Parts Manual User Manual

ManualsBrandsJLG ManualsSpecial machinery800A_AJ

Illustrated Parts Manual

Models

800A

800AJ

Prior to

S/N 0300069000

P/N

3120859

April 30, 2014

Summary of content (266 pages)

PAGE 1
Illustrated Parts Manual Models 800A 800AJ Prior to S/N 0300069000 P/N 3120859 April 30, 2014
PAGE 2
PAGE 3
REVISION LOG Note: See Note Below to Identify whether Machine is Equipped with ADE System. ADE SYSTEM All 800A and 800AJ machines from S/N 0300064432 to present incorporate the ADE System, but no clean S/N break exists. The following machine serial numbers prior to S/N 0300064432 also utilize ADE: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975, 0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 4
REVISION LOG March 15, 2008 - Revised November 28, 2008 - Revised May 15, 2009 - Revised October 15, 2009 - Revised April 15, 2010 - Revised December 30, 2010 - Revised April 27, 2011 - Revised July 29, 2011 - Revised October 21, 2011 - Revised January 10, 2012 - Revised May 31, 2012 - Revised July 31, 2012 - Revised December 14, 2012 - Revised March 26, 2013 - Revised June 20, 2013 - Revised June 20, 2013 - Revised September 16, 2013 - Revised December 30, 2013 - Revised April 30, 2014 - Revised B 312085
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS FIGURE NO. 4-8 4-9 4-10 4-11 TITLE PAGE NO. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 LOAD SENSING SYSTEM INSTALLATION (FRENCH SPEC) (PRIOR TO SN 0300067883) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 7
SECTION 1 FRAME TABLE OF CONTENTS FIGURE 1-1 1-2 1-3 1-4 1-5 1-6 DESCRIPTION AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HUB ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 8
SECTION 1 FRAME S E C T I O N FIGURE 1-1.
PAGE 9
SECTION 1 FRAME . FIGURE 1-1.
PAGE 10
SECTION 1 FRAME S E C T I O N FIGURE 1-1.
PAGE 11
SECTION 1 FRAME FIGURE 1-1.
PAGE 12
SECTION 1 FRAME S E C T I O N FIGURE 1-2.
PAGE 13
SECTION 1 FRAME . FIGURE 1-2.
PAGE 14
SECTION 1 FRAME S E C T I O N FIGURE 1-2.
PAGE 15
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 16
SECTION 1 FRAME S E C T I O N FIGURE 1-3. DRIVE BRAKE ASSEMBLY 25 NOTE: Figure applies to Machines prior to SN 0300056875 only. For Machines SN 0300056875 to SN 0300069000 see Parts List.
PAGE 17
SECTION 1 FRAME . FIGURE 1-3. DRIVE BRAKE ASSEMBLY FIG & ITEM # PART NUMBER 0920112 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 to 29 30 7003451 7003452 7003094 7003049 7003453 7003050 7003454 7000798 7000782 7003455 7003456 7003457 Not Used 7003459 7003460 7000722 7000723 7000724 7000725 7000796 7003461 7000728 7003462 7003463 7000731 Not Used See Note Use 0920119 7018612 7000731 7007990 3120859 DESCRIPTION DRIVE BRAKE ASSEMBLY (PRIOR TO SN 0300056875) QTY. REV.
PAGE 18
SECTION 1 FRAME S E C T I O N FIGURE 1-4.
PAGE 19
SECTION 1 FRAME . FIGURE 1-4.
PAGE 20
SECTION 1 FRAME S E C T I O N FIGURE 1-4. DRIVE HUB ASSEMBLIES FIG & ITEM # PART NUMBER 12 7017041 7017045 13 7017038 7017043 14 1 15 16 17 18 19 20 21 F R A M E 22 to 24 25 1-14 Not Required 7017046 7000287 7000288 7000289 Not Used 7000290 7017047 7017050 Not Required Not Used 7017068 DESCRIPTION QTY.
PAGE 21
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLIES FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 22
SECTION 1 FRAME S E C T I O N FIGURE 1-5.
PAGE 23
SECTION 1 FRAME . FIGURE 1-5. DRIVE MOTOR ASSEMBLY FIG & ITEM # PART NUMBER 3160204 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 7012701 Use 2900788 7012702 See Note 7012703 7012704 Use 2900788 7012705 7012706 7012707 7012708 7012709 7012710 Use 2900788 7012711 7012712 Use 2900788 7012713 Use 7012716 See Note Use 7012716 7012714 7012715 7012700 Not Used 2900788 31 7012716 3120859 DESCRIPTION DRIVE MOTOR ASSEMBLY QTY. REV.
PAGE 24
SECTION 1 FRAME S E C T I O N FIGURE 1-6.
PAGE 25
SECTION 1 FRAME . FIGURE 1-6.
PAGE 26
SECTION 1 FRAME S E C T I O N FIGURE 1-6. DRIVE VALVES INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 27
SECTION 2 TURNTABLE TABLE OF CONTENTS FIGURE 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 3120859 DESCRIPTION CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 28
SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 29
SECTION 2 TURNTABLE . FIGURE 2-1.
PAGE 30
SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 31
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 32
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 33
SECTION 2 TURNTABLE . FIGURE 2-2.
PAGE 34
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 35
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 36
SECTION 2 TURNTABLE FIGURE 2-3. ACCESSORY VALVE ASSEMBLY 7 S E C T I O N 2 2A 2C 2B 2 6 1 4 T U R N T A B L E 3 8 NOTE: TORQUE ITEMS 6, 7,103 &104 TO 60 IN/LBS.
