Parts Manual User guide

ManualsBrandsJLG ManualsSpecial machinery800A_AJ

Illustrated Parts Manual

Models

800A

800AJ

SN 0300140000 to

SN 0300183033 &

SN B300000100 to Present

P/N

3121271

April 30, 2014

Summary of content (298 pages)

PAGE 1
Illustrated Parts Manual Models 800A 800AJ SN 0300140000 to SN 0300183033 & SN B300000100 to Present P/N 3121271 April 30, 2014
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PAGE 3
REVISION LOG NOTE: The 800A & 800AJ Boom Lifts are manufactured by JLG Industries in the following countries: USA and China. Refer to the Serial Number Tag to identify the country of manufacture. The country of manufacture may be determined by the Serial Number. Machines manufactured in the USA will have a serial number prefix of 03 (i.e. 03XXXXXXXX). Machines manufactured in the China will have a serial number prefix of B3 (i.e. B3XXXXXXXX).
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REVISION LOG B 800A 800AJ 3121271
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 AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE AND WHEEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 UPRIGHT LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LIFT CYLINDER ASSEMBLY - JIB (800AJ ONLY) . . . . . . . . . . . . . . .
PAGE 7
SECTION 1 FRAME 3121271 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 QTY.
PAGE 12
SECTION 1 FRAME 207 101 103 114 109 101 104 115 107 110 204 202 203 205 206 201 301 302 303 FIGURE 1-2.
PAGE 13
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS ITEM # PART NUMBER QTY. DESCRIPTION 0273378 0273704 0274232 Ref Ref Ref Ref Ref WHEEL DRIVE INSTALLATION 2WD/2WS 4WD/2WS 4WD/4WS Note: Qty Shown is for 2WS Machines. Double Qty Required for 4WS Machines.
PAGE 14
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED) ITEM # PART NUMBER 201 QTY. 1 1702701 1702739 202 203 204 205 206 207 301 302 303 1-8 1 4520252 4520253 1001097408 4640113 1 1 4860224 1001097407 4860225 1120552 1300019 1705364 1 AR 1 0256196 Ref 1670776 0641550 0100011 4 20 AR DESCRIPTION REV. Decal Options: 95 PSI (15-625 Tires) 85 PSI (18-22.5 Tires) Tire Options: 15-625 18.625 18.22.5 Valve, Air Rim, Wheel Options: 13 x 24.5 14 x 22.5 15 x 24.
PAGE 15
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 16
SECTION 1 FRAME FIGURE 1-3.
PAGE 17
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 18
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 19
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY. 127 128 7024193 7024197 1 1 3121271 DESCRIPTION REV.
PAGE 20
SECTION 1 FRAME FIGURE 1-4.
PAGE 21
SECTION 1 FRAME FIGURE 1-4. DRIVE MOTOR ASSEMBLY ITEM # 1 2 3 4 5 6 7 7A PART NUMBER QTY.
PAGE 22
SECTION 1 FRAME FIGURE 1-4. DRIVE MOTOR ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY. 25 26 27 28 29 2220883 Use 7022328 2220888 Use 7022328 1 1 2 2 1 30 31 32 33 34 35 36 37 38 39 40 41 42 to 49 50 1-16 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 23
SECTION 1 FRAME FIGURE 1-4. DRIVE MOTOR ASSEMBLY (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 24
SECTION 1 FRAME FIGURE 1-5.
PAGE 25
SECTION 1 FRAME FIGURE 1-5. DRIVE VALVES & SHIELDS INSTALLATIONS ITEM # 1 2 3 to 10 11 12 12A 12B 12C 12D 13 101 102 103 to 109 110 111 111A 111B 111C 111D 111E 111F 111G 112 PART NUMBER QTY.
PAGE 26
SECTION 1 FRAME FIGURE 1-6.
PAGE 27
SECTION 1 FRAME FIGURE 1-6. TOW PACKAGE INSTALLATION (2WS ONLY) (ANSI, ANSI EXPORT & CE) ITEM # 1 to 100 101 102 103 104 105 106 PART NUMBER QTY. 0271352 Ref Not Used 0100011 0362726 0641508 0641608 0962152 AR 1 1 7 2 4 0962448 1001112651 107 108 109 0962292 0962348 2 1 2 1683740 1001097243 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 201 3121271 DESCRIPTION STEERING INSTALLATION REV.
PAGE 28
SECTION 1 FRAME FIGURE 1-6. TOW PACKAGE INSTALLATION (2WS ONLY) (ANSI, ANSI EXPORT & CE) ITEM # PART NUMBER QTY. DESCRIPTION 202 203 204 205 0232121 0641504 1260017 1 2 2ft/0.
PAGE 29
SECTION 2 TURNTABLE 3121271 800A 800AJ 2-1
PAGE 30
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS 6 18 NOTE: ALSO SEE SECTIONS 1 & 3 FOR VALVES LOCATED ON FRAME, BOOM & UPRIGHT.
PAGE 31
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 12A 12B 13 PART NUMBER QTY.
PAGE 32
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS (CONTINUED) ITEM # PART NUMBER 23 AR Not Required 4921928 0 1 0258670 1001143190 Ref Ref Ref Ref 101 102 103 104 105 106 107 2-4 QTY. 1 Use 1001137460 1001137460 0902415 0641610 4751600 0641506 4711500 0100011 1 1 1 3 3 4 4 AR 2901207 1 DESCRIPTION REV.
PAGE 33
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 34
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 35
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 22 23 23A 23B 3121271 PART NUMBER QTY.
PAGE 36
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 37
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 38
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 39
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 3121271 DESCRIPTION REV.
PAGE 40
SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 41
SECTION 2 TURNTABLE FIGURE 2-4. AUXILIARY PUMP ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 42
SECTION 2 TURNTABLE FIGURE 2-4. AUXILIARY PUMP ASSEMBLY (CONTINUED) ITEM # 101 102 103 104 105 106 107 108 109 110 111 2-14 PART NUMBER QTY. 1001137460 Ref 70004125 70003993 70004125 70004125 70004125 70004125 70004125 70004125 70003989 70004125 70004125 70003992 1 1 4 1 1 1 1 4 1 1 1 1 DESCRIPTION AUXILIARY PUMP ASSEMBLY (BUCHER BRAND) (SERVICE REPLACEMENT) REV.
PAGE 43
SECTION 2 TURNTABLE FIGURE 2-4. AUXILIARY PUMP ASSEMBLY (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 44
SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 45
SECTION 2 TURNTABLE FIGURE 2-5. TURNTABLE BEARING AND SWING DRIVE INSTALLATION ITEM # 1 2 3 4 5 6 7 8 101 102 103 104 105 201 202 203 204 301 302 303 304 305 3121271 PART NUMBER QTY.
PAGE 46
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 47
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 3121271 800A 800AJ 2-19
PAGE 48
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY 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 29 2-20 PART NUMBER QTY.
PAGE 49
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 50
2-22 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 32 301 414 304 317 334 412 70 70 62 18 3 20 16 1 66 30 34 45 26 40 60 37 59 44 424 417 416 301 305 418 314 318 421 12 62 42 326 36 323 425 413 301 304 428 317 301 309 313 316 324 325 332 302 44 328 304 68 317 301 307 434 316 324 404 406 3 65 301 21 37 301 311
PAGE 51
3121271 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 50
PAGE 52
SECTION 2 TURNTABLE FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION 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 2-24 PART NUMBER QTY.
