Parts Manual Instruction Manual

ManualsBrandsJLG ManualsSpecial machinery860SJ

Illustrated Parts Manual

Models

800S

860SJ

Prior to

SN 0300140000

3121140

January 17, 2014

Summary of content (446 pages)

PAGE 1
Illustrated Parts Manual Models 800S 860SJ Prior to SN 0300140000 3121140 January 17, 2014
PAGE 2
PAGE 3
REVISION LOG NOTES: GROUND MODULE MODULE IDENTIFICATION MODULE ON MACHINES “WITHOUT UGM” (UNIVERSAL GROUND MODULE) MODULE ON MACHINES “WITH UGM” (UNIVERSAL GROUND MODULE) REVISION LOG: October 15, 2001 - Original Issue Of Manual (Edited to B/M 0010575 Revision 3) December 15, 2001 - Revised Manual (Edited to B/M 0010575 Revision 7) April 25, 2002 - Revised Manual (Edited to B/M 0010575 Revision 14) November 19, 2002 - Revised Manual (Edited to B/M 0010575 Revision 22) April 9, 2003 - Revised Manual (Ed
PAGE 4
REVISION LOG November 4, 2009 - Revised Manual (Edited to B/M 0010575 Revision 104) May 3, 2010 - Revised Manual (Edited to B/M 0010575 Revision 110) November 30, 2010 - Revised Manual (Edited to B/M 0010575 Revision 119) April 21, 2011 - Revised Manual July 22, 2011 - Revised Manual October 14, 2011 - Revised Manual January 10, 2012 - Revised Manual June 15, 2012 - Revised Manual August 2, 2012 - Revised Manual January 4, 2013 - Revised Manual April 2, 2013 - Revised Manual June 28, 2013 - Revised Manual S
PAGE 5
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE. . . . . . . . . . . . . 1-2 AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . 1-6 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS FIGURE NO. 2-33 2-34 2-35 TITLE PAGE NO. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES. . . . . . . . . . .2-168 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES . . . . . . . . . . . . .2-172 SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 7
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 8-1 8-2 8-3 8-4 DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) . . . . . . . . . . . . . 8-2 DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) . . . . . 8-6 DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) . . . . . . . . 8-10 DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) .
PAGE 8
TABLE OF CONTENTS FIGURE NO. iv TITLE 800S 860SJ PAGE NO.
PAGE 9
SECTION 1 FRAME 3121140 800S 860SJ 1-1
PAGE 10
SECTION 1 FRAME FIGURE 1-1.
PAGE 11
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NUMBER QTY.
PAGE 12
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION REV. 0272003 Ref Ref STEERING INSTALLATIONS (2WS) Note: Before ordering king pin kit, verify that machines is equipped with the original components (king pin with 4 bolt holes) or service kit components (king pin with 8 bolt holes). - If the king pin hole in the axle measurement exceeds 2.252in OD or is elongated, use King Pin Kit p/n 1001137261.
PAGE 13
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED) ITEM # PART NUMBER QTY. 407 408 409 410 411 412 7010406 7000265 7017054 7017051 7017057 7017058 2 20 2 2 2 2 501 Ref 1 2360568 2360687 2360555 2360688 1 2360566 2360689 2360568 2360687 3121140 DESCRIPTION REV.
PAGE 14
SECTION 1 FRAME FIGURE 1-2.
PAGE 15
SECTION 1 FRAME FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE ITEM # PART NUMBER QTY.
PAGE 16
SECTION 1 FRAME FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED) ITEM # PART NUMBER QTY. 218 219 220 221 222 223 224 225 226 3841143 4130390 4130388 4740111 4740155 4740256 4740463 4740473 8 1 1 6 2 4 2 2 1 227 228 4846414 4846935 0641810 16 4 0741607 0741609 229 230 301 302 to 303 304 305 to 306 307 308 309 310 to 315 316 401 402 403 404 405 406 407 408 409 410 411 412 1-8 3340966 4071059 2 4 0271341 0273378 Ref Ref Ref DESCRIPTION REV.
PAGE 17
SECTION 1 FRAME FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED) ITEM # PART NUMBER 501 QTY. Ref 1 2360568 2360687 2360555 2360688 1 2360566 2360689 2360568 2360687 3121140 DESCRIPTION REV.
PAGE 18
SECTION 1 FRAME FIGURE 1-3.
PAGE 19
SECTION 1 FRAME FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS ITEM # 1 2 to 3 4 5 PART NUMBER QTY.
PAGE 20
SECTION 1 FRAME FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 21
SECTION 1 FRAME FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 22
SECTION 1 FRAME FIGURE 1-4.
PAGE 23
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) ITEM # PART NUMBER QTY.
PAGE 24
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) (CONTINUED) ITEM # PART NUMBER QTY. 16 17 18 19 20 21 7000288 7000289 Not Used 7000290 7017047 7017050 2 12 Thrustwasher Bolt 3/8in-16NC x 2-1/2in (Grade 8) 1 2 AR Coupling Pin, Dowel Thrustwasher Ref 100 1-16 7017068 1 DESCRIPTION REV.
PAGE 25
SECTION 1 FRAME FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 26
SECTION 1 FRAME FIGURE 1-5.
PAGE 27
SECTION 1 FRAME FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) ITEM # PART NUMBER QTY.
PAGE 28
SECTION 1 FRAME FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 29
SECTION 1 FRAME FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 30
SECTION 1 FRAME FIGURE 1-6.
PAGE 31
SECTION 1 FRAME FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 32
SECTION 1 FRAME FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 33
SECTION 1 FRAME FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY. Ref 200 200A 200B 201 201A Use 7024196 AR 1 1 AR 1 201B 7024196 1 201C 7024193 201D 7024197 3121140 7017068 7024194 1 1 DESCRIPTION REV.
PAGE 34
SECTION 1 FRAME FIGURE 1-7.
PAGE 35
SECTION 1 FRAME FIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD PRIOR TO SN 0300083331) 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 PART NUMBER QTY.
PAGE 36
SECTION 1 FRAME FIGURE 1-8.
PAGE 37
SECTION 1 FRAME FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 & ALL 4WD MACHINES) (4 BOLT ASSEMBLY) ITEM # 1 2 3 4 5 6 7 8 PART NUMBER QTY.
PAGE 38
SECTION 1 FRAME FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 & ALL 4WD MACHINES) (4 BOLT ASSEMBLY) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 39
SECTION 1 FRAME FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 & ALL 4WD MACHINES) (4 BOLT ASSEMBLY) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 40
SECTION 1 FRAME FIGURE 1-9.
PAGE 41
SECTION 1 FRAME FIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) ITEM # 1 2 3 4 5 6 7 7A PART NUMBER QTY.
PAGE 42
SECTION 1 FRAME FIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT 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 7027741 7022372 See Note 2220883 Use 7022328 2220886 Use 7022328 Use 7022328 Use 7022328 7024871 7024854 7007437 7022326 Use 7022328 7022371 1 2 2 1 1 1 1 1 1 1 1 1 Ref 100 1-34 7022328 1 DESCRIPTION REV.
PAGE 43
SECTION 1 FRAME FIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 44
SECTION 1 FRAME 9B 9 9B 9A 11 10 101 102 104 103 101 102 104 101 102 104 10B 10A 10A 11 1 3 1 3 MOUNTED INSIDE FRAME. SHOWN HERE FOR CLARITY FIGURE 1-10.
PAGE 45
SECTION 1 FRAME FIGURE 1-10. FRAME VALVES & SHIELDS INSTALLATIONS (PRIOR TO SN 0300083331) ITEM # 1 2 3 4 to 8 9 9A 9B PART NUMBER QTY.
PAGE 46
SECTION 1 FRAME FIGURE 1-11.
PAGE 47
SECTION 1 FRAME FIGURE 1-11. FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO SN 0300140000) ITEM # 1 2 3 to 10 11 12 12A 12B PART NUMBER QTY.
PAGE 48
SECTION 1 FRAME FIGURE 1-11. FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO SN 0300140000) (CONTINUED) ITEM # 201 202 203 204 205 1-40 PART NUMBER QTY. 0274267 Ref DESCRIPTION 0100011 0641608 3575718 Not Used 4751600 6 6 1 Compound, Locking Bolt, 3/8in - 16NC x 1in Plate, Cover Front 6 Flatwasher 3/8in Regular FRAME SHIELDS INSTALLATIONS 800S 860SJ REV.
PAGE 49
SECTION 1 FRAME FIGURE 1-11. FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO SN 0300140000) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 50
SECTION 1 FRAME FIGURE 1-12.
PAGE 51
SECTION 1 FRAME FIGURE 1-12. TOW PACKAGE INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 3121140 PART NUMBER QTY.
PAGE 52
SECTION 1 FRAME FIGURE 1-12. TOW PACKAGE INSTALLATION (CONTINUED) ITEM # 1-44 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 53
SECTION 2 TURNTABLE 3121140 800S 860SJ 2-1
PAGE 54
SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 55
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS ITEM # 1 2 3 4 5 PART NUMBER QTY.
PAGE 56
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 57
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED) ITEM # 201 202 203 204 205 206 207 208 209 210 to 212 213 213A 213B 213C 214 215 216 217 218 to 219 220 221 222 223 224 225 226 227 228 229 3121140 PART NUMBER QTY.
PAGE 58
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 59
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 PART NUMBER QTY.
PAGE 60
SECTION 2 TURNTABLE FIGURE 2-3.
PAGE 61
SECTION 2 TURNTABLE FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION ITEM # PART NUMBER QTY.