PAGE 37
SECTION 2 TURNTABLE . FIGURE 2-3. ACCESSORY VALVE ASSEMBLY FIG & ITEM # PART NUMBER 4640921 1 5 6 7012965 7012953 Use 70001976 7012773 7018945 7018912 7012772 7017421 7012998 7017422 7012998 4460499 7018946 7 8 7018942 7012776 2 2A 2B 2C 3 4 4640922 101 102A 102B 102C 103 7017420 7012998 7012774 7012773 7018945 7018912 7012772 7018946 104 105 106 7018942 7018948 7018947 102 3120859 DESCRIPTION QTY.
PAGE 38
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-4.
PAGE 39
SECTION 2 TURNTABLE . FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS (PRIOR TO SN 0300068040) FIG & ITEM # 1 2 PART NUMBER 4620119 0258407 0270331 SWING DRIVE INSTALLATION OPTIONS: Prior to SN 0300064566 SN 0300064566 to SN 0300068040 Ref Ref Ref 3570488 2780205 0920111 0920119 4 3160223 3160279 0642018 4892000 4740004 7 8 9 10 11 12 3932224 0681836 4891800 0100011 0100019 3311802 13 3971820 0254798 0259055 101 0440207 Use 2915096 102 103 104 3120859 QTY.
PAGE 40
SECTION 2 TURNTABLE FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS (PRIOR TO SN 0300068040) FIG & ITEM # S E C T I O N PART NUMBER 0239585 201 202 203 204 205 Not Used 3421627 3421565 3760170 1260017 0255316 301 302 303 304 305 2 T U R N T A B L E 2-14 2751095 2180344 2160003 2220063 2751032 DESCRIPTION QTY. REV.
PAGE 41
SECTION 2 TURNTABLE FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS (PRIOR TO SN 0300068040) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 42
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-5.
PAGE 43
SECTION 2 TURNTABLE . FIGURE 2-5. TURNTABLE AND SWING DRIVE INSTALLATIONS (SN 0300068040 TO SN 0300069000) FIG & ITEM # PART NUMBER 4620119 0272189 SWING DRIVE INSTALLATION Ref 0100011 0100019 0682214 3160286 5 6 7 8 9 10 11 3312002 3900293 3932224 3952020 4071009 4740057 4846430 0271002 0100019 0440244 0682023 0682032 4892000 0259147 201 202 203 204 4844958 3421565 3760170 1260017 0255316 301 302 303 304 305 3120859 QTY.
PAGE 44
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 45
SECTION 2 TURNTABLE . FIGURE 2-6.
PAGE 46
SECTION 2 TURNTABLE FIGURE 2-7. SWING BRAKE ASSEMBLY (PRIOR TO SN 0300068040) S E C T I O N 25 NOTE: Figure applies to Machines prior to SN 0300064566 only. For Machines SN 0300064566 to SN 0300068040 see Parts List.
PAGE 47
SECTION 2 TURNTABLE . FIGURE 2-7.
PAGE 48
SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 49
SECTION 2 TURNTABLE . FIGURE 2-8.
PAGE 50
SECTION 2 TURNTABLE FIGURE 2-9.
PAGE 51
SECTION 2 TURNTABLE S E C T I O N 27 220 101 121 40 125 230 231A 231B 231C 231D 208 213 214 102 104 207 105 217 218 103 106 2 104 T U R N T A B L E 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 3120859 35 19 205 2-25
PAGE 52
SECTION 2 TURNTABLE FIGURE 2-9.
PAGE 53
SECTION 2 TURNTABLE FIGURE 2-9.
PAGE 54
SECTION 2 TURNTABLE FIGURE 2-9. SWING MOTOR/HUB ASSEMBLY (SN 0300068040 TO SN 0300069000) (CONTINUED) S E C T I O N 2 FIG & ITEM # PART NUMBER 216 217 218 219 220 221 222 223 224 to 229 230 231 231A Use 7024194 Use 7024194 Use 7024194 7024190 See Note See Note Use 7024195 Use 7024196 Not Used 7024194 231B 7024196 231C 231D 7024193 7024197 T U R N T A B L E 2-28 7024195 DESCRIPTION Ring, Back-up O-Ring Ring, Back-up Pin, Dowel Plug (Note: Not Available - Purchase Locally.
PAGE 55
SECTION 2 TURNTABLE FIGURE 2-9. SWING MOTOR/HUB ASSEMBLY (SN 0300068040 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 56
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 57
SECTION 2 TURNTABLE . FIGURE 2-10. DEUTZ ENGINE INSTALLATION FIG & ITEM # PART NUMBER 0258415 0271371 1 2 3 4 5 6 7 7A 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 3120859 2000146 2000173 2000189 4845404 3539872 3620033 2060025 Use 3600295 3600295 1340060 7012664 0340041 4640751 3600278 7018995 7024918 7024930 3200406 3537420 3539971 3537416 3537417 4846479 4846566 0400075 0181727 0630498 3740067 4567112 4360392 2180798 3422446 3841143 3960389 0940070 3841340 DESCRIPTION QTY.
PAGE 58
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 59
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 60
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 61
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 62
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 63
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 64
SECTION 2 TURNTABLE FIGURE 2-11. GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) S E C T I O N NOTE: These Machine SN’s Also Equipped With ADE System: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975,0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 65
SECTION 2 TURNTABLE . FIGURE 2-11. GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) FIG & ITEM # PART NUMBER 0257853 0271544 0272480 0272293 0272482 0257857 0271547 0272481 1 2 3580158 2460011 2460032 2460039 2460013 2A 7012558 2460049 1001100321 7012513 7020108 7020109 7026199 70000122 70000123 7012514 7020190 7020110 7020111 7020193 3120859 DESCRIPTION QTY.
PAGE 66
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 67
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 68
2-42 1203 1201A 1201 2001 802 1204 806 805 1509 1502 155 105 104 103 101 102 OR 1220 111 106 165 604 1002 1003 1001 2005 1104 304 1220 2004 1401 110 603 605 110 OR 142 2004 141 1503 165 166 115 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 907 905 908 123 108 160 401 111 130 127 201 126 135 136 138 134 133 132 1525A 1525B 1526 133 131 124 125 128
PAGE 69
SECTION 2 TURNTABLE . FIGURE 2-12.