PAGE 53
SECTION 2 TURNTABLE FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 54
SECTION 2 TURNTABLE FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 105 106 107 108 109 110 111 112 113 0641808 0642010 1320022 1320176 1701505 2180348 2220313 2221176 1 1 7 1 1 1 1 1 2.6gal. 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 to 149 2300004 2300041 2720058 2750532 3422446 3460544 3841143 3841340 4711600 4752000 Not Used 0641508 3311505 3380429 3539957 3900272 Not Used 30ft/9.1m 6ft./1.
PAGE 55
SECTION 2 TURNTABLE FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 208 209 210 211 212 213 214 215 215A 215B 215C 215D 1001095354 2220415 1001094595 7023967 7023956 3790044 3960548 3960549 4751400 4891600 Not Used 1001112762 7027028 7027029 7027030 7027031 1 1 1 1 1 1 44in/1.
PAGE 56
SECTION 2 TURNTABLE FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 57
SECTION 2 TURNTABLE FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 58
2-30 800A 800AJ 209 256 237 201 259 215 237 262 256 256 209 256 38 223 111 243 208 254 238 256 209 232 211 265 235 254 238 256 209 241 232 412 401 247 255 237 256 409 411 225 227 212 201 226 256 237 256 237 240 205 226 239 402 227 209 256 215 224 259 201 233 237 211 249 223 204 254 210 238 37 36 219 13 301 351 405 228 222 303 353 242 19 260 101 103 302 352 245 305 259 304 101 117 112 112 110 114 101 103 108 201 215 115 236 206 213
PAGE 59
3121271 6 800A 800AJ 11 21D 21C 4 263 21A 102 104 106 22 BATTERY + 266 25 248 217 26 263 GRD. 21B 7 248 LOCATED ON TURNTABLE 107 246 421 AUX.PWR. START RELAY RELAY 201 216 21 218 5 GLOW PLUG RELAY STARTER 33 GLOW PLUGS ON ENGINE 257 GRD.
PAGE 60
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21A 21B 2-32 PART NUMBER QTY. DESCRIPTION REV.
PAGE 61
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 62
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # 101 102 103 103 104 105 106 107 108 PART NUMBER QTY.
PAGE 63
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 111 112 112 113 3960389 4891800 4891600 1001137898 5ft/1.5m AR AR 1 114 1001137899 1 115 4891600 7 116 0641814 2 117 0711025 4 118 0791608 3 119 3311605 3 1001098508 Ref Ref Ref 1001098508 Ref 1001099640 Ref 1001099640 Ref 1001137738 Ref Ref 1001137741 Ref 1001144320 Ref 0100011 Not Used 0340041 AR 201 202 to 203 204 3121271 2 DESCRIPTION REV.
PAGE 64
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER 249 QTY.
PAGE 66
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION REV. 1001153282 NLA KIT PUMP COUPLING AND MOUNTING PLATE (SN 0300174937 TO SN 030183033) (NOTE: PURCHASE P/N 1001162546 KIT) (NOT SHOWN) D 351 352 70004183 1 NSS 353 See Note 8 354 See Note 12 Coupling, Guardian Plate, Pump Adapter (Note: Not Available - Purchase Kit p/n 1001162546) Bolt M10 x 20mm Grade 10.9 (Note: Not Available - Purchase Locally) Bolt M10 x 25mm Grade 10.
PAGE 67
SECTION 2 TURNTABLE FIGURE 2-8. DEUTZ ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 68
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION 205 217 220 247 232 208 240 258 251 233 251 244 217 225 216 226 216 216 256 221 112 215 235 219 204 205 250 232 216 201 228 215 227 237 216 215 (NOT SHOWN) 203 203A 245 210 248 203C 212 254 248 233 223 43 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR DETAILED ENGINE BREAKDOWN.
PAGE 69
SECTION 2 TURNTABLE 2 18 42 12 TO LP FUEL SHUT-OFF 20 2 17 2 16 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR PART NUMBER. RETURN ON FUEL TANK 26 35 26 8 38 32 11 36 1 7 42 12 FITTING LOCATED IN BOTTOM OF FUEL TANK 23 1 6 38 27 24 35 TO ENGINE 22 22 31 21 25 36 203B 5 13 35 5 12 42 12 34 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR PART NUMBER.
PAGE 70
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NUMBER QTY.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 36 37 38 39 40 41 42 4711500 4751500 4751600 4752000 88521205 91401281 4 2 4 1 2 1 68in/1.
PAGE 72
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION (CONTINUED) ITEM # 101 102 103 104 105 106 106A 106B 106C 106D 106E 107 108 109 110 PART NUMBER QTY. 1001114637 Ref 0100011 0641407 0641808 0641812 1060637 2902533 7027018 7027015 7027017 7016824 7016825 3311405 3311805 3422532 AR 1 1 4 1 1 1 1 1 1 1 1 1 1 1 3600400 1001153622 3600400 1001153622 111 112 113 114 115 116 3790044 3960389 4751400 4751800 4891800 1001095354 2220415 1001094595 7023967 7023956 1 5ft/1.
PAGE 73
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 74
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 249 250 251 252 253 254 255 256 257 258 259 4740274 4751400 4751600 4751800 4791400 4831900 4920385 2180877 0641826 2720271 0100062 4 8 16 4 2 4 10ft/3m 1 2 2-46 18in/46cm AR DESCRIPTION REV.
PAGE 75
SECTION 2 TURNTABLE FIGURE 2-9. GM ENGINE INSTALLATION (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 76
2-48 800A 800AJ 1203 1201A 1201 2001 802 1502 806 805 1509 1204 1508 1511 1510 1103 141 1503 165 106 155 142 111 106 165 604 1002 1003 1001 2005 1104 304 1220 1401 110 603 605 110 105 104 103 101 102 166 166 115 1404 902 114 158 909 910 911 919 1403 906 2003 107 140 2002 168 918 916 167 916 918 168 119 121 2006 2008 118 137 501 120 2007 150 129 OR 107 907 905 908 123 108 160 401 111 130 127 201 126 135 136 138 134 133 132 1525A 1
PAGE 77
SECTION 2 TURNTABLE FIGURE 2-10. PISTON PUMP ASSEMBLY (SAUER DANFOSS) 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 3121271 PART NUMBER QTY.
PAGE 78
SECTION 2 TURNTABLE FIGURE 2-10. PISTON PUMP ASSEMBLY (SAUER DANFOSS) ITEM # PART NUMBER QTY.
PAGE 79
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 80
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 81
SECTION 2 TURNTABLE FIGURE 2-11. PISTON PUMP ASSEMBLY (EATON) 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 to 36 37 38 39 40 to 42 43 44 to 45 46 47 48 49 50 51 52 3121271 PART NUMBER QTY.
PAGE 82
SECTION 2 TURNTABLE FIGURE 2-11. PISTON PUMP ASSEMBLY (EATON) ITEM # PART NUMBER QTY.
PAGE 83
SECTION 2 TURNTABLE FIGURE 2-11. PISTON PUMP ASSEMBLY (EATON) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 84
SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 85
SECTION 2 TURNTABLE FIGURE 2-12. TANK INSTALLATIONS ITEM # PART NUMBER 0258382 0270396 1001116342 1 2 QTY.
