTINUED) ITEM # PART NUMBER 40 (cont’d) 1705240 Use 1705977 Not Used 4420051 Not Used 1704885 41 to 43 44 44 to 47 48 101 201 to 202 203 204 205 206 207 to 224 3121854 QTY. REV. Norwegian Spec Spanish Spec (was p/n 1702266) 23.
PAGE 322
8-6 800A 800AJ 31 44 30 15 9 48 31 4 9 13 48 12 7 34 26 22 20 24 21 23 3 32 44 11 205 1 206 5 11 10 12 3 4 27 24 101 23 27 3 4 25 35 4 24 4 29 14 2 4 47 24 25 40 203 17 16 18 26 7 8 31 30 13 36 44 SECTION 8 DECALS FIGURE 8-2.
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SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (SN 0300078346 TO SN 0300089982) ITEM # 1 2 3 4 5 to 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 to 29 30 31 32 33 34 3121854 PART NUMBER QTY.
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SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (SN 0300078346 TO SN 0300089982) (CONTINUED) ITEM # PART NUMBER QTY. 35 36 37 to 39 40 41 to 43 44 45 46 47 1703960 1701505 Not Used 1705977 Not Used 4420051 1703175 1702962 4 1 Decal - Max.
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SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (SN 0300078346 TO SN 0300089982) (CONTINUED) ITEM # 3121854 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
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8-10 800A 800AJ 23 38 45 35 23 11 32 24 24 23 31 35 36 30 43 44 45 9 8 2 39 25 23 33 205 21 206 23 46 9 8 24 23 7 29 101 5 42 23 24 23 24 31 41 8 44 37 203 2 8 34 32 52 22 CE SPEC SPEC 22 AUSTRALIAN SN 0300089982 TO SN 0300138365 SPEC 57 AUSTRALIAN SN 0300138365 TO SN 0300140000 4 3 10 AUSTRALIAN SPEC SN 0300138365 TO SN 0300140000 ONLY 22 55 7 29 38 49 SECTION 8 DECALS FIGURE 8-3.
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SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (SN 0300089982 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 to 20 21 22 23 24 25 26 to 28 29 30 31 32 33 34 35 36 37 38 39 40 to 41 42 43 44 45 46 3121854 PART NUMBER QTY.
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SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
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SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODEL 800A/800AJ The following list will service one machine (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
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SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODEL 800A/800AJ The following list will service one machine (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
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SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # PART NUMBER QTY. Ref 3121854 DESCRIPTION REV.
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SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # PART NUMBER QTY.
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SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # PART NUMBER QTY.
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SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # 10-4 PART NUMBER QTY.
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SECTION 11 PART NUMBER INDEX Part Number 0060031 0060041 0060066 0060069 0060077 0080163 0080181 0080241 0080243 0100009 0100011 0100019 0100020 0100035 0100038 0100040 0100048 0100063 0100079 0100081 0140001 0140011 0140032 0181727 0200048 0200742 0200819 3121854 Page ................ 3-7, 3-19 ................ 3-4, 3-19 ................ 3-7, 3-23 ................ 3-3, 3-23 ................ 3-4, 3-19 .............. 2-54, 2-63 .............. 2-30, 2-40 ....................... 2-99 ..............
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SECTION 11 Part Number 0274598 0274625 0274640 0274641 0274642 0274643 0274661 0274759 0274883 0275216 0275217 0275218 0275219 0275452 0275453 0275454 0275733 0275804 0275805 0340041 0340046 0360406 0362609 0362610 0362726 0362770 0362772 0370022 0370034 0400075 0440244 0480120 0480121 0561185 0561237 0561295 0630427 0630462 0630464 0630491 0630498 0630507 0630518 0630534 0630535 0630536 0630537 0630548 0630568 0641403 0641404 0641406 0641407 11-2 PART NUMBER INDEX Page ....................... 10-2 ..
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SECTION 11 Part Number 0903697 0920117 0920119 0940049 0940070 Page .............. 7-18, 7-35 ......................... 1-9 ......................... 1-9 ..................... 2-108 2-30, 2-40, 2-51, 261 0940071 .....2-103, 2-104, 2107, 2-108 0940088 ..................... 2-108 0940103 ....................... 4-31 0940133 ....................... 4-31 0940134 ....................... 4-31 0961816 ......................... 5-3 0961845 ......................... 4-4 0961893 .........................
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SECTION 11 Part Number 1001112570 1001112586 1001112587 1001112589 1001112592 1001112612 1001112743 1001112762 1001112849 1001113961 1001114033 1001114373 1001114374 1001114446 1001114448 1001115389 1001115400 1001115409 1001115410 1001115413 1001115414 1001116287 1001116288 1001116595 1001117320 1001118416 1001118417 1001119563 1001129555 1001131992 1001137005 1001137261 1001137460 1001137672 1001139132 1001139944 1001141967 1001141968 1001141969 1001142504 1001142505 1001143187 1001143188 1001143191 1001
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SECTION 11 Part Number 1702567 1702676 1702773 1702774 1702788 1702860 1702861 1702862 1702938 1702962 1703162 1703467 1703468 1703479 1703518 1703772 1703773 1703799 1703800 1703806 1703807 1703811 1703814 1703913 1703914 1703915 1703916 1703917 1703918 1703919 1703920 1703959 1703960 1703992 1704097 1704105 1704260 1704277 1704412 1704578 1704833 1704885 1704997 1705084 1705090 1705132 1705170 1705240 1705254 1705255 1705275 1705325 1705753 1705822 1705828 1705921 1705961 1705977 3121854 Page ........