PAGE 70
SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 72
SECTION 2 TURNTABLE FIGURE 2-13.
PAGE 73
SECTION 2 TURNTABLE . FIGURE 2-13.
PAGE 74
SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 75
SECTION 2 TURNTABLE . FIGURE 2-14.
PAGE 76
SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 77
SECTION 2 TURNTABLE . FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY (PRIOR TO SN 0300064432) FIG & ITEM # PART NUMBER 0861198 0861199 1 1A 2 2A 2A 2B 2C 3 0861131 0861302 7020246 4360289 4360475 7012611 7020175 7012612 7020176 4360319 4360470 3A 7012560 2860030 4 5 1703467 1703468 4922077 6 4922046 7 8 9 10 11 12 13 14 15 16 Not Used 1840012 1840013 1840014 1840015 3910608 3640970 4460602 4460601 4460603 17 18 19 4460631 4460600 4460628 3120859 DESCRIPTION QTY.
PAGE 78
SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 79
SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 80
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-16.
PAGE 81
SECTION 2 TURNTABLE . FIGURE 2-16.
PAGE 82
SECTION 2 TURNTABLE FIGURE 2-16.
PAGE 83
SECTION 2 TURNTABLE FIGURE 2-16. GROUND CONTROL BOX ASSEMBLY (ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 84
SECTION 2 TURNTABLE 10 11 14 18 26 16A 31 33 34 32 30 2 3 35 5 1 29 27 15 T U R N T A B L E 25 28 17 26 25 2 16 S E C T I O N 12 13 14 FIGURE 2-17.
PAGE 85
SECTION 2 TURNTABLE . FIGURE 2-17.
PAGE 86
SECTION 2 TURNTABLE FIGURE 2-17. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 28 29 30 31 32 33 34 35 36 37 38 39 40 4220162 0100011 2920113 3911040 3311005 4751000 4740362 3960461 Not Used 4240032 4460234 4360336 3790012 2 T U R N T A B L E 2-60 DESCRIPTION QTY.
PAGE 87
SECTION 2 TURNTABLE FIGURE 2-17. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 88
2-62 32 34 301 304 5 105 31 34 35 35 21 34 36 51 13 44 25 106 107 108 305 24 17 47 46 45 18 40 102 306 307 308 4 10 42 41 51 14 34 31 23 104 103 34 33 32 51 37 21 34 36 51 47 46 205 45 44 7 28 9 22 28 27 40 40 19 39 38 15 39 39 40 32 51 8 3B 32 34 23 29 28 34 35 45 44 20 40 34 32 51 32 47 46 35 34 29 22 210 28 40 32 34 51 34 32 6 205 12 202 21 34 36 51 203 2 109 42 43 41 105 26 32 51 34 51 50 32 49 11 34 48 37 51 39 34 33 205 206 207 208 26 2
PAGE 89
SECTION 2 TURNTABLE . FIGURE 2-18.
PAGE 90
SECTION 2 TURNTABLE FIGURE 2-18.
PAGE 91
SECTION 2 TURNTABLE FIGURE 2-18. HOODS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 307 308 4751500 0100011 DESCRIPTION Flatwasher 5/16in Compound, Locking QTY. REV.
PAGE 92
SECTION 2 TURNTABLE FIGURE 2-19.
PAGE 93
SECTION 2 TURNTABLE . FIGURE 2-19.
PAGE 94
SECTION 2 TURNTABLE FIGURE 2-19. ENGINE TRAY JACK INSTALLATION (OPTIONAL) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 95
SECTION 3 BOOM TABLE OF CONTENTS FIGURE 3-1 3-2 3-3 3-4 3-5 3-6 3-7 DESCRIPTION BOOM AND CYLINDER INSTALLATION - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM AND CYLINDER INSTALLATION - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 96
3-2 26 25 33 5 25 44 45 43 26 35 15 4 201 203 209 202 27 25 33 25 37 9 207 28 20 24 50 25 26 33 27 25 38 21 27 23 25 26 33 206 206 41 31 209 202 40 206 205 210 204 208 31 SIDE ENTRY PLATFORM 33 14 10 25 32 39 25 37 31 11 3 18 8 7 30 22 25 37 12 25 34 19 2 25 32 17 25 37 6 105 27 16 25 27 37 1 16 44 45 109 115 114 102 104 113 101 102 108 115 102 104 110 3 20 31 11 B O O M 112 S E C T I O N 25 30 29 119 102 107 117 116 106 118 103 111 41 31 F
PAGE 97
SECTION 3 BOOM . FIGURE 3-1.
PAGE 98
SECTION 3 BOOM FIGURE 3-1.
PAGE 99
SECTION 3 BOOM FIGURE 3-1.
PAGE 100
3-6 37 47 30 37 55 39 37 54 44 17 44 9 41 15 37 54 29 39 26 27 39 18 31 37 49 28 37 47 (TOWER BOOM) 37 45 32 38 LIFT CYLINDER 42 10 11 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 19 65 13 51 21 64 19 40 12 35 7 65 19 59 38 51 36 24 37 47 50 6 65 64 19 37 53 8 B O O M 39 3 21 16 58 43 3 37 54 17 19 4 101 36 22 102 105 109 4 206 209 202 206 206 207 FRONT ENTRY PLATFORM 111 110 107 106 108
PAGE 101
SECTION 3 BOOM . FIGURE 3-2.
PAGE 102
SECTION 3 BOOM FIGURE 3-2.
PAGE 103
SECTION 3 BOOM FIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ (CONTINUED) FIG & ITEM # PART NUMBER 102 103 104 105 106 107 108 109 110 111 0100011 0641606 0641810 0681610 0641820 3311805 3841340 4711600 4711800 201 202 203 204 205 206 207 208 209 210 3120859 DESCRIPTION QTY.