PAGE 86
SECTION 2 TURNTABLE FIGURE 2-12. TANK INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY. 27 28 29 30 4751800 0100062 0641818 1001118133 2 AR 2 2 4400452 Ref Ref 1001161901 Ref 7024481 Not Required 7024441 7024443 7024445 7024444 7024446 7024442 Not Required 7024439 Not Available 7024440 Not Available 1 0 1 1 1 1 1 1 0 1 1 1 1 101 101 102 103 103 104 105 106 106 107 107 108 108 Ref 201 1 7016314 70001103 70002716 70002716 1120487 2-58 DESCRIPTION REV.
PAGE 87
SECTION 2 TURNTABLE FIGURE 2-12. TANK INSTALLATIONS (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 88
SECTION 2 TURNTABLE FIGURE 2-13.
PAGE 89
SECTION 2 TURNTABLE FIGURE 2-13. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 PART NUMBER QTY. 0255524 Ref 1320220 1320127 2720144 0100020 2221197 2180125 2220261 2180388 2180389 2220418 2180387 0641606 4751600 2180418 Not Used 1320218 3910808 4750800 3310805 0181949 2221024 0362519 2 2 2 AR 1 1 2 1 1 1 2 8 8 2 4400275 4400420 3121271 2 2 4 2 2 2 4 1 DESCRIPTION LP TANK AND BRACKETS INSTALLATION REV.
PAGE 90
SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 91
SECTION 2 TURNTABLE FIGURE 2-14. ROTARY COUPLING INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 PART NUMBER QTY.
PAGE 92
SECTION 2 TURNTABLE FIGURE 2-14. ROTARY COUPLING INSTALLATION (CONTINUED) 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 2-64 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 93
SECTION 2 TURNTABLE FIGURE 2-14. ROTARY COUPLING INSTALLATION (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 94
SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 95
SECTION 2 TURNTABLE FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 96
SECTION 2 TURNTABLE FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 97
SECTION 2 TURNTABLE FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 98
SECTION 2 TURNTABLE 51 68 OR 52 61 57 60 58 56 2 4 3 5 1 55 53 54 51 29 68 25 28 15 17 18 52 16A 11 14 16 27 53 26 30 FIGURE 2-16.
PAGE 99
SECTION 2 TURNTABLE FIGURE 2-16. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # PART NUMBER QTY. Ref 1 2 3 4 5 6 to 10 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 11 12 to 13 14 15 16 0630491 0080241 Not Used 0100011 4240032 Use 0272507 1 1 1 AR 1 1 1 7016380 70001941 16A 17 18 19 to 24 3121271 1 4060907 2920215 4460234 0100048 Not Used 1 AR DESCRIPTION REV.
PAGE 100
SECTION 2 TURNTABLE FIGURE 2-16. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # PART NUMBER QTY. DESCRIPTION REV. 1001150406 Ref STROBE LIGHT INSTALLATION (AMBER) (OPTIONAL) (USA BUILT MACHINES SN 0300171629 TO PRESENT& CHINA BUILT MACHINES SN B300000766 TO PRESENT) Note: If machine is equipped with BLUE Strobe Light, see Section 10 SkyGuard Kit.
PAGE 101
SECTION 2 TURNTABLE FIGURE 2-16. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 102
2-74 800A 800AJ 221 44 24 1 4 203 209 218 219 224 202 6 35 214 215 216 212 1 6 11 17 26 45 46 49 46 27 301 305 34 31 23 47 43 16 25 220 1 6 217 224 204 46 209 51 213 7 8 46 27 46 26 17 1 11 18 213 201 223 205 207 206 210 208 209 21 211 222 20 45 306 307 308 30 45 5 2 1 46 7 13 6 5 1 6 12 45 25 5 22 45 45 25 46 42 46 41 1 27 20B 6 1 46 6 40 28 40 41 10 20A 33 1 17 26 46 1 3 42 23 47 51 103 43 8 14 39 45 25 50 42 46 38 37 36 46 39 27 28 111 42 6 23 4
PAGE 103
SECTION 2 TURNTABLE FIGURE 2-17. HOODS INSTALLATION (ABS) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20A 20B 21 PART NUMBER QTY. 0274759 1001099137 0275546 Ref Ref Ref Ref 0100011 0362770 0630507 0641406 0641506 0641508 0641608 0641609 0721006 0902143 0902161 0902219 0902223 0902351 0902412 0902426 0902491 0940071 1670842 1671228 1671233 3960453 0903308 AR 1 8 4 AR AR 22 5 6 1 1 2 1 1 1 1 1 4 1 1 Ref 1 68in/1.
PAGE 104
SECTION 2 TURNTABLE FIGURE 2-17. HOODS INSTALLATION (ABS) (CONTINUED) ITEM # PART NUMBER QTY. 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 3960389 3960470 4070410 4070411 4070412 4160139 4160143 4740076 4740171 4751000 4751400 4751500 4751600 4761000 Not Used 3321501 1120601 2940188 0940049 3311501 3.
PAGE 105
SECTION 2 TURNTABLE FIGURE 2-17. HOODS INSTALLATION (ABS) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 106
2-78 800A 800AJ 58 60 33 1 7 57 7 33 33 30 1 7 19 32 22 19 48 50 10 17 1 6 33 1 4 31 11 51 212 206 210 1 29 19 1 29 32 208 202 207 35 59 19 32 10 42 54 39 14 22 33 34 33 1 26 9 3 28 59 33 23 15 23 33 1 26 30 49 56 55 23 1 16 204 205 208 44 36 25 33 20 34 201 206 209 210 210 203 211 22 210 201 209 24 34 33 15 2 SECTION 2 TURNTABLE FIGURE 2-18.
PAGE 107
3121271 800A 800AJ 108 41 1 26 33 2 33 1 26 104 40 28 59 15 101 109 110 45 111 103 105 101 109 110 52 33 106 110 14 33 26 23 34 22 33 33 1 26 59 27 37 26 33 34 22 23 15 61 4 18 31 3 34 53 38 9 59 35 108 107 102 17 1 29 112 31 11 33 1 29 1 4 43 106 110 1 6 301 305 306 307 308 31 18 4 47 22 33 46 5 32 33 21 12 7 33 22 SECTION 2 TURNTABLE 2-79
PAGE 108
SECTION 2 TURNTABLE FIGURE 2-18. HOODS INSTALLATION (STEEL) 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 2-80 PART NUMBER QTY.
PAGE 109
SECTION 2 TURNTABLE FIGURE 2-18. HOODS INSTALLATION (STEEL) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 110
SECTION 2 TURNTABLE FIGURE 2-18. HOODS INSTALLATION (STEEL) (CONTINUED) ITEM # PART NUMBER QTY. 203 204 205 206 207 208 209 210 211 212 0700616 2560187 3290601 3311505 3340877 3900210 3900363 4711500 1001116290 1001116292 1 1 1 15 4 15 2 17 1 4 0256823 Ref 2820078 Not Used 3539955 0641506 4751500 0100011 1 1 2 2 AR 1001114636 1001114638 Ref Ref Ref 3311405 4751400 0641408 1001120508 3 3 3 1 301 302 to 304 305 306 307 308 401 402 403 404 2-82 DESCRIPTION REV.
PAGE 111
SECTION 2 TURNTABLE FIGURE 2-18. HOODS INSTALLATION (STEEL) (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 112
SECTION 2 TURNTABLE FIGURE 2-19.
PAGE 113
SECTION 2 TURNTABLE FIGURE 2-19. ENGINE TRAY JACK INSTALLATION (OPTIONAL) ITEM # 1 2 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3121271 PART NUMBER QTY.