PAGE 62
SECTION 2 TURNTABLE FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION (CONTINUED) ITEM # 201 202 203 204 301 302 303 304 305 2-10 PART NUMBER QTY. DESCRIPTION 0259147 Ref 4844958 3421565 3760170 1260017 1 1 2 9in/23cm 0271496 Ref REMOTE BEARING LUBE INSTALLATION 2160001 2180344 2220063 2220124 2751032 1 1 1 1 1 Fitting, Grease Fitting, Bulkhead Fitting, Elbow Fitting, Elbow (Prior to SN 0300111097) Hose, Grease TURNTABLE LOCK INSTALLATION REV.
PAGE 63
SECTION 2 TURNTABLE FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 64
SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-4. SWING HUB ASSEMBLY (PRIOR TO SN 0300066417) ITEM # PART NUMBER QTY.
PAGE 66
SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 67
SECTION 2 TURNTABLE FIGURE 2-5. SWING MOTOR ASSEMBLY (PRIOR TO SN 0300066417) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 to 21 22 23 24 to 29 30 31 to 40 41 42 43 43A PART NUMBER QTY.
PAGE 68
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 69
SECTION 2 TURNTABLE 27 220 101 208 213 214 102 104 207 105 217 218 103 106 104 209 107 215 104 216 108 201 104 206 36 109 203 31 110 104 206 112 203 29 204 23 219 202 115 28 222 223 221 113 30 21 32 114 116 117 118 29 28 22 119 120 212 210 211 3121140 800S 860SJ 35 19 205 2-17
PAGE 70
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) ITEM # PART NUMBER QTY.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) ITEM # PART NUMBER QTY.
PAGE 72
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) ITEM # PART NUMBER QTY. 219 220 221 222 223 7024190 See Note See Note Use 7024196 Use 7024196 2 1 1 AR AR Ref 300 300A AR Use 7024389 300B 301 301A Use 7024196 1 AR 1 301B 7024196 1 301C 7024193 301D 7024197 2-20 7024194 1 1 1 DESCRIPTION REV. Pin, Dowel Plug (Note: Not Available - Purchase Locally.) Plug (Note: Not Available - Purchase Locally.
PAGE 73
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 74
SECTION 2 TURNTABLE FIGURE 2-7.
PAGE 75
SECTION 2 TURNTABLE 101 26 102 104 8L 105 8A 103 106 104 107 8E 201 200A 200B 200C 8D 104 8F 108 8H 104 8K 109 8J 110 31 104 8K 112 8J 113 29 115 8K 28 8J 23 8K 8J 30 21 32 114 116 125 117 118 29 28 22 119 120 8K 35 3121140 800S 860SJ 2-23
PAGE 76
SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134352 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 77
SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134352 TO SN 0300140000) ITEM # PART NUMBER QTY. 23 24 25 26 27 28 29 30 31 32 33 to 34 35 36 to 43 44 7017023 See Note 7000281 7024763 Not Used See Note 70002069 7017085 70002075 7024784 Not Used 70002074 Not Used 7017028 2 1 2 1 Plug, Pipe Plate, ID (Note: Not Available for Purchase.) Screw, Drive O-Ring 2 2 2 1 1 Lug, Lifting (Note: Not Available for Purchase.
PAGE 78
67 2-26 144 10 27 33 53 37 68 29 49 53B 29 31 44 67 46 800S 860SJ 3 80 23 39 53A 18 66 41 73 48 19 3 57 15 46 68 14 40 27 217 207 2 214 209 35 27 210 226 206 212 204 221 27 218B 218 218A 68 56 116 4 64 205 216 34 63 223 224 59 32 71 20 1 68 70 19 222 213 36 28 67 3 22 21 18 41 66 48 14 215 68 46 220 52 202 4 50 77 225 38 29 37 201 76 44 51 14 68 46 66 48 41 69 102 13 43 30 121 145 68 3 22 65 147 45 3 81 6 148 70 12 211 67 18 28
PAGE 79
3121140 800S 860SJ 119 16 46 68 46 68 68 9 110 111 PRIOR TO SN 0300110581 5 GRD. GLOW PLUG RELAY 107E AUX.PWR. START RELAY RELAY AUX.PWR. PUMP GLOW PLUG RELAY 8 135 132 134 72 AUX.PWR. START RELAY RELAY 107B GRD. 113 121 107B GRD.
PAGE 80
SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 81
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) ITEM # PART NUMBER QTY.
PAGE 82
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) ITEM # PART NUMBER QTY. 4568788 4569177 1 1 1 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 1 4640750 Use 4640750 4711500 4740274 4751400 4751600 4751800 4811900 4832000 4846790 4846805 4922737 0721006 2720515 2220767 8 4 28 AR 1 AR 8 1 1 1 1 1 1 2.63gl/9.96Li 2300004 2300041 79 2.5gal/9.
PAGE 83
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) ITEM # PART NUMBER 0273527 0274626 1001106698 0275585 1001106699 101 102 QTY.
PAGE 84
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) ITEM # PART NUMBER QTY. 110 111 112 113 114 115 116 117 118 119 120 121 122 123 0642010 4752000 1320223 0641606 4711600 4060805 3960549 3790044 4891800 3960464 3539934 0100011 0100020 1 1 AR 2 4 2220273 Not Required 124 2ft/0.7mm 1ft/0.3mm 1 2 42in/1m 1 AR AR AR 1 0 1 2180536 125 126 127 2221176 2220313 2750532 2220250 Not Required 128 129 130 131 1 7ft./2.
PAGE 85
SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 86
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) ITEM # PART NUMBER QTY.
PAGE 87
SECTION 2 TURNTABLE FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) ITEM # PART NUMBER QTY. 228 70002766 7026801 70002764 70002767 70002761 70002762 70002845 70002846 Not Used 70002851 7026839 70002763 7026830 70002834 70002835 70002833 1 1 1 1 AR AR 1 1 229 230 231 232 3121140 1 1 1 1 1 1 1 DESCRIPTION REV.
PAGE 88
2-36 60 800S 860SJ 315 316 320 335 336 337 69 48B 31 48 33 7 69 60 62 330 211 407 3 17 62 13 3 52 51 77 425 76 321 32 412 322 327 301 304 415 317 418 334 70 70 2 402 70 35 301 304 411 317 301 309 313 316 301 324 303 332 325 310 302 316 44 328 304 68 317 301 307 316 324 413 65 405 21 301 37 301 311 12 306 319 59 74 316 62 324 16 42 29 48A 75 70 301 304 308 317 316 331 338 210 312 210 210 40 42 62 18 20 1 66 30 323 34 45 26 60 16 37 59 44 409 301 401 305 314 410 3
PAGE 89
3121140 800S 860SJ 106 ENGINE TRAY KEEPER PIN BOLT 121 + - BATTERY MTG BOLT FOR GLOW PLUG RELAY GLOW PLUG RELAY 215A 6 INCLUDES ITEMS 215A THRU 215D ENGINE MOUNTING BOLT 215B ITEM 215 - BATTERY CABLE KIT 215C STARTER AUX PWR RELAY 67 AUX POWER PUMP 215D 14 42 62 14 42 62 61 71 73 72 58 27 215B 205 212 206 3 11 101 105 120 25 101 103 53 53 24 15 63 43 404 202 107 SUPPLY 24 117 119 49 115 101 104 49 102 112 TANK REF.
PAGE 90
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 2-38 PART NUMBER QTY.
PAGE 91
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 92
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) ITEM # PART NUMBER QTY. 105 106 107 108 109 110 111 112 113 114 0641808 0642010 1320022 1320176 1701505 2180348 2200222 2220313 2221176 1 1 7 1 1 1 1 1 1 115 116 117 118 119 120 121 122 2.63gl/9.96Li 2300004 2300041 2720058 2750532 3422446 3460544 3841143 4711600 4752000 Not Used 30ft/9.1m 7ft./2.
PAGE 93
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 94
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 95
SECTION 2 TURNTABLE FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION 413 7026811 1 7026812 7026813 7026819 7026816 7026817 7026822 7026821 7026820 7026814 7026815 See Note 70002763 7026831 7026832 7026833 7026826 7026827 70002852 7026829 7026828 7026808 7026809 70002851 4569371 1 1 1 2 4 1 1 1 1 Filter, Oil Note: Machines with SkyPower use Remote Mounted Oil Filter - See Section 10. The same oil filter is used for all applications.
PAGE 96
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 97
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) ITEM # PART NUMBER QTY.
PAGE 98
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 99
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 100
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) (CONTINUED) ITEM # PART NUMBER QTY. 315 7024565 70003931 70003931 See Note 7024579 7020471 1 1 1 1 316 317 318 4 1 70002415 70002416 70002417 401 402 403 404 405 406 407 2-48 0256847 Ref 1660234 0080163 0700810 4831900 Not Used 4832000 3020021 1 1 6 6 8 AR DESCRIPTION REV.
PAGE 101
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 102
2-50 800S 860SJ 254 208 254 235 201 251 214 208 254 37 221 111 241 111 264 254 208 258 236 235 254 235 230 254 208 253 252 236 239 230 412 401 245 205 232 112 409 411 210 252 254 235 223 226 201 211 225 254 235 254 111 238 235 201 214 402 208 254 251 210 225 237 222 221 233 40 420 405 430 41 209 252 423 424 227 301 307 240A 351 231 236 226 204 220 OR 217 OR 240B 267 201 268 201 208 250 261 260 306 248 114 101 103 108 110 269 250 259
PAGE 103
3121140 4 6 800S 860SJ 4 257 6 22 2 3 SN 0300077586 TO SN 0300110581 20 19 21 7 8A 8B AUX PWR PUMP 17E GLOW PLUG RELAY STARTER 17D 17A + GRD. 17E 17D 23 246 106 113 102 246 216 14 266 11 16 265 28 15 242 266 GLOW PLUG RELAY AUX.PWR. START RELAY RELAY BATTERY + BATTERY CABLES RETURN SN 0300138238 24 TO SN 0300140000 17A STARTER 265 GRD. 17B 244 419 11 36 35 107 GLOW PLUGS ON ENGINE AUX PWR PUMP AUX.PWR.