PAGE 104
SECTION 3 BOOM FIGURE 3-3.
PAGE 105
SECTION 3 BOOM . FIGURE 3-3.
PAGE 106
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 112 113 114 115 116 117 3311605 3841340 3900262 4711600 0630539 S E C T I O N 118 Use 0259420 0259420 3340859 DESCRIPTION Locknut 3/8in-16NC Rod, Hose Loop Bolt 3/8in-16NC x 4-3/4in Flatwasher 3/8in Narrow Bolt 3/8in-16NC x 3-1/2in Clamp Assembly Options: Prior to SN 0300043680 (was qty 2 of p/n 1320252) SN 0300043680 to SN 0300069000 Pad, Rubber QTY. REV.
PAGE 107
SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 108
101B 3-14 101A 17 23 7 117 17 21 104 101 17 20 14 13 12 110 109 111 11 10 12 9 13 17 18 123 124 103 3 1 102 109 111 118 110 113 119 124 114 122 109 111 110 24 2 4 106 800AJ 15 3 16 110 111 121 110 109 111 5 17 6 20 B O O M GEMCO GORTRAC 101D 101F 106 2 17 22 24 12 14 14 107 105 111 116 108 25 12 17 18 112 17 18 11 10 113 120 124 122 115 800A 14 17 19 17 19 9 S E C T I O N 8 101C 101E SECTION 3 BOOM FIGURE 3-4.
PAGE 109
SECTION 3 BOOM . FIGURE 3-4. MAIN BOOM ASSEMBLIES FIG & ITEM # PART NUMBER 0801135 0801136 1 Use 0801185 0801185 Use 0801191 0801191 2 0801138 0801140 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1683607 1683672 3422457 3422690 3841143 0561295 0962102 3340705 3340871 4070863 4070864 3340756 3340881 4070897 4070898 3760133 4711600 0100011 0641606 0641607 0641608 0641609 3900259 0641612 1670836 Not Required 0961951 3120859 DESCRIPTION QTY. REV.
PAGE 110
SECTION 3 BOOM FIGURE 3-4.
PAGE 111
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER 121 122 123 124 3900232 3311605 4071052 0100081 DESCRIPTION Screw, Button Head 3/8in-16NC x 1-1/4in Locknut 3/8in-16NC (SN 0300066130 to SN 0300069000) Shim (SN 0300066130 to SN 0300069000) Adhesive QTY. REV.
PAGE 112
SECTION 3 BOOM FIGURE 3-5.
PAGE 113
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLIES (FRONT ENTRY PLATFORM) FIG & ITEM # PART NUMBER 0060041 0060077 0060031 1001103095 1 See Note 2 Use 7017177 7017162 See Note 3 7017115 7017163 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Use 7017174 7017164 See Note Use 7017142 7017102 7017119 3272605 See Note See Note See Note See Note See Note See Note See Note See Note Use 7017183 7017183 17A 7011331 7017193 2900770 3120859 DESCRIPTION QTY.
PAGE 114
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLIES (FRONT ENTRY PLATFORM) (CONTINUED) FIG & ITEM # PART NUMBER 17A (cont’d) See Note 17B S E C T I O N 18 19 7017118 See Note 20 3790110 3 21 to 24 25 Not Used 7011332 See Note 7011346 See NOte 7017157 B O O M 7017158 70000342 26 3-20 27 7017156 7017159 7017142 27A 70001697 DESCRIPTION Seal Kit - 7017193 Valve (Note: Not Available for Purchase.
PAGE 115
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLIES (FRONT ENTRY PLATFORM) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 116
SECTION 3 BOOM FIGURE 3-6.
PAGE 117
SECTION 3 BOOM FIGURE 3-6. ROTATOR ASSEMBLIES (SIDE ENTRY PLATFORM) FIG & ITEM # PART NUMBER 0060069 0060066 1 See Note 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 16 7017183 7017193 See Note See Note See Note 17 to 24 25 26 3120859 DESCRIPTION ROTATOR ASSEMBLIES 800A 800AJ Housing/Ring Gear Assembly (Note: Not Available Purchase Complete Assembly.
PAGE 118
SECTION 3 BOOM FIGURE 3-7.
PAGE 119
SECTION 3 BOOM . FIGURE 3-7.
PAGE 120
SECTION 3 BOOM FIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER 18 3572607 19 4360498 20 4360499 S E C T I O N DESCRIPTION Plate, Lower Boom Proximity Switch Mount (SN 0300056439 to SN 0300069000) Switch Proximity (SN 0300056439 to SN 0300069000) (Note: Machines Prior to S/N 0300056439 may have been retrofitted with this switch.
PAGE 121
SECTION 3 BOOM FIGURE 3-7.
PAGE 122
SECTION 3 BOOM FIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 123
SECTION 4 PLATFORM TABLE OF CONTENTS FIGURE 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 DESCRIPTION PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300064432). . . . . . . . . . . . . . . . . . . . . . PLATFORM CONSOLE ASSEMBLIES (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) . . . . . . . . . . . . . . . . . . . .
PAGE 124
SECTION 4 PLATFORM FIGURE 4-1.PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) NOTE: These Machine SN’s Also Equipped With ADE System: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975,0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 125
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) FIG & ITEM # PART NUMBER 3510760 3510728 3510542 3510565 3510543 3510566 1 4846253 4846101 4844954 4844928 2 4846254 4846102 4844955 4845408 4844924 4845412 3 4 5 6 7 8 9 4846255 4846103 4844956 4845409 4844925 4845413 4845328 4845426 4845469 3900207 3300393 3520072 2600219 2600287 3120859 DESCRIPTION QTY.