PAGE 114
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 115
SECTION 2 TURNTABLE FIGURE 2-20. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # 1 2 PART NUMBER QTY.
PAGE 116
SECTION 2 TURNTABLE FIGURE 2-20. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # PART NUMBER QTY.
PAGE 117
SECTION 2 TURNTABLE FIGURE 2-20. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. 110 111 112 113 114 4750800 4760600 1001094375 1001094509 4460018 1 2 1 1 1 3121271 DESCRIPTION REV.
PAGE 118
SECTION 2 TURNTABLE FIGURE 2-21.
PAGE 119
SECTION 2 TURNTABLE FIGURE 2-21. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # 1 2 PART NUMBER QTY.
PAGE 120
SECTION 2 TURNTABLE FIGURE 2-21. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER QTY.
PAGE 121
SECTION 2 TURNTABLE FIGURE 2-21. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 122
SECTION 2 TURNTABLE FIGURE 2-22.
PAGE 123
SECTION 2 TURNTABLE FIGURE 2-22. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # PART NUMBER QTY.
PAGE 124
SECTION 2 TURNTABLE FIGURE 2-22. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. 25 26 27 28 29 4740397 4751000 4751500 4811900 4891600 1 2 4 1 1 1001094475 Ref Not Used 0720808 2420165 3310601 3310805 3910608 4240032 4420060 4460234 4750800 4760600 1001094375 1001094509 4460018 1 1 2 1 2 4 3in/7cm 3 1 2 1 1 1 101 102 103 104 105 106 107 108 109 110 111 112 113 114 2-96 DESCRIPTION REV.
PAGE 125
SECTION 2 TURNTABLE FIGURE 2-22. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 126
SECTION 2 TURNTABLE FIGURE 2-23.
PAGE 127
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES ITEM # 1 2 3 4 5 6 PART NUMBER QTY.
PAGE 128
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 129
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 130
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (CONTINUED) ITEM # PART NUMBER QTY. 51 4751400 2 52 53 54 55 56 57 58 4300157 3311801 0100062 0771415 4460315 0100020 0641405 1 1 1 1 4 AR AR 59 4761400 2 101 102 0861542 Ref Ref 0861567 Ref 0861541 1 2ft/.6m 1060494 See Note 103 104 105 106 107 108 109 110 111 to 115 116 117 118 to 120 121 122 123 to 124 125 126 127 128 2.5ft/.
PAGE 131
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (CONTINUED) ITEM # 201 202 203 PART NUMBER QTY.
PAGE 132
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (CONTINUED) ITEM # PART NUMBER 407 QTY. 2 4460607 70002824 408 7 4460957 70002825 409 410 501 502 503 504 505 506 507 508 509 510 511 512 513 514 2-104 2 4461001 70002826 ‘3641533 1 1001094475 Ref Not Used 0720808 2420165 3310601 3310805 3910608 4240032 4420060 4460234 4750800 4760600 1001094375 1001094509 4460018 1 1 2 1 2 4 3in/7cm 3 1 2 1 1 1 DESCRIPTION REV.
PAGE 133
SECTION 2 TURNTABLE FIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 134
SECTION 2 TURNTABLE FIGURE 2-24.
PAGE 135
SECTION 2 TURNTABLE FIGURE 2-24. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES ITEM # PART NUMBER QTY. Ref DESCRIPTION Note: Only Available on USA Built Machines.
PAGE 136
SECTION 2 TURNTABLE FIGURE 2-24. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES ITEM # PART NUMBER QTY.
PAGE 137
SECTION 2 TURNTABLE FIGURE 2-24. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES ITEM # PART NUMBER QTY. 106 107 108 109 110 111 to 115 116 117 118 to 120 121 122 123 to 124 125 126 127 128 3310601 1060343 Not Used 3910610 4360070 Not Used 4460425 4460426 Not Used 4750600 4760600 Not Used 1671092 4460963 Not Used 2 1.5ft/.
PAGE 138
SECTION 2 TURNTABLE FIGURE 2-24. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES ITEM # PART NUMBER 402 QTY.
PAGE 139
SECTION 3 BOOM 3121271 800A 800AJ 3-1
PAGE 140
3-2 800A 800AJ 15 109 102 4 103 31 40 106 107 28 24 42 9 25 38 25 37 21 25 33 27 23 25 26 33 106 106 41 31 3 109 102 105 110 101 104 108 PLATFORM SUPPORT 5 25 44 45 26 46 33 47 43 26 35 25 33 14 10 25 32 39 31 11 25 27 37 20 31 11 26 20 25 33 27 18 8 7 30 22 25 37 12 25 34 19 2 25 32 17 25 37 6 27 16 37 27 25 1 16 25 36 29 SECTION 3 BOOM FIGURE 3-1.
PAGE 141
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A ITEM # PART NUMBER QTY.
PAGE 142
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A (CONTINUED) ITEM # PART NUMBER QTY. 41 42 43 44 45 46 47 1670864 3900239 0961951 0641516 1320159 4711500 3311505 1 1 2 1 1 1 1 0272070 See Note Ref Ref Ref See Note Ref See Note Ref 0100011 0641812 0642684 0681608 3300243 3311805 4846573 4891600 4891800 4892600 AR 8 1 8 1 8 1 8 8 1 101 102 103 104 105 106 107 108 109 110 3-4 DESCRIPTION REV.
PAGE 143
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 144
SECTION 3 BOOM FIGURE 3-2.
PAGE 145
SECTION 3 BOOM PLATFORM SUPPORT 105 110 101 104 108 106 4 106 103 13 25 8 40 45 57 6A 64 102 6 6A 37 38 46 106 58 43 107 36 109 65 23 64 38 46 109 38 20 23 59 37 46 16 102 51 38 21 22 19 12 48 59 58 43 65 36 7 6A 20 37 47 38 4 51 21 19 59 3121271 800A 800AJ 3-7
PAGE 146
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ ITEM # 1 PART NUMBER QTY.
PAGE 147
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 148
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ (CONTINUED) ITEM # PART NUMBER QTY. Ref 101 102 103 104 105 106 107 108 109 110 3-10 0272070 See Note Ref Ref See Note Ref See Note Ref 0100011 0641812 0642684 0681608 3300243 3311805 4846573 4891600 4891800 4892600 AR 8 1 8 1 8 1 8 8 1 DESCRIPTION REV. PLATFORM SUPPORT INSTALLATION (SIDE ENTRY PLATFORM) Machines without Load Sensing and without SkyGlazier.
PAGE 149
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 150
SECTION 3 BOOM FIGURE 3-3.
PAGE 151
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 152
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY. 110 111 112 113 114 115 116 117 3311601 3311602 3311605 3841340 3900262 4711600 0641624 0259420 3340859 3340859 4 4 6 2 4 AR 2 1 2 2 118 3-14 DESCRIPTION REV.
PAGE 153
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 154
3-16 8 101A 16 110 111 120 7 17 23 117 800A 800AJ 17 21 104 101 101 101B 17 20 110 109 111 14 13 12 110 109 111 17 18 13 11 12 9 10 5 17 6 20 121 123 103 3 1 102 109 111 112 110 114 119 121 116 122 109 111 110 2 106 800AJ 15 4 106 2 17 22 12 14 14 107 111 113 108 105 25 12 17 18 124 17 18 11 10 122 115 118 121 114 800A 14 17 19 17 19 9 SECTION 3 BOOM FIGURE 3-4.