PAGE 104
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # PART NUMBER 0273800 0274302 1001099829 0275584 1001100382 1 2 3 4 5 6 7 8 8A 8B 9 10 11 12 13 14 15 16 17 17A 17B 2-52 Not Used 0642010 4752000 0630498 1001093382 3311605 4751600 0400075 QTY.
PAGE 105
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # PART NUMBER QTY. 17C 7016803 1 Not Required 1 17D 17E 18 19 7016824 7016825 4922737 4751400 1 1 1 4 20 21 3311405 0641406 4 4 22 23 24 25 26 27 28 29 30 31 32 33 34 3960464 3539934 1320022 1320223 0100020 2200222 2720058 2180348 2221176 2750532 2220313 1701505 4922978 3.5ft/1.1m 1 5 1 AR 1 30ft/9.2m 1 1 7ft/2.
PAGE 106
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # PART NUMBER QTY. 45 1702943 1 46 47 48 1702944 2580024 2580050 1 1 1 49 50 0641608 1060625 1 1 51 1320223 2 2000233 2000285 1001099828 2000391 1001100381 101 102 103 104 105 0100011 0641407 0641812 Not Used 3020016 3.
PAGE 107
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 108
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # 228 229 230 231 232 PART NUMBER 2720434 1001091179 2720449 2750532 1001091892 3200362 3200406 QTY.
PAGE 109
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # 250 251 PART NUMBER 1001104308 4711600 QTY. AR AR 4711900 252 253 254 255 256 257 258 259 260 261 4812200 4740274 4751400 4751600 4791400 4845395 4845404 1001094321 4846566 4711700 4751700 4 AR AR AR 1 1 1 6 2 2 0701012 0701015 262 4751400 4711400 263 AR 4 6 3.
PAGE 110
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 111
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 112
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # 420 421 422 423 424 425 426 PART NUMBER QTY. 7027796 70000345 7020459 7020460 1 4 1 1 1 70000264 70001870 7024579 7027245 1 1 1 7027239 See Note 427 70001847 70001126 428 1 1 1 1 70003001 70003002 70003003 1 70002415 70002416 70002417 429 1 70000800 See Note 430 431 70002200 8 1 See Note 432 2-60 7027794 70001872 7027793 70001847 1 1 70001126 1 DESCRIPTION REV. Harness.
PAGE 113
SECTION 2 TURNTABLE FIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 114
SECTION 2 TURNTABLE FIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) 15 24 15 24 20 407 20 308 17 21 23 401 126 143 144 FUEL RETURN161 126 134 143 156 143 191 143 190 126 161 9 404 309 122 18 21 23 402 401 VENT LINE 307 325 183 19 24 16 405 406 SEE DUAL FUEL INSTL.
PAGE 115
SECTION 2 TURNTABLE FIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) ITEM # PART NUMBER QTY.
PAGE 116
SECTION 2 TURNTABLE FIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 117
SECTION 2 TURNTABLE FIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) (CONTINUED) ITEM # PART NUMBER QTY. 154 155 156 157 158 158A 158B 158C 158D 158E 159 160 161 162 163 164 165 166 167 168 169 170 171 172 2720436 1641808 2220430 2180798 2901608 7016800 7016807 7016808 7016824 7016825 4460611 Not Used 2720058 1320223 3422532 0641606 0642010 4752000 0700819 4831900 0961986 1060637 1701542 4060804 1 2 1 AR 1 1 1 1 1 1 1 21ft/6.2m 3 1 3 1 1 4 4 2 1 1 AR 19in/49cm 2.9ft/0.
PAGE 118
SECTION 2 TURNTABLE FIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 119
SECTION 2 TURNTABLE FIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) (CONTINUED) ITEM # PART NUMBER 325 326 327 328 329 330 331 332 333 334 335 3 7023613 7023695 7023644 70002567 7022149 7025124 7022144 7023657 7022153 7027411 7019925 7019930 7022157 7019932 7022151 7022150 7027402 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 3124114 1 0258390 0258391 Ref Ref Ref 401 402 403 404 405 406 407 3121140 QTY.
PAGE 120
2-68 212 264 228 110 249 110 327 217 800S 860SJ 211 264 243 264 210 243 264 240 269 203 216 230 111 264 325 202 243 213 261 10 40 248 244 264 243 264 240 210 26 13 315 24 13 SUPPLY 213 261 313 310 ENGINE 306 203 308 221 242 221 201 262 228 273 208 220 203 234 216 223 244 253 320 319 226 241 264 243 264 245 110 223 262 210 24 13 316 204 231 305 RETURN 255 205 221 213 246 264 210 261 243 264 314 261 213 240 263 264 210 244 264 243 101 103 1
PAGE 121
3121140 800S 860SJ 7 37 29 38 38 35 268 28C 11 39 28E 28A 4 5 32 28B (INCLUDES ITEMS 28A THRU 28E) # 28 - BATTERY CABLE KIT BATTERY AUX.PWR. RELAY FRONT ENGINE MOUNTING BOLT AUX.PWR. 28D PUMP STARTER 212 243 264 30 212 243 264 GRD.
PAGE 122
SECTION 2 TURNTABLE FIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # QTY.
PAGE 123
SECTION 2 TURNTABLE FIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # PART NUMBER QTY. 37 38 39 40 41 42 43 4751400 4751600 4752000 4771800 1700818 3311801 4922737 AR 4 1 1 1 1 1 2000271 2000323 Ref Ref Ref 101 102 103 104 105 106 107 0100011 0641406 0641812 Not Used 3311405 3422532 3600410 AR 1 4 108 3600411 1 109 1 1 1 1 110 111 3790152 3790044 3960548 3960549 112 113 114 4711400 4891800 2300004 1 2 2.
PAGE 124
SECTION 2 TURNTABLE FIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 125
SECTION 2 TURNTABLE FIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 126
SECTION 2 TURNTABLE FIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 127
SECTION 2 TURNTABLE FIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 128
SECTION 2 TURNTABLE FIGURE 2-14. DUAL FUEL INSTALLATIONS 1 7 4 184 3 8 DUAL FUEL ENGINE COMPONENTS.
PAGE 129
SECTION 2 TURNTABLE FIGURE 2-14. DUAL FUEL INSTALLATIONS ITEM # PART NUMBER QTY.
PAGE 130
SECTION 2 TURNTABLE FIGURE 2-14. DUAL FUEL INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 131
SECTION 2 TURNTABLE FIGURE 2-14. DUAL FUEL INSTALLATIONS (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 132
SECTION 2 TURNTABLE FIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) 205 250 232 240 217 220 204 111 205 219 247 216 201 232 258 208 251 251 221 233 215 228 235 225 217 215 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR DETAILED ENGINE BREAKDOWN.
PAGE 133
SECTION 2 TURNTABLE 203 256 216 226 216 244 216 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR DETAILED ENGINE BREAKDOWN.
PAGE 134
SECTION 2 TURNTABLE FIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) 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 2-82 PART NUMBER QTY.
PAGE 135
SECTION 2 TURNTABLE FIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) (CONTINUED) ITEM # PART NUMBER QTY. 40 41 42 43 44 45 46 47 48 49 50 3422446 3790012 3841143 4360336 4711500 4751400 4751600 4752000 4771800 4922737 4751500 1 1 1 1 4 8 4 1 1 1 2 51 52 88521205 2300004 2 2.63gal.
PAGE 136
SECTION 2 TURNTABLE FIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) (CONTINUED) ITEM # 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 PART NUMBER QTY.
PAGE 137
SECTION 2 TURNTABLE FIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) (CONTINUED) ITEM # PART NUMBER QTY. 234 235 236 237 3311805 3539872 3572280 3620040 Use 8180311 3740067 3960468 3960469 4060805 4341239 4341241 4569342 4569394 4 1 1 1 1 2 1 1 3ft/0.
PAGE 138
SECTION 2 TURNTABLE FIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) 114 220 205 217 247 232 208 204 240 113 219 205 250 232 216 201 258 251 233 251 113 244 217 225 216 216 256 221 215 235 216 226 228 215 227 237 216 215 (NOT SHOWN) 245 203C 203 210 248 203A 212 254 248 233 223 230 255 41 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR DETAILED ENGINE BREAKDOWN.
PAGE 139
SECTION 2 TURNTABLE RETURN ON FUEL TANK 28 40 11 25 1 6 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR PART NUMBER. 35 TO LP FUEL SHUT-OFF 22 24 TO ENGINE 24 7 2 17 2 19 12 29 34 34 203B 35 28 26 NOTE: SEE GM ENGINE SUPPLEMENT P/N 3121245 FOR PART NUMBER.
PAGE 140
SECTION 2 TURNTABLE FIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 101 102 103 2-88 PART NUMBER QTY.
PAGE 141
SECTION 2 TURNTABLE FIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 104 105 106 106A 106B 106C 106D 106E 107 108 109 110 0641812 1060637 2902533 7027018 7027015 7027017 7016824 7016825 3311405 3311805 3422532 3600410 4 1 1 1 1 1 1 1 1 1 1 1 111 3600411 1 112 113 114 115 116 117 3790044 3960548 3960549 4711400 4751800 4891800 1 3.66ft/1.1m 1ft/0.