PAGE 126
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 127
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 128
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 249 to 257 258 259 to 272 273 274 275 Not Used 4751400 Not Used 3380434 0641414 3311405 DESCRIPTION Flatwasher 1/4in 4 Panel, Poly Bolt 1/4in-20NC x 1-3/4in Locknut 1/4in-20NC 1 2 2 TRAY INSTALLATIONS (OPTIONAL) 301 302 1580012 1580013 QTY. Tray, Storage (Center) Tray, Storage (Rail Mounted - Not Shown) REV.
PAGE 129
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 130
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 131
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) FIG & ITEM # PART NUMBER Use 1001144023 Use 1001144024 1 2 3 4 5 6 0100040 2080040 2600281 2940074 3311001 See Note 7 8 9 10 3520072 3911008 4751000 4846452 1001144629 0271941 101 102 103 104 0641406 0641408 0641610 0861517 104A Use 0272970 4360031 1001117320 104B 104C 3120859 7000625 70003483 1060918 4460071 DESCRIPTION QTY. REV. PLATFORM ASSEMBLIES: 8ft (2.44m) with No Mesh (was p/n 3510822) 6ft (1.
PAGE 132
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 133
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 134
SECTION 4 PLATFORM FIGURE 4-3.PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300064432) NOTE: These Machine SN’s Also Equipped With ADE System: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975, 0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 135
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300064432) FIG & ITEM # PART NUMBER 0861237 0861236 1 2 3 4 0860984 4340678 3538819 1600284 5 1600283 6 7 8 9 10 11 12 13 14 15 16 17 4340684 1702676 1702564 1702565 1702566 1702567 2760105 4360387 2560136 4360407 3910610 17A 4360289 4360475 7012611 17A 7020175 17B 17C 7012612 7020176 18 19 20 21 22 23 4360282 4360476 4360314 4360331 0140026 3790012 3520028 24 1600218 3120859 DESCRIPTION QTY.
PAGE 136
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 137
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 138
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 139
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300064432) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 140
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 141
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 142
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 143
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 144
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER 604 605 3311001 4460598 0271340 S E C T I O N 701 4360328 3790012 0258945 801 4360331 3790012 DESCRIPTION Nut #10-24NC Connector, Strain Relief JIB SWITCH INSTALLATION (OPTIONAL) Switch, Toggle O-Ring STEER SWITCH (4WS) INSTALLATION (OPTIONAL) Switch, Toggle O-Ring QTY. REV.
PAGE 145
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 146
SECTION 4 PLATFORM FIGURE 4-5.CONTROLLER ASSEMBLY (SWING AND LIFT) (PRIOR TO SN 0300064432) S E C T I O N 1B 1C NOTE: These Machine SN’s Also Equipped With ADE System: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975,0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 147
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (SWING AND LIFT) (PRIOR TO SN 0300064432) FIG & ITEM # PART NUMBER 1600284 1 7019141 1A 1B 1C 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 7019197 7003928 7022808 7019142 7019111 7019143 7019144 7019145 7019146 7003977 7019147 7003974 7019142 7003992 7003993 7003976 7019149 7003952 7019150 Use 7022813 Use 7022813 7003956 7003953 7019137 See Note 4460266 4460268 4460265 4460267 7019122 7019123 25 26 3120859 DESCRIPTION QTY.
PAGE 148
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 149
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (SWING AND LIFT) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) FIG & ITEM # PART NUMBER DESCRIPTION Note: Original Equipment controller may have been replaced with Service Replacement controller. Visually identify controller before ordering parts.
PAGE 150
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (SWING AND LIFT) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 106 107 108 109 110 111 7022815 70002733 70002734 70002735 70002906 Use 1001129555 1 1 4 1 1 1 112 7022819 4460871 Bezel Adapter Screw Can, Enclosure Cap Mechanical Assembly (Note: Not Available for Purchase.) Plug, Male 8 Position (Natural) (Not Shown) Socket, Female S E C T I O N REV.
PAGE 151
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (SWING AND LIFT) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 152
SECTION 4 PLATFORM FIGURE 4-7.
PAGE 153
SECTION 4 PLATFORM FIGURE 4-7.
PAGE 154
SECTION 4 PLATFORM FIGURE 4-8.
PAGE 155
SECTION 4 PLATFORM FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) FIG & ITEM # PART NUMBER DESCRIPTION Note: Original Equipment controller may have been replaced with Service Replacement controller. Visually identify controller before ordering parts.
PAGE 156
SECTION 4 PLATFORM FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 106 70002727 1 107 108 70002728 Use 1001118416 109 Use 1001113961 4460871 Handle Assembly (See Items 201-210 for Breakdown) Screw Mechanical Assembly (Note: Not Available for Purchase.
PAGE 157
SECTION 4 PLATFORM FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 158
SECTION 4 PLATFORM FIGURE 4-9.
PAGE 159
SECTION 4 PLATFORM FIGURE 4-9. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) FIG & ITEM # PART NUMBER 0257849 0271550 0257850 0271551 1 4845308 4845309 2 3 4 5 6 7 1670804 1670803 1670787 1670785 1670786 1670793 1670798 1670796 8 1670797 1670795 9 1670799 1670789 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3120859 1670801 1670791 0940038 1670788 3539719 0630462 4761500 4751800 3311501 4751500 4460049 3530072 Not Used 4360057 0731005 DESCRIPTION QTY.
PAGE 160
SECTION 4 PLATFORM FIGURE 4-9.
PAGE 161
SECTION 4 PLATFORM FIGURE 4-9. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 162
SECTION 4 PLATFORM FIGURE 4-10.LOAD SENSING SYSTEM INSTALLATION (FRENCH SPEC) (PRIOR TO SN 0300067883) NOTE: These Machine SN’s Also Equipped With ADE System: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975,0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 163
SECTION 4 PLATFORM FIGURE 4-10. LOAD SENSING SYSTEM INSTALLATION (FRENCH SPEC) (PRIOR TO SN 0300067883) FIG & ITEM # PART NUMBER 0258767 0258768 1 1A 1B 1C 2 3 4 5 6 7 8 9 10 11 12 13 to 15 16 17 2901557 7020057 7020058 7020059 3570740 0962180 0641818 3311805 4751800 0641616 3311605 4751600 0641416 3311405 4751400 Not Used 1703801 3124025 0259233 101 101A 101B 102 103 104 105 106 107 3120859 2901811 3990109 7023332 7023331 7023333 0701010 4812000 1670900 0641407 4761400 3311401 DESCRIPTION QTY.