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SECTION 11 Part Number 2220888 2220893 2220923 2220940 2220947 2220950 2220999 2221029 2221030 2221036 2221176 2300004 2300014 2300016 2300021 2300027 2300029 2300040 2360591 2360601 2360603 2360639 2360641 2360643 2360645 2360647 2360709 2400060 2400064 2400065 2400066 2400068 2400070 2410014 2420172 2420203 2460013 2460032 2460039 2460049 2460055 2460056 2460057 2560136 2580055 2600209 2600219 2600233 2600244 2600281 2600287 2680436 2680437 2680448 2680450 2680451 2720058 11-6 PART NUMBER INDEX Page
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SECTION 11 Part Number 2901514 2901526 2901537 2901549 2901556 2901609 2901712 2902065 2902300 2902303 2902329 2902353 2902396 2902401 2902443 2902456 2902457 2902459 2902533 2910467 2910872 2910925 2910926 2910948 2915014 2915139 2920028 2920029 2920095 2920110 2920113 2920129 2920140 2920162 2920215 2940074 2940088 2940188 3020008 3020016 3020021 3160204 3160266 3160286 3160294 3160308 3160347 3160348 3200362 3200406 3220103 3220104 3220113 3250872 3251102 3251242 3121854 Page ........................
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SECTION 11 Part Number 3570690 3570775 3570928 3570979 3571712 3572604 3572605 3572606 3572607 3573001 3574091 3574206 3574207 3574208 3574684 3574696 3574978 3575359 3575718 3580134 3580158 3580276 3580322 3600278 3600287 3600295 3600400 3600401 3600458 3620033 3620047 3641569 3740049 3740067 3740080 3760133 3760170 3760367 3760368 3760369 3760370 3760374 3790012 3790044 3790110 3820001 3820020 3841143 11-8 PART NUMBER INDEX Page .............. 1-31, 1-34 ....................... 5-23 ................
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SECTION 11 Part Number Page 20, 4-31 4460267 7-10, 7-16, 7-29, 733 4460268 2-99, 7-10, 7-12, 715, 7-16, 7-29, 7-30, 7-31, 7-33 4460320 7-10, 7-16, 7-29, 733 4460321 .....7-20, 7-22, 7-39 4460326 7-10, 7-16, 7-29, 733 4460339 ....................... 7-13 4460374 7-13, 7-21, 7-31, 737, 7-38 4460375 7-13, 7-21, 7-31, 738 4460418 7-6, 7-11, 7-27, 7-29 4460419 7-6, 7-11, 7-27, 7-29 4460424 . 2-99, 7-9, 7-10, 712, 7-16, 7-29, 7-30, 7-33 4460425 4-15, 4-21, 4-31, 721, 7-22, 7-38, 7-39 4460426 .
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SECTION 11 Part Number 4711800 4711900 4740036 4740057 4740076 4740111 4740119 4740155 4740171 4740256 4740274 4740362 4740397 4740411 4740439 4740444 4740463 4740472 4740473 4740500 4751000 4751400 4751500 4751600 4751700 4751800 4751900 4752000 4761000 4761400 4761600 4762000 4770600 11-10 PART NUMBER INDEX Page 2-113, 3-4, 3-9, 4-11 .............. 2-53, 2-62 ....................... 1-38 ....................... 2-17 .......... 2-103, 2-108 ................ 1-5, 1-37 ..................... 2-113 .
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SECTION 11 Part Number 70000797 70000800 70000912 70000913 70000914 70000915 70000916 70000917 70000918 70000919 70000934 70000970 70000976 70001002 70001017 70001051 70001059 70001060 70001061 70001062 70001063 70001064 70001065 70001066 70001067 70001068 70001069 70001120 70001126 70001132 70001248 70001249 70001423 70001435 70001498 70001681 70001697 70001742 70001835 70001836 70001837 70001838 70001839 70001841 70001847 70001848 70001850 70001866 70001868 70001870 70001872 70001874 70001941 70001976 70
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SECTION 11 Part Number 7004047 7004049 7004275 7004276 7006137 7007208 7007412 7007413 7007414 7007417 7007419 7007420 7007423 7007425 7007435 7007437 7007438 7007439 7007441 7007442 7007446 7007452 7007453 7007454 7007457 7007463 7007464 7007465 7007466 7007470 7007472 7007474 7007475 7007478 7007483 7007484 7007485 7007487 7007488 7007494 7007496 7007497 7007498 7007633 7007990 7010116 7010122 7010404 7010405 7010406 7010461 7010464 7010474 7010492 7010542 7010543 7010545 7010795 7010903 11-12 PART NUM
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SECTION 11 Part Number 7018912 7018941 7018942 7018945 7018946 7018947 7018948 7018951 7018991 7018992 7018993 7018994 7018995 7019103 7019110 7019111 7019112 7019114 7019115 7019122 7019123 7019141 7019142 7019143 7019144 7019145 7019147 7019149 7019150 7019151 7019154 7019155 7019160 7019161 7019162 7019164 7019165 7019166 7019167 7019168 7019171 7019174 7019177 7019194 7019196 7019197 7019658 7019680 7020020 7020021 7020064 7020065 7020066 7020067 7020108 7020109 7020110 7020111 7020168 3121854 Page
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SECTION 11 Part Number 7024717 7024718 7024762 7024763 7024781 7024782 7024783 7024784 7024828 7024854 7024861 7024862 7024865 7024867 7024868 7024870 7024871 7024881 7024918 7024930 7026189 7026197 7026199 7026503 7026504 7026505 7026506 7026507 7026508 7026509 7026510 7026511 7026512 7026522 7026607 7026608 7026631 7026800 7026801 7026802 7026803 7026804 7026805 7026806 7026807 7026808 7026809 7026810 7026811 7026812 7026813 7026814 7026815 7026816 7026817 7026818 7026819 7026820 7026821 11-14 PART NUM
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3121854 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.