PAGE 142
SECTION 2 TURNTABLE FIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 143
SECTION 2 TURNTABLE FIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 144
2-92 800S 860SJ 1203 1201A 1201 2001 802 1502 806 805 1509 1204 1508 1511 1510 1103 141 1503 165 106 155 142 2004 1104 304 1220 1401 110 603 605 110 105 104 103 101 102 166 111 106 165 604 1002 1003 1001 166 115 1404 902 114 907 905 908 168 918 916 167 916 918 168 108 107 140 2003 119 118 137 501 120 129 2005 2007 121 123 PRIOR TO SN 0300084615 SN 0300084615 TO SN 0300140000 2006 150 158 909 910 911 919 1403 906 2002 160 401 111 130 127
PAGE 145
SECTION 2 TURNTABLE FIGURE 2-17. PISTON PUMP ASSEMBLY ITEM # 1 to 100 101 102 103 104 105 106 107 108 109 110 111 112 to 113 114 115 116 to117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 to 149 150 151 to 154 155 156 to 157 158 3121140 PART NUMBER QTY.
PAGE 146
SECTION 2 TURNTABLE FIGURE 2-17. PISTON PUMP ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 147
SECTION 2 TURNTABLE FIGURE 2-17.
PAGE 148
SECTION 2 TURNTABLE FIGURE 2-18.
PAGE 149
SECTION 2 TURNTABLE FIGURE 2-18. LOAD SENSING PUMP ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 150
SECTION 2 TURNTABLE FIGURE 2-18. LOAD SENSING PUMP ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 151
SECTION 2 TURNTABLE FIGURE 2-18. LOAD SENSING PUMP ASSEMBLY (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 152
SECTION 2 TURNTABLE FIGURE 2-19.
PAGE 153
SECTION 2 TURNTABLE FIGURE 2-19. TANK INSTALLATIONS ITEM # 1 2 3 4 5 6 7 8 PART NUMBER QTY.
PAGE 154
SECTION 2 TURNTABLE FIGURE 2-19. TANK INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY. 206 207 207A 208 209 7024445 7024446 7024374 7024375 7024439 7024440 1 1 1 1 1 1 Ref 301 1 7016314 70001103 1120484 1120487 2-102 DESCRIPTION REV.
PAGE 155
SECTION 2 TURNTABLE FIGURE 2-19. TANK INSTALLATIONS (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 156
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 157
SECTION 2 TURNTABLE FIGURE 2-20. ROTARY COUPLING INSTALLATION (PRIOR TO SN 0300083331) ITEM # PART NUMBER QTY.
PAGE 158
SECTION 2 TURNTABLE FIGURE 2-21.
PAGE 159
SECTION 2 TURNTABLE FIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 101 PART NUMBER QTY.
PAGE 160
SECTION 2 TURNTABLE FIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER 115 116 117 118 119 120 QTY. 2 See Note Use 70001248 7024404 7026505 7026506 7026507 1 1 1 1 1 7026508 Use 7024404 121 122 7026509 1 1 123 7026189 Use 70001248 70003454 1 124 4711000 4 125 See Note 2 126 See Note 4 127 128 4360517 See Note 1 AR Ref 200 200A 7026510 200B 70001248 2-108 1 DESCRIPTION REV. Bearing Options: p/n 1660257 (Note: No Longer Available.
PAGE 161
SECTION 2 TURNTABLE FIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 162
SECTION 2 TURNTABLE FIGURE 2-22.
PAGE 163
SECTION 2 TURNTABLE FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) ITEM # PART NUMBER 0861625 0861753 1810101 0861626 0861754 1810106 0861456 0861718 1810099 1001102248 0861457 0861719 1810104 1001102249 0861454 0861751 0861455 0861752 0861792 1810098 0861793 1810103 1 2 3 3A 4 0630518 0630548 0861389 7020246 QTY.
PAGE 164
SECTION 2 TURNTABLE FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED) ITEM # PART NUMBER 6 QTY.
PAGE 165
SECTION 2 TURNTABLE FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 166
SECTION 2 TURNTABLE FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 167
SECTION 2 TURNTABLE FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 168
SECTION 2 TURNTABLE FIGURE 2-23.
PAGE 169
SECTION 2 TURNTABLE FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) ITEM # 1 2 3 4 5 5A 6 7 8 9 PART NUMBER QTY.
PAGE 170
SECTION 2 TURNTABLE FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY. 32 33 34 4761400 0641506 4922594 6 4 1 35 36 1 1001110341 1001110340 1001110338 1001110339 37 38 39 40 41 2-118 1 1 1001110344 1001110343 1001110342 4460496 4460497 0641407 1001106736 1 1 1 1 DESCRIPTION REV.
PAGE 171
SECTION 2 TURNTABLE FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 172
SECTION 2 TURNTABLE FIGURE 2-24.
PAGE 173
SECTION 2 TURNTABLE FIGURE 2-24. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS ITEM # PART NUMBER QTY. Ref 0271360 0271362 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0100011 0100035 Use 1001106480 1001106480 0641403 1671022 3310805 3930816 3930828 Use 4360578 Use 4360578 Use 4360578 4420060 4751400 Use 1001106449 1001106449 0641406 Not Used 1671059 4071043 4360517 4750800 1001097942 4460968 20 Ref Ref Ref AR AR 1 4 1 4 4 4 4 31.2ft/9.
PAGE 174
SECTION 2 TURNTABLE FIGURE 2-24. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS (CONTINUED) ITEM # 201 202 203 204 205 to 209 210 211 PART NUMBER QTY.
PAGE 175
SECTION 2 TURNTABLE FIGURE 2-24. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY. 231 3911040 4 232 233 234 235 236 237 238 3311005 4751000 4740362 3960461 Not Used 4240032 4460234 4 4 4 2 AR AR 240 4360336 4360522 3790012 1 1 1 1 241 242 3820001 1705170 11 1 239 3121140 DESCRIPTION REV.
PAGE 176
2-124 153 162 152 302 168 169 41 156 50 151 158 303 159 31 155 6 167 50 159 31 103 104 110 172 154 10 102 170 61 47 1 1730 50 30 26 105 14 106 1 47 105 1 107 8 6 50 10 108 163 164 165 31 1 166 1 30 63 17 50 30 109 64 161 65 66 67 23 101 157 21 160 403 404 405 24 401 12 800S 860SJ 2 50 6 11 ITEMS 301 LOCATED ON SIDE 301 TOWARD ENGINE 31 26 44 19 47 53 20 4 48 31 45 50 1 7 50 57 5 27 38 29 49 43 26 402 1 47 47 32 46 8 402 49 29 62 1 43 6 50 1 6 50 31 1 17 3 3 1 6 50 29 210
PAGE 177
SECTION 2 TURNTABLE FIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982) 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 178
SECTION 2 TURNTABLE FIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982) (CONTINUED) ITEM # PART NUMBER 23 (cont’d) 24 1671236 25 26 27 28 29 30 31 32 33 34 35 QTY.
PAGE 179
SECTION 2 TURNTABLE FIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982) (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION 61 62 63 64 65 66 67 3960470 0182077 0641406 3311405 3571712 3960389 4751400 1 1 4 4 1 3.5ft/1.
PAGE 180
SECTION 2 TURNTABLE FIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982) (CONTINUED) ITEM # PART NUMBER QTY. 169 170 171 172 0641606 2600209 3960464 3960462 4 1 201 202 203 204 205 206 207 208 209 210 211 65in/1.67m 61in/1.55m 2680492 Ref Ref Use 2680492 2600233 3311605 4711600 2940088 0721008 4751000 3311005 3960462 3960464 3960438 1 1 5 5 2 4 4 4 1671228 53in/1.35m 83in/2.11m 55in/1.
PAGE 181
SECTION 2 TURNTABLE FIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982) (CONTINUED) ITEM # 401 402 403 404 405 3121140 PART NUMBER QTY. 2680488 Ref Use 2680488 2940088 0721008 4751000 3311005 1 1 2 2 2 DESCRIPTION HOOD ASSEMBLY (STORAGE COMPARTMENT) (PRIOR TO SN 0300087262) REV.
PAGE 182
SECTION 2 TURNTABLE FIGURE 2-26.
PAGE 183
SECTION 2 TURNTABLE 14 1 7 48 1 9 48 48 2 32 48 1 4 33 44 1 7 301 32 1 6 47 32 36 47 1 49 5 47 30 47 11 11 47 30 1 7 1 48 7 48 1 7 12 46 29 11 48 31 1 31 20 16 48 37 48 42 47 12 50 1 6 7 48 30 48 32 40 52 45 1 10 1 48 7 28 45 32 113 1 7 48 39 32 38 121 120 7 110 48 109 117 101 21 106 109 108 107 109 105 112 123 125 124 125 122 121 103 104 23 111 102 116 115 114 113 109 118 119 126 3121140 800S 860SJ 2-131
PAGE 184
SECTION 2 TURNTABLE FIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) ITEM # PART NUMBER 0274762 0274762 1001100386 0274768 0275547 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 0100011 0182077 0362770 0630507 0641406 0641508 0641608 0641610 0641616 0721006 0901921 0902219 0902223 0902351 0902412 0902491 0902673 0902674 0902769 0940071 1671201 1671228 QTY.
PAGE 185
SECTION 2 TURNTABLE FIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 3380444 3380461 3380575 3380580 3571712 3960389 3960470 4160139 4160143 4740076 4740171 4751000 4751400 4751500 4751600 0940088 3321501 1120601 2940188 1 1 1 1 1 3.5ft/1.