PAGE 164
SECTION 4 PLATFORM FIGURE 4-10. LOAD SENSING SYSTEM INSTALLATION (FRENCH SPEC) (PRIOR TO SN 0300067883) (CONTINUED) FIG & ITEM # 201 202 203 204 205 206 207 208 209 S E C T I O N PART NUMBER DESCRIPTION QTY. REV.
PAGE 165
SECTION 4 PLATFORM FIGURE 4-10. LOAD SENSING SYSTEM INSTALLATION (FRENCH SPEC) (PRIOR TO SN 0300067883) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 166
SECTION 4 PLATFORM FIGURE 4-11.
PAGE 167
SECTION 4 PLATFORM FIGURE 4-11.
PAGE 168
SECTION 4 PLATFORM FIGURE 4-11. PLATFORM SUPPORT (LOAD SENSING) (SN 0300067883 TO SN 0300069000) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 169
SECTION 5 CYLINDER TABLE OF CONTENTS FIGURE 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UPRIGHT LEVEL CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - JIB (800AJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . .
PAGE 170
SECTION 5 CYLINDER 12 13 1 23 8 10 S E C T I O N 4 11 14 15 16 FIGURE 5-1.
PAGE 171
SECTION 5 CYLINDER FIGURE 5-1.
PAGE 172
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 173
SECTION 5 CYLINDER FIGURE 5-2. UPRIGHT LEVEL CYLINDER ASSEMBLY FIG & 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 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 0641818 27 to 29 30 3120859 0630537 Not Used 2901526 DESCRIPTION QTY.
PAGE 174
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 175
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 176
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 177
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 178
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 179
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 180
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 181
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 182
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 183
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 184
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 185
SECTION 5 CYLINDER . FIGURE 5-8. SLAVE CYLINDER ASSEMBLIES FIG & ITEM # PART NUMBER DESCRIPTION Note: Original Equipment Cylinder may have been replaced with Service Replacement Cylinder. Identify p/n stamped on cylinder before ordering parts.
PAGE 186
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 187
SECTION 5 CYLINDER FIGURE 5-8. SLAVE CYLINDER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 188
SECTION 5 CYLINDER FIGURE 5-9.
PAGE 189
SECTION 5 CYLINDER FIGURE 5-9. STEER CYLINDER ASSEMBLY FIG & ITEM # PART NUMBER 1683605 1683740 1683740 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 to 19 20 3120859 7017210 7017211 Use 7017215 Use 7017215 7017234 7023023 7023023 7017236 7017213 Use 7017215 Use 7017215 Use 7017215 Use 7017215 7017214 Use 7017215 0961977 Not Used 7017215 DESCRIPTION QTY. Note: Original Equipment Cylinder may have been replaced with Service Replacement Cylinder. Identify p/n stamped on cylinder before ordering parts.
PAGE 190
SECTION 5 CYLINDER FIGURE 5-10.
PAGE 191
SECTION 5 CYLINDER FIGURE 5-10.
PAGE 192
SECTION 5 CYLINDER FIGURE 5-11.
PAGE 193
SECTION 5 CYLINDER . FIGURE 5-11.
PAGE 194
SECTION 5 CYLINDER FIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY - TOWER (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 195
SECTION 6 HYDRAULIC TABLE OF CONTENTS FIGURE 6-1 6-2 6-3 6-4 6-5 6-6 DESCRIPTION AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) . . . . . .
PAGE 196
SECTION 6 HYDRAULIC FIGURE 6-1.
PAGE 197
SECTION 6 HYDRAULIC FIGURE 6-1.
PAGE 198
6-4 7 C S A B 24 40 FREE FLOW 41 5 RIGHT REAR DRIVE MOTOR 12 13 6 44 3 10 3 27 11 26 25 T B S TOP CASE PORT 19 34 CYLINDER PUMP 52 4 56 14 1 M1 B M3 35 1 2 29 51 14 33 B A REAR PORT #1 30 50 UPPER CASE PORT 32 FRONT PORT #1 35 30 1 11 DRIVE PUMP NOTE: REMOVE O-RING PLUGS & INSTALL #14 14 A M2 47 4 4 6 M4 5 FLOW DIVIDER COMBINER REAR PORT FRONT PORT #6 #2 2-SPEED PORT #2 FORWARD SHIFT 11 9 48 ***IMPORTANT*** THIS HOSE MUST CONNECT TO THE REAR
PAGE 199
SECTION 6 HYDRAULIC FIGURE 6-2.
PAGE 200
SECTION 6 HYDRAULIC FIGURE 6-2.
PAGE 201
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 202
X BRAKE S 3 X 39 B A X X X 40 39 A X 6 3 26 27 11 25 A X X T B S 2-SPEED VALVE REF. HYD. LOCKOUT DIA.
PAGE 203
SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 204
SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 205
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 206
SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 207
SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 208
SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 209
SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 210
6-16 2 P1 X V1 4 35 41 X V1 34 X X V2 2 P2 32 31 49 Port Block on Upright Lift Cylinder P1 V2 23 Port Block on Lower Lift Cylinder 19 X 4 70 30 85 60 65 V2 V1 62 LIFT DOWN LIFT UP 30 C V 5 SWING MOTOR X 59 23 22 1 2 71 68 30 72 V2 T V1 ROTATOR ACTUATOR R E PORT BLOCK ON TOWER TELE CYL.