PAGE 155
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES ITEM # PART NUMBER QTY.
PAGE 156
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 157
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 158
SECTION 3 BOOM FIGURE 3-5.
PAGE 159
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY 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 16 7017162 7017163 7017164 See Note Use 7017159 Use 7017159 See Note See Note See Note See Note See Note Use 7017159 70001697 See Note 7017183 7017193 See Note 1 1 1 2 1 2 2 1 1 1 1 1 6 3 1 2 2 See Note 1 See Note 1 17 to 24 25 26 3121271 DESCRIPTION ROTATOR ASSEMBLIES 800A 800AJ REV.
PAGE 160
SECTION 3 BOOM FIGURE 3-6.
PAGE 161
SECTION 3 BOOM FIGURE 3-6. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) ITEM # PART NUMBER QTY.
PAGE 162
SECTION 3 BOOM FIGURE 3-6. 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 163
SECTION 4 PLATFORM 3121271 800A 800AJ 4-1
PAGE 164
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION 204 404 201 402 403 207 401 11 4 10 112 204 8 207 106 111 103 7 107 3 301 2 101 105 110 109 105 OR 109 101 56 112C 62 57 112B 112A 102 105 109 54 60 58 63 6 61 59 52 4-2 NOTE: REPLACEMENT DECALS MUST BE ORDERED SEPARATELY – SEE SECTION 8.
PAGE 165
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION ITEM # PART NUMBER QTY. DESCRIPTION Use 1001144027 Ref Ref 1001144027 Ref 1001144025 Use 1001144024 Ref Ref 1001144024 Ref Use 1001144023 Ref 1001144023 Ref PLATFORM ASSEMBLIES: Platform 30in x 4ft (76cm x 1.22m) with No Mesh (USA Built Machines SN 0300140000 to SN 0300168426 & China Built Machines SN B300000100 to SN B300000734) (was p/n 3510830) Platform 30in x 4ft (76cm x 1.
PAGE 166
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION Use 1001144018 Ref Ref 1001144018 Ref 1001144020 Use 1001144021 Ref Ref 1001144021 Ref Use 1001144022 Ref 1001144022 Ref PLATFORM ASSEMBLY WITH DROP-BAR Platform 30in x 4ft (76cm x 1.22m) with No Mesh (USA Built Machines SN 0300140000 to SN 0300168426 & China Built Machines SN B300000100 to SN B300000734) (was p/n 1001138431) Platform 30in x 4ft (76cm x 1.
PAGE 167
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED) ITEM # 101 102 103 104 105 106 107 108 109 110 111 112 PART NUMBER QTY.
PAGE 168
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 112C 112D 4460071 4460226 1 2 112E 4460464 1 0273484 0273485 Ref Ref Ref 201 202 to 203 204 205 to 206 207 208 to 212 213 214 to 216 217 218 2080040 Not Used 2920140 7016399 Not Used 3536089 Not Used 4460426 Not Used 2820035 4240099 401 402 403 404 405 4-6 REV.
PAGE 169
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 170
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 171
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3121271 PART NUMBER QTY. DESCRIPTION 3510884 3510868 Ref Ref Ref Ref PLATFORM ASSEMBLY (FALL ARREST) 6ft Platform 8ft Platform Note: Replacement Decals Must be purchased separately See DECAL SECTION.
PAGE 172
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 173
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NUMBER QTY.
PAGE 174
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 175
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (CONTINUED) ITEM # 501 502 503 504 505 601 to 604 605 701 801 901 to 903 904 905 to 907 908 PART NUMBER QTY. 0273824 0272427 1001108256 0273706 Ref Ref Ref Ref Ref SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) 6Ft/1.8m Platforms 8Ft/2.4m Platforms 6Ft/1.8m Platforms w/Fall Arrest 8Ft/2.
PAGE 176
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 177
SECTION 4 PLATFORM FIGURE 4-4. CONTROLLER ASSEMBLY (SWING & LIFT) ITEM # PART NUMBER QTY.
PAGE 178
SECTION 4 PLATFORM FIGURE 4-4. CONTROLLER ASSEMBLY (SWING & LIFT) (CONTINUED) ITEM # PART NUMBER QTY. 1001118417 NLA Ref 101 102 103 104 105 106 107 108 109 110 111 112 4-16 70002730 7003928 7022808 70002731 70002732 7022815 70002733 70002734 70002735 70002906 7022819 4460871 1 1 1 1 4 1 1 4 1 1 NSS 1 6 DESCRIPTION REV.
PAGE 179
SECTION 4 PLATFORM FIGURE 4-4. CONTROLLER ASSEMBLY (SWING & LIFT) (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 180
SECTION 4 PLATFORM FIGURE 4-5.
PAGE 181
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE & STEER) ITEM # PART NUMBER QTY.
PAGE 182
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED) ITEM # 101 102 103 104 105 106 107 108 109 201 202 203 204 205 206 207 208 209 210 4-20 PART NUMBER QTY. 1001118416 Ref 70002724 7003941 70002725 7019162 70002726 70002727 70002728 Use 1001118416 Use 1001113961 4460871 1 2 2 1 1 1 1 1 1 7 7022812 70002727 Ref Ref Ref 7003972 7003973 7003980 7019167 7019164 7019165 7019196 7019166 70002729 7003982 7003983 7019194 7003989 1 2 4 4 1 1 1 2 2 2 1 2 DESCRIPTION REV.
PAGE 183
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 184
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 185
SECTION 4 PLATFORM FIGURE 4-6. 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 3121271 PART NUMBER QTY. 0273824 0272427 1001108256 0273706 Ref Ref Ref Ref Ref Ref 0100011 0200048 0630462 0641414 0731005 0940134 0940103 0940177 0940133 1060341 1060903 Not Used 3311401 3311501 3575359 3574091 4240099 4360057 Not Used 4420068 AR 2 8 8 4 1 AR 4 8 8 2 7 2 SOFT TOUCH SYSTEM INSTALLATIONS OPTIONS: 6Ft/1.8m Platforms 8Ft/2.
PAGE 186
SECTION 4 PLATFORM FIGURE 4-6. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (CONTINUED) ITEM # 4-24 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 187
SECTION 5 CYLINDER 3121271 800A 800AJ 5-1
PAGE 188
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 189
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 3121271 PART NUMBER QTY.
PAGE 190
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 191
SECTION 5 CYLINDER FIGURE 5-2. UPRIGHT LEVEL CYLINDER ASSEMBLY 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 3121271 PART NUMBER QTY.
PAGE 192
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 193
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 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 to 29 30 PART NUMBER QTY.
PAGE 194
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 195
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 29 30 31 32 to 39 40 3121271 PART NUMBER QTY.
PAGE 196
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 197
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 3121271 PART NUMBER QTY.
PAGE 198
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 199
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 3121271 PART NUMBER QTY.
PAGE 200
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 201
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 to 29 30 PART NUMBER QTY.
PAGE 202
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 203
SECTION 5 CYLINDER FIGURE 5-8. SLAVE CYLINDER ASSEMBLY - 800A ITEM # 1 2 2A 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 to 100 101 102 103 104 105 106 107 108 109 110 to 124 125 3121271 PART NUMBER QTY.
PAGE 204
SECTION 5 CYLINDER FIGURE 5-9.
PAGE 205
SECTION 5 CYLINDER FIGURE 5-9. SLAVE CYLINDER ASSEMBLY - 800AJ ITEM # 1 2 2A 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 to 100 101 102 103 104 105 106 107 108 109 110 to 124 125 PART NUMBER QTY.