PAGE 186
SECTION 2 TURNTABLE FIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 107 QTY.
PAGE 187
SECTION 2 TURNTABLE FIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 125 1001117140 AR 126 0100011 AR 1671228 Ref Ref 1671231 1671232 2940088 0721008 4751000 3311005 2600233 1321384 0641606 4711600 3960464 3960438 3960462 1 1 2 4 4 4 1 4 9 9 201 202 203 204 205 206 207 208 209 210 211 212 213 301 3121140 83in/2.11m 55in/1.4m 53in/1.35m 0272081 Ref 2820078 1 DESCRIPTION REV.
PAGE 188
SECTION 2 TURNTABLE FIGURE 2-27.
PAGE 189
SECTION 2 TURNTABLE FIGURE 2-27. ENGINE TRAY JACK INSTALLATION (OPTIONAL) ITEM # 1 2 3 3A 3B 3C 3D 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3121140 PART NUMBER QTY.
PAGE 190
SECTION 2 TURNTABLE FIGURE 2-28.
PAGE 191
SECTION 2 TURNTABLE FIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ITEM # PART NUMBER 0273518 0274081 1001115404 0273538 0274091 1001102547 1001115413 0273539 0274087 1001102548 1001115414 1 2 3580322 QTY.
PAGE 192
SECTION 2 TURNTABLE FIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) (CONTINUED) ITEM # PART NUMBER 2B QTY.
PAGE 193
SECTION 2 TURNTABLE FIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 194
SECTION 2 TURNTABLE FIGURE 2-29.
PAGE 195
SECTION 2 TURNTABLE FIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER 0271544 0272480 0274082 1001115405 0272482 0274090 1001100308 1001115410 0271547 0272481 0274086 1001099868 1001115409 1 2 3580158 QTY.
PAGE 196
SECTION 2 TURNTABLE FIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 197
SECTION 2 TURNTABLE FIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 198
SECTION 2 TURNTABLE FIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) (CONTINUED) ITEM # 101 102 103 104 105 106 107 108 109 110 111 112 113 114 2-146 PART NUMBER QTY. 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 HOURMETER INSTALLATION (OPTIONAL) REV.
PAGE 199
SECTION 2 TURNTABLE FIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 200
SECTION 2 TURNTABLE FIGURE 2-30.
PAGE 201
SECTION 2 TURNTABLE FIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO SN 03000079612) (OPTIONAL) ITEM # 1 2 PART NUMBER QTY.
PAGE 202
SECTION 2 TURNTABLE FIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO SN 03000079612) (OPTIONAL) (CONTINUED) ITEM # PART NUMBER 5 QTY.
PAGE 203
SECTION 2 TURNTABLE FIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO SN 03000079612) (OPTIONAL) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 204
SECTION 2 TURNTABLE FIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL) 1 8 37 2 12 40 29 5 15 1 9 23 31 40 7 39 18 16B 16A 16C 22 1 9 24 32 40 16D 1 8 37 1 20 36 16 1 13 1 10 34 6 21 33 14 1 7 39 2 26 41 25 1 11 38 RELAY MOUNTED ON BRACKET ON OPPOSITE SIDE OF ENGINE.
PAGE 205
SECTION 2 TURNTABLE FIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NUMBER QTY.
PAGE 206
SECTION 2 TURNTABLE FIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL) (CONTINUED) ITEM # PART NUMBER 16D 17 18 QTY.
PAGE 207
SECTION 2 TURNTABLE FIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 208
SECTION 2 TURNTABLE FIGURE 2-32.
PAGE 209
SECTION 2 TURNTABLE FIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # 1 2 3 4 5 6 7 8 8A 8B 8C 8D 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3121140 PART NUMBER QTY.
PAGE 210
SECTION 2 TURNTABLE FIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. 27 28 29 4751500 4811900 4891600 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 2-158 DESCRIPTION REV.
PAGE 211
SECTION 2 TURNTABLE FIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 212
SECTION 2 TURNTABLE FIGURE 2-33.
PAGE 213
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES ITEM # 1 2 3 4 5 6 PART NUMBER QTY. 0273540 Ref Ref 1001115398 Ref 0272344 Ref 1001115388 Ref 60Hz & Deutz Engine (SN 0300139080 to SN 0300140000) Ref Note: SkyPower Generator is Standard On ANSI & CSA Specs. Optional on All Other Specs.
PAGE 214
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED) ITEM # PART NUMBER 26 27 28 QTY.
PAGE 215
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 216
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED) ITEM # 101 102 103 104 105 106 107 108 109 110 111 to 115 116 117 118 to 120 121 122 123 to 124 125 126 127 128 PART NUMBER QTY. 0861542 Ref JUNCTION BOX ASSEMBLY 0861541 1060494 1060708 1705376 3300396 3310601 1060343 Not Used 3910610 4360070 Not Used 4460425 4460426 Not Used 4750600 4760600 Not Used 1671092 4460963 Not Used 1 2ft/.6m 1.5ft/.
PAGE 217
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED) ITEM # 401 402 403 404 405 406 407 408 409 410 411 412 413 414 PART NUMBER QTY.
PAGE 218
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED) ITEM # PART NUMBER 510 1 3640986 3641533 2-166 QTY. DESCRIPTION REV.
PAGE 219
SECTION 2 TURNTABLE FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 220
SECTION 2 TURNTABLE FIGURE 2-34.
PAGE 221
SECTION 2 TURNTABLE FIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES ITEM # PART NUMBER QTY.
PAGE 222
SECTION 2 TURNTABLE FIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES ITEM # PART NUMBER QTY.
PAGE 223
SECTION 2 TURNTABLE FIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES ITEM # 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 to 124 125 126 127 201 202 203 204 301 301A 301B 301C 302 to 303 304 305 3121140 PART NUMBER QTY.
PAGE 224
SECTION 2 TURNTABLE FIGURE 2-35.
PAGE 225
SECTION 2 TURNTABLE FIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES ITEM # PART NUMBER QTY.
PAGE 226
SECTION 2 TURNTABLE FIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES ITEM # PART NUMBER QTY. 18G 19 20 21 22 23 24 25 26 27 28 29 30 30A 30B 31 32 32A 32B 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Use 70004169 2820031 3252764 3311405 3311505 3311601 3580312 3580314 3580348 3740080 3910606 3960422 1 1 1 6 3 2 2 1 1 2 8 2 1 101 102 103 104 105 106 107 108 109 110 2-174 4060700 1001110873 4060802 1 1 DESCRIPTION REV.
PAGE 227
SECTION 2 TURNTABLE FIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES ITEM # PART NUMBER 111 to 115 116 117 118 to 120 121 122 123 to 124 125 126 127 128 Not Used 4460425 4460426 Not Used 4750600 4760600 Not Used 1671092 4460963 Not Used QTY.
PAGE 228
SECTION 2 TURNTABLE FIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES ITEM # PART NUMBER QTY. 412 413 414 1001094375 1001094509 4460018 1 1 1 NPN Ref Ref 1001121340 Ref 501 2 4460411 70002818 502 4 4460412 70002819 503 2 4460413 70002820 504 2 4460414 70002821 505 4 4460415 70002822 506 1 4460956 70002823 507 2 4460607 70002824 508 7 4460957 70002825 509 510 2-176 2 4461001 70002826 3641533 1 DESCRIPTION REV.
PAGE 229
SECTION 3 BOOM 3121140 800S 860SJ 3-1
PAGE 230
SECTION 3 BOOM FIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION 21 40 39 2 5 38 33 37 32 2 5 18 NOTE: PLACE WASHER (41) ON TOWER BOOM ON SIDE OF LIMIT SWITCHES.
PAGE 231
SECTION 3 BOOM FIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 to 13 14 PART NUMBER QTY.
PAGE 232
SECTION 3 BOOM FIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION (CONTINUED) 3-4 ITEM # PART NUMBER QTY. 38 39 40 41 42 43 44 4160187 4711600 Use 1001157180 4740492 4846427 0641812 4711800 2 AR 1 1 1 4 8 DESCRIPTION REV.
PAGE 233
SECTION 3 BOOM FIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 234
SECTION 3 BOOM FIGURE 3-2.
PAGE 235
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM INSTALLATION - 800S ITEM # 1 2 3 PART NUMBER QTY.
PAGE 236
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM INSTALLATION - 800S (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION REV.
PAGE 237
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM INSTALLATION - 800S (CONTINUED) ITEM # PART NUMBER 124 QTY. 1 4846402 4846554 125 126 3121140 1 4846403 4846558 3311608 4 DESCRIPTION REV.
PAGE 238
SECTION 3 BOOM FIGURE 3-3.
PAGE 239
SECTION 3 BOOM FIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ ITEM # 1 2 3 4 to 6 7 8 9 10 11 to 12 13 PART NUMBER QTY.
PAGE 240
SECTION 3 BOOM FIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 241
SECTION 3 BOOM FIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ (CONTINUED) ITEM # PART NUMBER QTY. 211 212 213 214 215 216 217 218 219 220 221 3311605 3340787 3340936 3340942 3340943 3573418 3900283 3900316 4070969 4711600 4 1 2 2 4 1 4 4 2 20 1 Not Required 4846553 222 1 4846420 4846555 223 224 225 3121140 1 4846421 4846558 3311608 1320263 4 2 DESCRIPTION REV.
PAGE 242
SECTION 3 BOOM FIGURE 3-4.
PAGE 243
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLY ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 to 15 16 17 18 19 20 21 PART NUMBER QTY.