PAGE 211
SECTION 6 HYDRAULIC FIGURE 6-5.
PAGE 212
SECTION 6 HYDRAULIC FIGURE 6-5.
PAGE 213
SECTION 6 HYDRAULIC FIGURE 6-5. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP (CONTINUED) FIG & ITEM # PART NUMBER 83 84 85 86 87 to 88 89 90 91 92 2220873 2220947 2221036 2220950 Not Used 2220655 2220501 2220603 Not Required 2180724 93 94 95 96 97 98 Not Required 2180380 0100019 1001109690 2220606 2220923 1001143192 2902456 2902457 2902459 2902457 3120859 DESCRIPTION QTY.
PAGE 214
SECTION 6 HYDRAULIC FIGURE 6-6.HYDRAULIC DIAGRAM LIST S E C T I O N Note: Diagrams with asterisk (*) are shown in the preceding pages. Information on diagrams not shown is available from JLG Service/Parts Departments.
PAGE 215
SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE 7-1 7-2 7-3 DESCRIPTION PAGE ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 HARNESS COMPONENTS INSTALLATION (PRIOR TO SN 0300064432). . . . . . . . . . . . . . . . 7-6 HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 216
SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. NOTE: THESE MACHINE SN’S ALSO EQUIPPED WITH ADE SYSTEM: 0300062045, 0300062797, 0300063013, 0300063665, 0300063975, 0300064000-0300064017, 0300064390, 0300064392 & 0300064411.
PAGE 217
SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER QTY. REV.
PAGE 218
SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION NOTE: FOR SCHEMATIC P/N 1870132 SEE FIELD BULLETIN FSB107C2 FOR PLATFORM AND MTB WIRING. QTY. REV.
PAGE 219
SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 220
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 221
SECTION 7 ELECTRICAL S E C T I O N 7 E L E C T R I C A L 3120859 7-7
PAGE 222
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (PRIOR TO SN 0300064432) FIG & ITEM # PART NUMBER 4922155 4922137 1 to 38 39 40 to 43 44 45 to 47 48 49 50 51 to 54 55 56 57 to 59 60 61 62 63 64 65 66 67 68 69 to 89 90 91 S E C T I O N 7 E L E C T R I C A L Not Used 1060012 Not Used 2920129 Not Used 4460265 4460418 4460419 Not Used 4460720 4460721 Not Used 4460464 4460508 3990001 Not Used 4460225 4460267 3990010 Not Used 4120035 Not Used 4460613 4460503 DESCRIPTION QTY.
PAGE 223
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 224
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 225
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 226
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 227
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 228
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 229
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (PRIOR TO SN 0300064432) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 230
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 231
SECTION 7 ELECTRICAL S E C T I O N 7 E L E C T R I C A L 3120859 7-17
PAGE 232
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 233
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 234
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 235
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 236
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 237
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 238
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 239
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 240
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM) (SN 0300064432 TO SN 0300069000) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 241
SECTION 8 DECALS TABLE OF CONTENTS FIGURE 8-1 DESCRIPTION PAGE DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 242
44 8-2 31 9 48 7 26 22 20 24 21 23 44 12 34 206 207 5 8 9 48 15 11 1 D E C A L S 8 25 13 35 4 27 24 10 12 27 4 32 2 4 24 29 14 23 S E C T I O N 31 30 4 101 23 40 224 17 16 18 26 7 24 25 4 35 31 30 13 36 44 SECTION 8 DECALS FIGURE 8-1.
PAGE 243
SECTION 8 DECALS FIGURE 8-1.
PAGE 244
SECTION 8 DECALS FIGURE 8-1.
PAGE 245
SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 36 37 to 39 40 1701505 Not Used 41 to 43 44 44 to 47 48 Use 1705977 Use 1705977 Use 1705977 Use 1705977 Use 1705977 Use 1705977 Not Used 4420051 Not Used 1704885 0258671 101 0860520 1060279 0641408 0641406 4751400 3311405 0100011 1001091538 1001093187 201 to 205 206 207 208 to 223 224 3120859 Not Used 1707111 1707113 Not Used 1705977 DESCRIPTION QTY.
PAGE 246
SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 247
SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 800A/800AJ The following list will service fleets of machines (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 248
S E C T I O N 9 R E C O M M E N D E D S E R V I C E P A R T S S T O C K SECTION 9 RECOMMENDED SERVICE PARTS MODELS 800A/800AJ The following list will service fleets of machines (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 249
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 10-1 MISCELLANEOUS SPECIAL OPTIONS: QTY.
PAGE 250
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.
PAGE 251
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 1001149560 1001143256 SkyGuard Component Options: SkyGuard Complete Add-On Kit (Non-UGM Machines) SkyGuard Blue Beacon Kit QTY.
PAGE 252
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. S E C T I O N FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 253
SECTION 11 PART NUMBER INDEX Part Number 0060031 0060033 0060041 0060066 0060069 0060074 0060077 0080163 0080241 0100009 0100011 0100019 0100020 0100035 0100038 0100040 0100048 0100063 0100079 0100081 0100083 0140001 0140011 0140026 0140032 0181727 0200530 0200550 0200741 0200742 0239585 0254798 0255262 0255294 0255316 0255398 3120859 Page ................ 3-7, 3-19 .............. 2-32, 7-11 ................ 3-4, 3-19 ................ 3-7, 3-23 ................ 3-3, 3-23 .........................
PAGE 254
SECTION 11 Part Number 0630462 0630464 0630491 0630498 0630507 0630518 0630534 0630535 0630536 0630537 0630539 0630548 0641403 0641404 0641405 0641406 0641407 0641408 0641410 0641414 0641416 0641418 0641420 0641422 0641436 0641506 0641508 0641510 0641514 0641524 0641550 0641552 0641604 0641605 0641606 0641607 0641608 0641609 0641610 0641611 0641612 0641614 0641615 0641616 0641618 11-2 PART NUMBER INDEX Page ....................... 4-37 .............. 4-14, 4-19 ....................... 2-59 ........