PAGE 206
SECTION 5 CYLINDER FIGURE 5-10.
PAGE 207
SECTION 5 CYLINDER FIGURE 5-10. STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 0300140000 TO SN 0300142666) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 to 19 20 3121271 PART NUMBER QTY.
PAGE 208
SECTION 5 CYLINDER FIGURE 5-11.
PAGE 209
SECTION 5 CYLINDER FIGURE 5-11. STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 0300142664 TO SN 030183033 ONLY & CHINA BUILT MACHINES SN B300000100 TO PRESENT ONLY) ITEM # PART NUMBER QTY.
PAGE 210
SECTION 5 CYLINDER FIGURE 5-12.
PAGE 211
SECTION 5 CYLINDER FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY - MAIN ITEM # PART NUMBER 1683672 Ref Ref Ref Ref 1001149284 Ref 0100011 0100038 0641806 0961897 0962524 AR AR 4 1 1 1 1683607 1 2 3 4 5 6 QTY.
PAGE 212
SECTION 5 CYLINDER FIGURE 5-13.
PAGE 213
SECTION 5 CYLINDER FIGURE 5-13. 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 3121271 PART NUMBER QTY.
PAGE 214
SECTION 5 CYLINDER FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLY - TOWER (CONTINUED) ITEM # 5-28 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 215
SECTION 6 HYDRAULIC 3121271 800A 800AJ 6-1
PAGE 216
SECTION 6 HYDRAULIC FIGURE 6-1.
PAGE 217
SECTION 6 HYDRAULIC FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM ITEM # 101 102 103 104 105 106 107 108 109 110 3121271 PART NUMBER QTY. DESCRIPTION 2792648 Ref 2110406 2110606 2110408 2170504 2170506 Not Used 2753629 2753630 2753624 2753627 2 2 1 1 1 Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Tee Fitting, Tee 2 1 2 1 Hose Hose Hose Hose AXLE LOCKOUT HYDRAULIC DIAGRAM 800A 800AJ REV.
PAGE 218
6-4 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 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 64 11 8 62 7 9 25 43 26 3 11 63 2 1 4 70 43 1 32 43 27 28 34 30 71 43 69 66 68 29 36 37 32 68 66 67 67 35 64 65 65 64 10 SECTION 6 HYDRAULIC FIGURE 6-2.
PAGE 219
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD 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 3121271 PART NUMBER QTY.
PAGE 220
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED) 6-6 ITEM # PART NUMBER QTY.
PAGE 221
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 222
6-8 800A 800AJ 18 68 64 19 70 78 47 30 47 78 19 51 51 48 20 69 20 17 77 45 30 45 17 54 71 66 71 31 72 54 46 66 41 72 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 36 37 23 26 43 30 43 28 82 28 82 28 82 28 82 35 56 57 60 79 58 23 30 52 26 22 49 22 9 SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 223
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS 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 PART NUMBER QTY.
PAGE 224
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 225
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 226
SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 227
SECTION 6 HYDRAULIC FIGURE 6-4. STANDARD HYDRAULIC DIAGRAM (WITH 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 45 3121271 PART NUMBER QTY.
PAGE 228
SECTION 6 HYDRAULIC FIGURE 6-4. STANDARD HYDRAULIC DIAGRAM (WITH HALDEX BRAND AUXILIARY PUMP) ITEM # PART NUMBER QTY.
PAGE 229
SECTION 6 HYDRAULIC FIGURE 6-4. STANDARD HYDRAULIC DIAGRAM (WITH HALDEX BRAND AUXILIARY PUMP) ITEM # PART NUMBER QTY. 85 86 87 88 89 90 to 91 92 93 94 2221036 2220950 2220603 2220501 2220655 Not Used 2180724 2180380 0100019 1 1 2 1 1 1 1 AR 1 2902456 2902457 2902459 2902457 3121271 DESCRIPTION REV.
PAGE 230
6-16 800A 800AJ 2 X 4 35 41 X V2 P1 30 85 65 V1 23 P1 V1 V2 P2 32 34 X X 2 31 V2 V1 62 49 Port Block on Upright Lift Cylinder X 4 70 LIFT UP 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 231
SECTION 6 HYDRAULIC FIGURE 6-5. 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 3121271 PART NUMBER QTY.
PAGE 232
SECTION 6 HYDRAULIC FIGURE 6-5. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) ITEM # PART NUMBER QTY.
PAGE 233
SECTION 6 HYDRAULIC FIGURE 6-5. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) ITEM # PART NUMBER QTY.
PAGE 234
SECTION 6 HYDRAULIC FIGURE 6-6. HYDRAULIC DIAGRAM LIST ITEM # 6-20 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 235
SECTION 7 ELECTRICAL 3121271 800A 800AJ 7-1
PAGE 236
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST ITEM # PART NUMBER QTY.
PAGE 237
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED) ITEM # 3121271 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 238
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 239
SECTION 7 ELECTRICAL 208 OR 704G 704P 208 704Q 208 704F 704E 207 704M 704N 704L 704J 704R 704Q 707B 706D 704K 704D 704B 2500W 706G 704C GENERATOR 707A 706C 706C RELAY 707 706F 706J 709J 706H 7500W GENERATOR CONTROL BOX 211B 2500W GENERATOR 713G TO ALTERNATOR (CAT) 602E 602 FUEL PUMP (CAT) 706E 538 DIAGNOSTIC CONNECTOR (CAT) 553 EGR RELAY (DEUTZ) 602F ENGINE HARNESS (DEUTZ) 703A 703B DRIVE ORIENTATION SWITCH 517 552 605A 334C 334B 334E 334B HORN 606 FUEL LEVEL SENSOR 334A 701 701C
PAGE 240
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION ITEM # 1 to2 3 4 to 5 6 6A 6B 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 7-6 PART NUMBER QTY.
PAGE 241
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 242
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 201 QTY. 1 4922575 1001091315 4922582 4923490 1060896 AR 4923462 AR 67ft/20.4m 64ft/19.5m 201A 201B 201C 201D 201E 201F 202 202A 202B 203 0100009 4460865 4460465 4460509 4460466 4460473 4460866 4460464 4460508 4460466 4923613 1060978 1001097051 1001097082 4460466 4460464 AR 1 11 4 4 1 1 11 4 4 1 2ft/0.6m 1 3 1 3 1 4922576 4923489 1060896 44ft/13.4m 4923462 44ft/13.
PAGE 243
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 203A 4460465 4460891 2 1 1 204 Not Required 4922868 1001091319 204A 4922580 1060902 4923466 4460464 4460897 205 30ft/9.1m 30ft/9.1m 2 1 1 4922578 4923487 4922578 Use 4923487 4923487 206 1 4922578 4923487 207 1 4922215 4922218 1001125127 1001091324 Use 1001125127 4922216 4922219 Use 1001125126 4923485 208 1 4922217 4922220 Use 1001125125 4923486 3121271 DESCRIPTION REV.
PAGE 244
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 208 cont’d Use 1001125125 209 QTY.
PAGE 245
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 246
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # 401 402 to 407 408 409 501 to 516 517 518 519 520 to 521 522 523 524 525 526 to 527 528 529 to 532 533 534 to 537 538 539 540 to 546 7-12 PART NUMBER QTY.
PAGE 247
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 248
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 601C QTY.