PAGE 244
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 245
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLY (CONTINUED) ITEM # PART NUMBER 66 QTY. 6 0791614 0811614 67 68 69 70 71 72 3121140 6 0791616 0811616 4071020 1120510 4751400 4891600 0641613 2 1 4 2 4 DESCRIPTION REV.
PAGE 246
SECTION 3 BOOM FIGURE 3-5.
PAGE 247
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 248
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY. Ref 100 100A 100B 100C 101 101A 101B 102 103 3-20 1 7017158 70000342 7017137 1 7017159 7017138 7017142 1 70001697 4 DESCRIPTION REV.
PAGE 249
SECTION 3 BOOM FIGURE 3-5. ROTATOR ASSEMBLY (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 250
SECTION 3 BOOM FIGURE 3-6.
PAGE 251
SECTION 3 BOOM FIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 101 102 103 104 to 105 106 107 108 to 110 3121140 PART NUMBER QTY.
PAGE 252
SECTION 3 BOOM FIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 253
SECTION 3 BOOM FIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (CONTINUED) ITEM # PART NUMBER QTY. 309 7023922 7017402 7017452 7017402 7012944 7021616 7024832 1 1 1 2 4 1 1 0271381 0273695 Ref Ref Ref 310 311 312 313 401 402 403 404 405 406 407 408 409 410 3121140 0100011 0100035 0641406 0641604 0720603 3930606 1671044 3200436 3200449 3440410 Use 4360544 Use 4360544 4360544 4711600 AR AR 4 6 4 2 2 2 2 6 DESCRIPTION REV.
PAGE 254
SECTION 3 BOOM FIGURE 3-7.
PAGE 255
SECTION 3 BOOM FIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS ITEM # 1 2 3 to 4 5 6 7 8 to 15 16 17 to 18 19 PART NUMBER QTY.
PAGE 256
SECTION 3 BOOM FIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS (CONTINUED) ITEM # 3-28 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 257
SECTION 4 PLATFORM 3121140 800S 860SJ 4-1
PAGE 258
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 259
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORM ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 101 102 103 104 to 105 106 107 108 109 110 111 3121140 PART NUMBER QTY. DESCRIPTION 3510772 3510816 3510837 3510817 3510821 Ref Ref Ref Ref Ref Ref Ref PLATFORM ASSEMBLIES: 8ft (2.44m) with Standard Gate/No Mesh 8ft (2.44m) with Self-Closing Gate/No Mesh 8ft (2.44m) with Self-Closing Gate/Mesh to Top Rail 6ft (1.83m) with Standard Gate/No Mesh 6ft (1.
PAGE 260
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORM (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION 112 to 126 127 Not Used See Note 1 Footswitch (Note: See PLATFORM ASSEMBLIES - SIDE ENTRY PLATFORM for Service Parts) 128 to 134 135 Not Used 4460071 1 Connector, Strain Relief 0270814 Ref 3536089 0641414 3311405 4711400 2920140 7016399 4240099 2820035 Not Used 4460598 2 4 4 8 2 2 10 9ft/2.
PAGE 261
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORM (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 262
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 263
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM ASSEMBLIES - SIDE ENTRY (SN 0300067916 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION Use 1001144027 Ref Ref Use 1001144026 Ref Use 1001144024 Ref Use 1001144023 Ref PLATFORM ASSEMBLIES: Platform 30in x 4ft (76cm x 1.22m) with No Mesh (was p/n 3510830) Platform 30in x 5ft (76cm x 1.5m) with No Mesh (was p/n 3510831) Platform 36in x 6ft (91.5cm x 1.83m) with No Mesh (was p/n 3510833) Platform 36in x 8ft (91.5cm x 2.
PAGE 264
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM ASSEMBLIES - SIDE ENTRY (SN 0300067916 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 103 104 105 0641408 0641610 3 4 1 105A 105B 0861416 1001108866 1001114896 0272970 1 1060918 Use 0272970 7ft/2.
PAGE 265
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM ASSEMBLIES - SIDE ENTRY (SN 0300067916 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 209 QTY.
PAGE 266
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 267
SECTION 4 PLATFORM FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3121140 PART NUMBER QTY. DESCRIPTION 3510884 3510868 Ref Ref Ref Ref PLATFORM ASSEMBLY (FALL ARREST) OPTIONS: PLATFORM ASSEMBLY (36 x 72) PLATFORM ASSEMBLY (36 x 96) Note: Replacement Decals Must be Ordered Separately - See DECAL SECTION.
PAGE 268
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 269
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY ITEM # 1 2 3 4 5 6 7 PART NUMBER QTY.
PAGE 270
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 271
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 272
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (CONTINUED) ITEM # PART NUMBER 605 QTY. 1 4460598 4460426 0258608 701 Ref 1 4360314 4360328 3790012 1 Ref 801 4-16 4360336 3790012 1 1 DESCRIPTION REV.
PAGE 273
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 274
SECTION 4 PLATFORM FIGURE 4-5.
PAGE 275
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) ITEM # PART NUMBER QTY.
PAGE 276
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) (CONTINUED) ITEM # PART NUMBER QTY. DESCRIPTION 108 109 110 111 112 70002734 70002735 70002906 Use 1001129555 7022819 4460871 4 1 1 1 1 6 Screw Can, Enclosure Cap Mechanical Assembly (Note: Not Available for Purchase) Plug, Male 8 Position (Natural) (Not Shown) Socket, Female 4-20 800S 860SJ REV.
PAGE 277
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 278
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 279
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER) ITEM # PART NUMBER QTY.
PAGE 280
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER) (CONTINUED) ITEM # PART NUMBER QTY. 109 Use 1001113961 4460871 1 7 7022812 70002727 Ref Ref Ref 201 202 203 204 205 206 207 7003972 7003973 7003980 7019167 7019164 7019165 1 2 4 4 1 1 1 7019196 70002729 2 208 209 210 4-24 7019166 7003982 7003983 7019194 7003989 2 1 2 DESCRIPTION REV.
PAGE 281
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 282
SECTION 4 PLATFORM FIGURE 4-7.
PAGE 283
SECTION 4 PLATFORM FIGURE 4-7. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL) ITEM # PART NUMBER QTY.
PAGE 284
SECTION 4 PLATFORM FIGURE 4-7. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL) (CONTINUED) ITEM # PART NUMBER 29 30 31 32 33 34 35 36 37 38 39 3010088 1260136 4360387 1702938 Not Used 1320040 0641406 4711400 3311405 1060341 4460425 4-28 QTY. DESCRIPTION 16 10ft/3m 1 1 Link, Quick Chain Switch, Push Button Decal - Soft Touch Override 4 4 8 4 16ft/4.
PAGE 285
SECTION 4 PLATFORM FIGURE 4-7. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 286
SECTION 4 PLATFORM FIGURE 4-8.
PAGE 287
SECTION 4 PLATFORM FIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) ITEM # 1 2 3 4 5 6 PART NUMBER QTY.
PAGE 288
SECTION 4 PLATFORM FIGURE 4-9.
PAGE 289
SECTION 4 PLATFORM FIGURE 4-9. PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) ITEM # 1 2 3 4 5 6 7 8 9 10 3121140 PART NUMBER QTY. 0273542 Ref 0940092 0940094 0940131 0641516 4751500 3311505 0641813 3311805 4891800 4420068 4 9ft/2.7m 1 2 2 2 4 4 4 30ft/9.1m DESCRIPTION PADDING INSTALLATION (30 X 48 SIDE ENTRY PLATFORM) REV.
PAGE 290
SECTION 4 PLATFORM FIGURE 4-9. PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) (CONTINUED) ITEM # 4-34 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 291
SECTION 5 CYLINDER 3121140 800S 860SJ 5-1
PAGE 292
SECTION 5 CYLINDER FIGURE 5-1.
PAGE 293
SECTION 5 CYLINDER FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 294
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 295
SECTION 5 CYLINDER FIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) ITEM # 1 1A 2 3 4 5 5A 6 7 8 9 10 11 12 PART NUMBER QTY.
PAGE 296
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 297
SECTION 5 CYLINDER FIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM ITEM # 1 2 3 4 5 6 7 8 PART NUMBER QTY.
PAGE 298
SECTION 5 CYLINDER FIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 299
SECTION 5 CYLINDER FIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 300
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 301
SECTION 5 CYLINDER FIGURE 5-4. LEVEL CYLINDER ASSEMBLY - PLATFORM ITEM # 1 2 3 4 5 6 7 8 PART NUMBER QTY.
PAGE 302
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 303
SECTION 5 CYLINDER FIGURE 5-5. STEER CYLINDER ASSEMBLY ITEM # PART NUMBER QTY.
PAGE 304
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 305
SECTION 5 CYLINDER FIGURE 5-6. TELESCOPE CYLINDER ASSEMBLY ITEM # 1 2 3 4 5 6 7 PART NUMBER QTY.
PAGE 306
SECTION 5 CYLINDER FIGURE 5-6. TELESCOPE CYLINDER ASSEMBLY (CONTINUED) ITEM # 101 to 109 110 111 to 113 114 114A 114B 114C 5-16 PART NUMBER QTY. 0272750 Ref Not Used 3931480 Not Used 4641262 7026015 7026004 7026016 7011346 3790112 DESCRIPTION MANUAL DESCENT INSTALLATION (SN 0300068651 TO SN 0300140000) 4 Capscrew 1/4in-20NC x 5in 1 1 1 1 1 2 Valve, Assembly (Manual Descent) Cartridge Seal Kit - 7026015 Cartridge Cartridge Seal Kit - 7026016 Cartridge O-Ring 800S 860SJ REV.
PAGE 307
SECTION 6 HYDRAULIC 3121140 800S 860SJ 6-1
PAGE 308
SECTION 6 HYDRAULIC FIGURE 6-1.