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SECTION 11 Part Number Page 1001143191 ................... 2-4 1001143192 ................. 6-19 1001143256 ................. 10-3 1001144023 ................... 4-9 1001144024 ................... 4-9 1001144629 ................... 4-9 1001148902 ................. 10-1 1001148903 ................. 10-1 1001148904 ................. 10-1 1001148905 ................. 10-1 1001148906 ................. 10-1 1001148971 ................. 10-2 1001149560 ................. 10-3 1060012 ................
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SECTION 11 Part Number 1705165 1705325 1705977 1707111 1707113 1840012 1840013 1840014 1840015 1870064 1870132 2000146 2000173 2000189 2060025 2080040 2080044 2120150 2120163 2120167 2120168 2160003 2180344 2180380 2180536 2180615 2180724 2180798 2200222 2220063 2220235 2220237 2220240 2220242 2220250 2220273 2220313 2220362 2220363 2220365 2220366 2220371 2220373 2220374 2220375 2220376 2220377 2220379 2220380 2220381 2220385 2220414 2220415 2220428 2220429 2220451 11-4 PART NUMBER INDEX Page ........
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SECTION 11 Part Number 2753161 2753162 2753187 2753189 2753190 2753191 2753192 2753195 2753196 2753197 2753199 2753200 2753216 2753231 2760105 2780205 2780227 2780228 2780229 2792351 2792362 2792363 2792364 2792365 2792366 2792367 2820031 2820035 2820078 2820079 2820080 2820081 2840016 2860012 2860030 2900708 2900770 2900788 2900792 2900838 2901271 2901273 2901301 2901303 2901392 2901443 2901514 2901526 2901537 2901549 2901556 2901557 2901609 2901712 2901811 2902396 3120859 Page ........................
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SECTION 11 Part Number 3539281 3539685 3539719 3539872 3539877 3539878 3539934 3539955 3539957 3539971 3539979 3570488 3570686 3570690 3570740 3570775 3570928 3570979 3572604 3572605 3572606 3572607 3573447 3573448 3573515 3573516 3580134 3580158 3580276 3600277 3600278 3600287 3600295 3620033 3640970 3640986 3641182 3730023 3730099 3740049 3740057 3740058 3740063 3740066 3740067 3740080 3740112 3740113 3740115 3760133 3760170 3760367 3760368 3760369 3760370 3760374 11-6 PART NUMBER INDEX Page .......
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SECTION 11 Part Number Page 4460419 7-8, 7-10, 7-18, 7-21 4460424 2-59, 7-11, 7-13, 721, 7-22, 7-23 4460425 .....4-38, 7-14, 7-24 4460426 .....2-52, 2-55, 7-21 4460428 2-52, 3-25, 3-26, 327, 4-14, 4-20, 7-8, 7-18 4460434 .............. 7-18, 7-21 4460442 ....................... 7-14 4460445 7-11, 7-13, 7-21, 723 4460449 ....................... 7-11 4460457 .............. 7-11, 7-22 4460458 .............. 7-11, 7-22 4460460 ..............
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SECTION 11 Part Number 4845409 4845411 4845412 4845413 4845426 4845469 4845531 4845593 4845617 4845658 4845680 4845682 4845701 4845702 4845703 4845716 4845729 4845730 4845871 4845872 4845928 4846081 4846101 4846102 4846103 4846184 4846194 4846195 4846228 4846229 4846240 4846241 4846253 4846254 4846255 4846430 4846452 4846479 4846566 4846573 4891500 4891600 4891800 4892000 4892600 4920018 4921028 4921820 4921829 4921850 4921927 4921928 4921938 4921955 4921957 4922008 4922012 4922046 11-8 PART NUMBER INDEX
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SECTION 11 Part Number 7000798 7001498 7001901 7001902 7001903 7001906 7001909 7001911 7001912 7001928 7001931 7001985 7001987 7001988 7002111 7002117 7002123 7002821 7002822 7002823 7002826 7002828 7002840 7003049 7003050 7003094 7003451 7003452 7003453 7003454 7003455 7003456 7003457 7003458 7003459 7003460 7003461 7003462 7003463 7003657 7003928 7003933 7003935 7003941 7003946 7003952 7003953 7003954 7003955 7003956 7003969 7003972 7003973 7003974 7003976 7003977 7003980 7003982 7003983 3120859 Page
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SECTION 11 Part Number 7017034 7017035 7017036 7017037 7017038 7017039 7017040 7017041 7017042 7017043 7017044 7017045 7017046 7017047 7017048 7017050 7017051 7017052 7017053 7017054 7017055 7017056 7017057 7017058 7017068 7017070 7017082 7017085 7017089 7017101 7017102 7017115 7017116 7017117 7017118 7017119 7017142 7017156 7017157 7017158 7017159 7017162 7017163 7017164 7017174 7017177 7017183 7017193 7017210 7017211 7017213 7017214 7017215 7017234 7017236 7017414 7017420 7017421 7017422 11-10 PART NUM
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SECTION 11 Part Number 7022396 7022397 7022398 7022399 7022808 7022810 7022812 7022813 7022814 7022815 7022816 7022817 7022818 7022819 7022822 7022823 7022824 7022825 7023023 7023206 7023207 7023331 7023332 7023333 7023340 7023366 7023900 7023977 7023981 7024100 7024155 7024185 7024189 7024190 7024191 7024192 7024193 7024194 7024195 7024196 7024197 7024318 7024379 7024380 7024396 7024397 7024398 7024413 7024453 7024454 7024455 7024456 7024457 7024458 7024459 7024508 7024560 7024565 7024579 3120859 Page
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SECTION 11 Part Number 11-12 PART NUMBER INDEX Page Part Number Page Part Number Page Part Number Page 3120859
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3120859 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.