PAGE 249
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 250
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 704 Ref 0272259 Ref 0256202 Ref 0272260 Ref 0274619 Ref 0272433 Ref Ref 7-16 0256202 1001091969 1001091970 1001091971 Ref Ref Ref Ref 1001091972 Ref 1001091973 Ref 1001091974 Ref 1001091975 Ref 1001092145 Ref 1001100326 1001092145 1001100327 1001100328 Ref Ref Ref Ref 1001100329 Ref 1001100331 Ref 1001100333 Ref 1001100337 Ref 1001109558 Ref DESCRIPTION REV.
PAGE 251
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 704A QTY. 1 0860038 0861781 See Note 0861731 1001141967 704B 1 See Note 4460346 4460125 4461198 4461201 Use 1001100343 Use 1001100344 1001141968 1001141969 4461244 4461245 4461246 704C 1 See Note 1001110873 4060092 4461198 4461201 Use 1001100343 Use 1001100344 1001141968 1001141969 4461244 4461245 4461246 3121271 DESCRIPTION REV.
PAGE 252
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 704D QTY. 1 4460051 4460071 1001101191 1 1001101196 1001101197 704E 1 4460205 4460233 4460709 704F 1 4460134 4460701 4460710 704G 1 See Note 4460205 4460233 4461196 4461199 4461202 4461205 4461249 Not Required 704H 0903484 1 704J 0903697 1 704K AR 1001109654 1001109654 1001109648 1 See Note Ref 7-18 1001109475 1001109482 1 1 1001109475 1 DESCRIPTION REV.
PAGE 253
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 704K cont’d 1001109482 1 1001109477 1001109482 0861880 4460956 4460957 1060908 1001097150 1001101191 1 1 1 1 1 12ft/3.
PAGE 254
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 704R cont’d 1001100344 QTY. 1001100347 1001100346 706A 706B 706C 706D 706E 706F 706G 706H 706J 707 707A 707B 708 7-20 REV.
PAGE 255
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER 709 QTY.
PAGE 256
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY. 710F 1671092 4460963 1 1 Ref Ref 711 1001112586 4933349 711A 711B 711C 711D 711E 711F 711G 712 712A 712B 712C 713 713A 713B 713C 713D 713E 713F 1 1001112587 4923420 4460374 4460375 4460967 4460465 2400060 2400064 4460742 4460743 4460458 4922641 4460226 See Note 1060341 3740049 4922643 4460426 2920140 2920095 1001098234 1001098349 4460426 4460598 2400070 2 AR 1 3 1 1 1 2 2 1 2 1 48ft/14.
PAGE 257
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 258
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED) ITEM # 7-24 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 259
SECTION 8 DECALS 3121271 800A 800AJ 8-1
PAGE 260
8-2 800A 800AJ 18 38 45 35 18 26 32 24 31 35 9 36 30 43 8 53 24 18 45 33 44 20 2 21 39 55 54 25 23 33 23 20 40 50 51 7 29 101 5 24 23 51 8 46 9 56 23 13 24 54 55 2 8 50 34 32 24 22 37 18 10 8 31 41 44 55 7 29 18 38 33 71 49 SECTION 8 DECALS FIGURE 8-1.
PAGE 261
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) ITEM # 1 2 3 to 4 5 6 7 8 9 10 11 to 12 13 14 to 17 18 19 20 21 22 23 24 25 26 27 to 28 29 30 PART NUMBER QTY.
PAGE 262
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (CONTINUED) ITEM # PART NUMBER 34 QTY.
PAGE 263
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (CONTINUED) ITEM # 101 3121271 PART NUMBER QTY. 0258671 Ref 0860520 1060279 1 1 0641408 1 0641406 4751400 3311405 4 AR AR DESCRIPTION MANUAL STORAGE BOX INSTALLATION REV.
PAGE 264
8-6 800A 800AJ 18 38 45 35 18 26 44 31 35 24 18 45 33 9 25 23 33 21 23 20 40 12 32 36 30 8 2 39 55 54 17 49 253 24 20 51 7 29 50 101 5 24 23 27 51 8 46 9 56 23 24 13 54 55 2 8 50 34 32 24 22 37 18 10 8 31 41 44 55 7 29 18 38 33 49 SECTION 8 DECALS FIGURE 8-2.
PAGE 265
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) ITEM # PART NUMBER QTY. Ref 0274519 0274470 0274472 0274466 0274468 0274462 0274464 0274471 0274473 0274467 0274469 0274463 0274465 1 2 3 to 4 5 6 7 8 9 10 11 12 13 14 to 16 17 Not Used 1701499 Not Used 1701509 Not Used 1703811 1703814 1704277 1704412 Not Used 1705514 1704007 1705901 Not Required Not Required REV.
PAGE 266
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) (CONTINUED) ITEM # PART NUMBER 18 19 20 QTY.
PAGE 267
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) (CONTINUED) ITEM # PART NUMBER 25 QTY.
PAGE 268
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) (CONTINUED) ITEM # PART NUMBER 33 Cont’d 1001121656 1001121807 1001121808 1001122200 1001121918 34 QTY. 1 1 4 2 1 Rivet Decal - JLG Lift (8in Height) Decal - JLG Lift (3-1/2in Height) 1707045 1707044 1707046 1707047 1707048 1707049 1707051 1707052 1707053 1707054 1707043 1707042 35 36 37 38 39 AR 1 1 2 1 1700584 1001131269 40 41 42 43 44 45 8-10 1001108495 1001095809 Not Used 3820001 1702861 1702774 REV.
PAGE 269
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 270
8-12 800A 800AJ 23 38 45 35 23 11 32 44 23 31 35 36 253 30 8 43 24 24 45 9 2 39 25 23 33 21 23 46 9 8 24 23 7 29 101 5 42 23 24 23 24 31 41 37 2 8 34 32 52 22 CE SPEC 57 AUSTRALIAN SPEC 22 AUSTRALIAN SPEC ONLY 10 8 44 55 7 29 38 49 SECTION 8 DECALS FIGURE 8-3.
PAGE 271
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPEC) ITEM # 1 2 3 to 4 5 6 7 8 9 10 11 PART NUMBER QTY.
PAGE 272
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPEC) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 273
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.
PAGE 274
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. Part Number Description Qty.
PAGE 275
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 REV.
PAGE 276
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 # 10-2 PART NUMBER QTY. DESCRIPTION 0274883 Ref Ref Cold Weather Transformer Installation (ANSI Export Only) Note: Cold Weather Transformer Installation used on Deutz Engines with Cold Weather Package.
PAGE 277
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.
PAGE 278
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.
PAGE 279
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 # 3121271 PART NUMBER QTY.
PAGE 280
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 # 10-6 PART NUMBER QTY. DESCRIPTION REV.
PAGE 281
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 # 3121271 PART NUMBER QTY. DESCRIPTION 7004275 7004276 7002826 7016655 7016652 70000017 1001137005 1 1 1 1 1 1 1 0258918 Ref Utility Rack Installation 0258826 0258827 Ref Ref Ref Weld Leads to Platform Installation Options: 800A 800AJ REV.
PAGE 282
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 # 10-8 PART NUMBER QTY. DESCRIPTION 800A 800AJ REV.
PAGE 283
SECTION 11 PARTS NUMBER INDEX Part Number 0010580 0060066 0060069 0080181 0080201 0080241 0080243 0100009 0100011 0100019 0100020 0100035 0100038 0100048 0100062 0100079 0100081 0140001 0140011 0140032 0181949 0200048 0200742 0200819 0232121 0255316 0255524 0256196 0256202 0256789 0256823 0257195 3121271 Page .............. 8-11, 8-14 ................ 3-8, 3-21 ................ 3-3, 3-21 ....................... 2-24 ....................... 2-44 ....................... 2-71 .......................