PAGE 309
SECTION 6 HYDRAULIC FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM ITEM # PART NUMBER QTY. 2792502 2792648 Ref Ref Ref 1 2 3 4 5 6 7 8 9 10 3121140 2 2110404 2110406 2110606 2110408 2170504 2170506 2110404 2170406 2753629 2753630 2753624 2753627 2 1 1 1 1 2 1 2 1 DESCRIPTION AXLE LOCKOUT HYDRAULIC DIAGRAM Prior to SN 0300083331 SN 0300083331 to SN 0300140000 REV.
PAGE 310
SECTION 6 HYDRAULIC FIGURE 6-2.
PAGE 311
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331) 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 PART NUMBER QTY.
PAGE 312
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331) (CONTINUED) 6-6 ITEM # PART NUMBER QTY. 46 47 48 49 50 51 52 2753667 2753685 2753652 2753687 2753688 2753689 4641198 2 1 2 2 2 1 1 DESCRIPTION REV.
PAGE 313
SECTION 6 HYDRAULIC FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 314
6-8 40 800S 860SJ 1 34 1 48 8 6 6 48 8 22 21 4 2 2 32 8 8 49 22 49 35 18 28 38 3 50 50 51 9 8 5 9 46 13 104 104 39 9 9 8 5 103 52 12 33 11 11 26 2 31 105 107 53 11 36 108 3 33 45 102 101 44 5 41 6 43 23 55 42 47 14 24 10 SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 315
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 PART NUMBER QTY.
PAGE 316
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER 40 QTY.
PAGE 317
SECTION 6 HYDRAULIC FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 318
6-12 800S 860SJ 24 21 39 56 6 2 4 56 6 35 21 23 30 2 6 4 6 33 24 36 17 43 43 3 13 20 18 25 46 43 57 9 20 38 47 45 4 18 4 13 14 14 38 9 54 16 16 45 44 14 19 9 9 44 22 13 14 13 55 30 14 42 23 6 2 41 2 14 34 13 14 11 40 24 34 37 31 1 1 24 12 17 2 4 52 7 3 3 49 9 7 29 51 53 28 49 32 50 15 32 10 SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 319
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331) 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 3121140 PART NUMBER QTY.
PAGE 320
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331) (CONTINUED) ITEM # PART NUMBER QTY. 46 47 48 49 50 51 52 53 2753634 2753635 Not Used 2753659 2753660 2753661 2753664 1 1 Hose Hose 2 1 1 1 1 Hose Hose Hose Hose Hose Options: Prior to SN 0300066054 SN 0300066054 to SN 0300083331 Hose Hose Hose Valve, Check 54 55 56 57 6-14 2753666 2753807 2753667 2753685 2753686 4641198 2 1 2 1 DESCRIPTION 800S 860SJ REV.
PAGE 321
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 322
6-16 800S 860SJ 4 33 3 1 5 31 31 33 20 1 5 20 40 5 5 4 3 40 19 43 43 52 17 32 43 34 50 3 15 48 3 7 54 54 103 3 10 13 37 7 48 50 104 104 55 13 12 13 35 13 19 28 9 44 42 28 9 47 42 18 57 18 57 29 20 29 11 13 41 9 9 35 20 35 46 39 5 38 22 102 101 21 25 2 13 36 28 18 41 57 11 18 57 1 17 9 30 105 107 108 45 51 26 53 23 24 14 24 8 SECTION 6 HYDRAULIC FIGURE 6-5.
PAGE 323
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300083331 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PART NUMBER QTY.
PAGE 324
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 325
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY. 57 2220811 4 3600410 Ref 2111010 2111616 2131212 2131616 2110408 Not Used 2220811 2110810 1 1 1 2 1 Fitting, Straight Fitting, Straight Fitting, Elbow Fitting, Elbow Fitting, Straight 1 1 Fitting, Reducer Fitting, Straight 101 102 103 104 105 106 107 108 3121140 DESCRIPTION REV.
PAGE 326
SECTION 6 HYDRAULIC 4 2 14 13 9 10 4 6 1 8 12 6 6 11 8 8 7 6 15 5 4 3 1 FIGURE 6-6.
PAGE 327
SECTION 6 HYDRAULIC FIGURE 6-6. MANUAL DESCENT HYDRAULIC DIAGRAM ( OPTIONAL) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3121140 PART NUMBER QTY. 2792597 Ref 2170708 2110406 2753578 2130406 2170804 2130404 2220235 2753678 2170306 2753895 2753896 2753897 4640774 4568708 2110604 2 1 1 5 1 6 1 3 1 1 1 2 1 1 1 DESCRIPTION MANUAL DESCENT HYDRAULIC DIAGRAM REV.
PAGE 328
6-22 40 49 39 800S 860SJ 15 16 23 47 50 48 46 13 38 34 28 29 40 6 39 5 4 4 5 11 22 1 21 30 31 24 13 28 2 2 3 2 13 29 2 13 33 34 1 1 27 20 11 12 53 25 45 42 1 23 43 2 8 1 1 2 44 1 23 26 14 32 36 17 41 103 101 18 2 54 55 104 51 102 9 35 7 10 37 SECTION 6 HYDRAULIC FIGURE 6-7.
PAGE 329
SECTION 6 HYDRAULIC FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM 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 PART NUMBER QTY.
PAGE 330
SECTION 6 HYDRAULIC FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (CONTINUED) ITEM # PART NUMBER 38 39 40 41 42 43 2753693 2753692 2753670 2753671 2753672 2753674 QTY.
PAGE 331
SECTION 6 HYDRAULIC FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 332
SECTION 6 HYDRAULIC FIGURE 6-8. HYDRAULIC DIAGRAM LIST ITEM # 6-26 PART NUMBER QTY. DESCRIPTION REV. Ref Note: Diagrams with asterisk (*) are shown in the preceding pages. Information on diagrams not shown are available from JLG Service/Parts Departments.
PAGE 333
SECTION 7 ELECTRICAL 3121140 800S 860SJ 7-1
PAGE 334
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST ITEM # 7-2 PART NUMBER QTY.
PAGE 335
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 336
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 337
SECTION 7 ELECTRICAL RECEPTACLE AT PLATFORM (OPTIONAL) 701A 710 710A LP 701B CONVERTOR 701C (FORD DUAL 701J FUEL) 203 238 701D 701G 213 217E 217F 217G 207 701K PUMP 439 440 454 212 211 702A 703D 701E 203 239 421 451 325 334 334C 332 706A 609A 333 SEE ENGINE INSTALLATION FOR BATTERY CABLE CALL-OUTS.
PAGE 338
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) ITEM # PART NUMBER QTY.
PAGE 339
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 340
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY. 204 1060902 AR 134ft/41m 138ft/42m AR 20ft/6m 34ft/10.4m AR 20ft/6m 34ft/10.4m AR 13ft/4m 15ft/4.6m AR 13ft/4m 15ft/4.6m 20ft/6m 20ft/6m 205 to 206 207 208 209 210 211 212 213 214 215 216 217 Not Used 3573047 4360506 4460464 4460465 4460470 4460471 4460866 4460891 4460897 Not Used 218A 218B 218C 218D 7-8 REV.
PAGE 341
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY. 218E 219 to 232 233 4460466 Not Used 4922660 8 233A 233B 4460880 4460320 4460226 4460424 4460267 Not Used 4922871 2 1 2 1 2 1060902 4460464 4460897 34ft/10.4m 1060902 4460464 4460897 4922872 34ft/10.
PAGE 342
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 343
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 344
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 345
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 346
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY. 701G (cont’d) 1060494 18in/46cm 1060461 30in/76cm 701H 701J 701K 1 4460205 4460709 3960422 1 1 4460134 4460701 4460710 702 1 Ref 4922741 4922742 4922743 6ft/1.
PAGE 347
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY. 704A 4460320 4460267 0257887 4460424 4460268 See Note 1060341 3740049 4922643 1 2 1 1 2 1 705 705A 706 706A 707 707A 2920140 2920157 4460320 37ft/11.
PAGE 348
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # PART NUMBER QTY. 707J 707K 708 2400070 2400066 See Note 1 1 1 708A 708B 708C 709 1060341 4460226 4460425 See Note 22ft/6.7m 2 1 1 709A 710 4460224 4460226 See Note 1 6 1 710A 7023679 1 7002821 7002823 4460467 Ref 1 1 1 4460510 1 7002828 1 801 802 803 804 7-16 DESCRIPTION REV.
PAGE 349
SECTION 7 ELECTRICAL FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 350
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 351
SECTION 7 ELECTRICAL 714E OR 706D 708E 714B 707B 714F 714G 239 708E 714E 708J 714C 714D 707A 706A 2500W GENERATOR RELAY 706D 2500W GENERATOR 709J 709H CONTROL BOX 706E 2500W GENERATOR 706H 239 706G 712G 713D FUEL PUMP (CAT) 608 608A 422 ALTERNATOR (FORD) 430 341 FUEL SHUT OFF SWITCH (CAT) HYDRAULIC PUMPS BOOM PROX.
PAGE 352
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 353
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # 101 102 103 104 105 106 107 108 109 110 201 to 206 207 208 209 to 210 211 212 213 214 to 216 217 PART NUMBER QTY.
PAGE 354
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 217 (cont’d) 4922567 4923595 1060896 4923462 1060896 4923462 2820031 217A 217B 217C 217D 217E 217F 217G 218 4460465 4460865 4460509 4460473 4460466 4460464 4460508 QTY. AR 85ft/26m 85ft/26m 95ft/29m 95ft/29m 4in/9cm 11 1 4 1 8 11 4 1 4922569 Use 4923596 4923596 20ft/6.