PAGE 284
SECTION 11 Part Number PARTS NUMBER INDEX Page 0630518 ....................... 2-67 0630534 ................ 5-7, 5-13 0630535 ..5-3, 5-15, 5-17, 519, 5-25, 5-27 0630536 ....................... 5-11 0630537 .................. 5-5, 5-9 0630548 ....................... 2-67 0630568 ....................... 4-12 0641403 ....................... 3-24 0641404 2-92, 2-100, 2-101, 3-3, 3-9, 4-11 0641405 .
PAGE 285
SECTION 11 Part Number 1001093248 1001093382 1001093389 1001093746 1001093748 1001093943 1001094101 1001094321 1001094375 1001094400 1001094475 1001094509 1001094595 1001094661 1001094662 1001094889 1001095354 1001095391 1001095809 1001096141 1001096736 1001097051 1001097082 1001097150 1001097243 1001097407 1001097408 1001097519 1001097553 1001097964 1001097965 1001098149 1001098234 1001098349 1001098506 1001098507 1001098508 1001099051 1001099121 1001099137 1001099138 1001099139 1001099421 1001099422 100
PAGE 286
SECTION 11 Part Number 1001116457 1001116474 1001116544 1001116545 1001116562 1001116565 1001116566 1001116595 1001116618 1001116846 1001116849 1001116851 1001117040 1001117045 1001117052 1001117139 1001117140 1001117172 1001117174 1001117209 1001117219 1001117234 1001117236 1001117249 1001117294 1001117307 1001117320 1001117427 1001117428 1001117441 1001117503 1001117504 1001117523 1001117525 1001117568 1001117598 1001118133 1001118236 1001118263 1001118264 1001118344 1001118345 1001118416 1001118417 1001
PAGE 287
SECTION 11 Part Number 1282571 1283309 1300019 1320011 1320012 1320016 1320022 1320127 1320159 1320176 1320218 1320220 1320223 1320224 1320250 1320251 1320256 1320263 1320288 1320289 1320318 1320323 1321384 1340060 1340061 1380147 1580011 1580012 1580013 1600244 1600317 1600318 1660239 1670769 1670776 1670829 1670842 1670844 1670850 1670864 1671092 1671093 1671228 1671230 1671231 1671232 1671233 1671249 1671311 1683050 1683053 1683055 1683059 1683061 1683071 3121271 Page ......................... 7-2 .
PAGE 288
SECTION 11 Part Number 1706957 1706960 1707013 1707014 1707042 1707043 1707044 1707045 1707046 1707047 1707048 1707049 1707051 1707052 1707053 1707054 1707055 1707056 1707057 1707058 1707059 1707060 2060025 2080040 2080044 2110404 2110406 2110408 2110606 2110808 2110812 2111212 2111616 2120167 2120168 2120209 2120210 2130404 2130406 2130604 2130606 2130808 2131616 2150406 2150606 2150808 2151616 2160003 2170350 2170408 2170504 2170506 2170508 2170516 2180125 2180344 2180348 2180380 2180387 11-6 PARTS NUM
PAGE 289
SECTION 11 Part Number 2753123 2753124 2753125 2753126 2753128 2753129 2753189 2753190 2753191 2753192 2753195 2753196 2753197 2753199 2753200 2753216 2753231 2753540 2753549 2753550 2753622 2753624 2753625 2753626 2753627 2753628 2753629 2753630 2753634 2753635 2753685 2753686 2753688 2753725 2753970 2753971 2754040 2754044 2754238 2754240 2754242 2754243 2754337 2754338 2754401 2754402 2754718 2754719 2754720 2754743 2754744 2760105 2780227 2780229 2780272 2792365 2792366 2792629 2792648 3121271 Page
PAGE 290
SECTION 11 Part Number 3422582 3422583 3422681 3422683 3422684 3422685 3422686 3422687 3422688 3422689 3422690 3422701 3422702 3422703 3422729 3422754 3422755 3422813 3422848 3422860 3422861 3422867 3422972 3430816 3450404 3460544 3470003 3480176 3480188 3480210 3480211 3480232 3480233 3480234 3480236 3480237 3480238 3510822 3510830 3510833 3510868 3510884 3520028 3520030 3520034 3520035 3520054 3520072 3520189 3520198 3536089 3537416 3537445 3537446 3538047 3538758 3539219 3539662 3539872 11-8 PARTS NUM
PAGE 291
SECTION 11 Part Number Page 4240032 2-71, 2-72, 2-88, 292, 2-96, 2-104, 2-110 4240099 ................ 4-6, 4-23 4240113 ....................... 2-57 4280295 ....................... 2-57 4300111 ..................... 2-108 4300157 ..................... 2-102 4340706 ....................... 3-13 4341239 ....................... 2-45 4341241 ....................... 2-45 4360031 ......................... 4-5 4360057 ................ 4-23, 9-2 4360070 ...
PAGE 292
SECTION 11 Part Number 4640858 4640866 4640921 4640922 4640929 4640932 4640952 4641022 4641027 4641032 4641033 4641162 4641192 4641303 4641317 4641435 4641453 4711400 4711500 4711600 4711700 4711800 4740036 4740057 4740076 4740111 4740119 4740155 4740171 4740256 4740274 4740362 4740397 4740439 4740444 4740463 4740472 4740473 4740500 4740508 4750600 4750800 4751000 4751400 11-10 PARTS NUMBER INDEX Page ......................... 5-3 ......................... 2-3 ................ 2-3, 2-11 ...........
PAGE 293
SECTION 11 Part Number Page 70001837 ..................... 2-39 70001838 ..................... 2-39 70001839 ..................... 2-39 70001841 ..................... 2-39 70001847 ..................... 2-39 70001848 ..................... 2-38 70001850 ..................... 2-38 70001866 ..................... 2-39 70001868 ..................... 2-39 70001870 ..................... 2-39 70001872 ............ 2-39, 7-14 70001874 ..................... 2-39 70001931 ..................... 7-15 70001941 .......
PAGE 294
SECTION 11 Part Number 7004276 7004906 7004907 7004908 7006137 7007208 7007412 7007413 7007414 7007417 7007419 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 7010116 7010122 7010404 7010405 7010406 7010464 7010492 7010542 7010543 7010545 7010903 7010944 7011008 7011022 7011043 7011044 11-12 PARTS NU
PAGE 295
SECTION 11 Part Number 7021232 7021249 7021275 7021276 7021277 7021310 7021311 7021601 7021602 7021625 7021639 7022302 7022305 7022310 7022311 7022312 7022313 7022314 7022326 7022328 7022368 7022371 7022372 7022397 7022399 7022721 7022808 7022812 7022814 7022815 7022816 7022817 7022818 7022819 7022822 7022823 7022824 7022825 7023023 7023318 7023907 7023908 7023910 7023917 7023933 7023956 7023967 7023977 7024100 7024146 7024147 7024148 7024149 7024151 7024154 7024155 7024182 7024189 7024190 3121271 Page
PAGE 296
SECTION 11 Part Number 11-14 PARTS NUMBER INDEX Page Part Number Page Part Number 800A 800AJ Page Part Number Page 3121271
PAGE 297
PAGE 298
3121271 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.