PAGE 355
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 235 (cont’d) 4923466 4460464 4460897 236 QTY. 2 1 1 4922872 Use 4923599 4923599 20ft/6m 1060902 4923466 4460465 4460891 237 1061018 1061019 238 2 1 AR 2 2 1 4922873 4922790 1001091620 Use 4922790 4922790 4922877 4922808 4923600 Use 4922808 4922808 239 1 4922874 4922809 Use 4923601 4923601 Use 4922809 4922809 3121140 DESCRIPTION REV.
PAGE 356
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 240 4460959 1 241 1671092 4460960 1 1 1671093 1 1 242 4922872 1001098908 Use 4923599 4923599 1001098910 20ft/6m 1060902 4923466 2 4460465 4460464 1 4460891 4460897 243 1 4922871 1001098909 4923598 1001098911 34ft/10.4m 1060902 1060902 4923466 2 4460464 4460465 1 4460897 4460891 7-24 DESCRIPTION REV.
PAGE 357
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 358
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 359
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 360
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 361
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY. 511 4922771 1060902 4460226 4460424 4460894 1 9.5ft/2.
PAGE 362
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 601B (cont’d) 601C 601D 7027018 7016824 QTY.
PAGE 363
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 364
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 706 QTY. AR 4933300 1001100027 706A 706B 706C 706D 706E 706F 706G 706H 707 4933300 4933350 4460321 4460906 4922641 4460226 4922970 4923445 4460961 4460705 4460742 4460743 4460458 1001100305 7020193 1 4 1 2 1 1 4 1 2 2 1 1 1 Ref 4922741 4922742 4922743 6ft/1.
PAGE 365
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 708B QTY. 1 4460346 4460125 708C 1 4060700 1001110873 708D 708E 4060092 4460051 1 1 4460205 4460233 See Note 708F 1 4460205 4460233 4460709 708G 708H to 708J 708K 709 1 4460134 4460701 4460710 Not Required 3960422 0273540 1 Ref Ref REV.
PAGE 366
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER 709D QTY. DESCRIPTION REV. 1 Cover, Receptacle Options: 60Hz Spec (Side Hinged Cover) (SN 0300085332 to SN 0300138287) 60Hz Spec (Top Hinged Cover) (SN 0300138287 to SN 0300140000) 50Hz Spec (Note: Not Available - Purchase Locally.) Receptacle Options: 60Hz Spec 50Hz Spec (Note: Not Available - Purchase Locally.
PAGE 367
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 368
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 369
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 370
SECTION 7 ELECTRICAL FIGURE 7-4.
PAGE 371
SECTION 7 ELECTRICAL 714E OR 706D 708E 714B 707B 714F 714G 232 714E 708J 714C 714D 707A 706A 2500W GENERATOR RELAY 706D 2500W GENERATOR 709J 709H CONTROL BOX 707 709K 711B 7500W GENERATOR CONTROL BOX 711C 239 238 711A 706G 231 712G 713E FUEL PUMP (CAT) 711G 706F RELAY 458 (DEUTZ) 452 706D 603 335 ACTUATOR CAT DGC ECM MODULE CAT 447 BOSCH FUEL REGULATOR (GM) 604A 604F 604D 604C 604B 428 605A TACH SENSOR/ SPEED PICK-UP (CAT) 610 453 604E 601C HYDRAULIC PUMPS DRIVE BOOM ORIENTATION S
PAGE 372
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) ITEM # PART NUMBER 1001114896 1 to 4 5 6 to 34 35 36 to 38 39 40 41 42 43 44 45 46 to 48 49 49A 50 50A 50B 50C 50D 51 52 101 102 103 104 105 106 7-40 Not Used 1060918 Not Used 4460071 Not Used 4460428 4460470 4460471 4460496 4460497 4460708 4460905 Not Used 4922666 4460226 4460761 4460227 4922749 4460880 4460928 4460918 4460926 4460913 4460910 4460917 1560012 Not Used 1001107796 QTY. DESCRIPTION REV.
PAGE 373
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 374
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER 218 (cont’d) 218A 218B 218C 218D 218E 219 to 228 229 229A 229B 229C 230 231 QTY. 20ft/6.
PAGE 375
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER 234 QTY. 1 4922871 4923598 34ft/10.4m 1060902 4923466 4460464 4460897 235 1061018 1061019 236 2 1 AR 2 2 1 1001098908 1001098910 20ft/6m 1060902 4923466 4460464 4460897 237 2 1 1 1001098909 1001098911 34ft/10.
PAGE 376
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 377
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER 337 338 339 340 341 401 to 416 417 418 419 420 to 422 423 424 to 427 428 429 to 430 431 432 433 434 to 437 438 439 440 441 442 to 445 3121140 QTY.
PAGE 378
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 379
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 380
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 381
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER QTY. 704A 4460320 4460267 See Note 1 2 1 705 1060341 AR 37ft/11.3m 40ft/12.
PAGE 382
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER 708C 708D 708E QTY.
PAGE 383
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER 710A QTY. 2ft/.6m 1060494 See Note 710B 2.5ft/.76m See Note 710F 1060343 4460425 4460426 4460426 3520189 1671092 4460963 711 1001112586 4933349 711A 711B 711C 711D 711E 711F 711G 712 712A 712B 712C 712D 712E 712F 712G 713 713A 713B 713C 3121140 REV. Cable, Electrical 12/3 60Hz Spec 50Hz Spec (Note: Not Available - Purchase Locally.) 1060708 710C 710D 710E DESCRIPTION 1.5ft/.
PAGE 384
SECTION 7 ELECTRICAL FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) (CONTINUED) ITEM # PART NUMBER 713D 713E 713F 713G 714 to 714G 715 QTY. 1 4922873 4922877 4922874 1060708 1001098234 1001098349 Not Required 1001094509 1 11ft/3.4m 1 1 1 Ref 801 802 7002821 7002823 1 1 803 4460467 1 804 4460510 1 805 806 806A 806B 806C 7002828 2901443 1600244 1060633 4460321 4460226 1 1 1 1 2 8 7-52 DESCRIPTION REV. Harness, Console Box to Connector Options: 800S Harness (85ft/25.
PAGE 385
SECTION 8 DECALS 3121140 800S 860SJ 8-1
PAGE 386
8-2 800S 860SJ 15 49 3 25 35 25 4 26 38 24 26 3 3 14 22 33 37 6 20 45 44 8 24 47 24 14 18 2 44 7 7 37 8 26 48 38 19 21 27 6 36 101 25 26 12 28 31 32 23 11 9 29 30 31 32 49 12 5 13 34 17 1 16 10 12 4 18 46 SECTION 8 DECALS FIGURE 8-1.
PAGE 387
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NUMBER QTY.
PAGE 388
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) (CONTINUED) ITEM # PART NUMBER QTY. 34 35 3252347 1 4 1703475 1703482 36 1 1701542 1701505 37 Not Required 1701543 38 39 to 43 44 45 46 47 48 49 101 8-4 Not Required 1700818 Not Used 1701499 3252781 1704412 1704540 1701691 1704885 AR 0 1 AR 0 1 4 1 1 1 4 2 0272341 Ref 1705363 1 DESCRIPTION REV.
PAGE 389
SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 390
8-6 800S 860SJ 11 26 39 35 47 24 18 7 BOTH SIDES 29 BOTH SIDES 7 BOTH SIDES 8 32 32 24 23 30 49 2 62 8 31 8 22 2 32 49 54 24 34 38 2 BOTH SIDES SIDES 51 52 41 18 24 BOTH 8 SIDES 32 18 61 7 24 53 31 55 BOTH BOTH SIDES BOTH SIDES 36 17 23 13 29 40 4 3 10 34 18 33 20 41 56 9 DECAL LOCATIONS FOR DUAL LANGUAGES ONLY! 24 38 56 31 50 23 57 22 52 37 59 9 23 25 47 20 33 21 51 5 43 45 46 47 48 60 SECTION 8 DECALS FIGURE 8-2.
PAGE 391
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 to 12 13 14 to 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 PART NUMBER QTY.
PAGE 392
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER 34 QTY.
PAGE 393
SECTION 8 DECALS FIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 394
8-10 800S 860SJ 15 49 3 35 25 25 4 26 38 24 26 3 3 14 22 33 37 6 20 45 44 8 24 47 24 14 18 2 44 7 7 26 37 8 48 27 38 19 21 6 36 26 23 12 28 31 32 25 11 9 29 30 31 32 49 12 17 39 16 5 13 18 34 46 1 10 12 13 4 SIDE ENTRY PLATFORM 11 9 49 12 34 5 11 23 12 10 13 29 30 31 32 28 31 32 SECTION 8 DECALS FIGURE 8-3.
PAGE 395
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) ITEM # PART NUMBER 0270933 0270931 0270929 0270923 0270925 0270927 0270934 0270932 0270930 0270924 0270926 0270928 0272548 0272547 0272546 0272540 0272541 0270927 0272568 0272567 0272566 0272561 0272562 0270928 0271386 1 QTY.
PAGE 396
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) ITEM # PART NUMBER 3 (cont’d) 4 1703935 QTY.
PAGE 397
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) ITEM # PART NUMBER QTY.
PAGE 398
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) ITEM # PART NUMBER QTY. 44 45 46 47 48 49 1701499 3252781 1704412 1704540 1701691 1704885 4 1 1 1 4 2 8-14 DESCRIPTION REV.
PAGE 399
SECTION 8 DECALS FIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 400
8-16 800S 860SJ 12 11 26 39 24 35 47 18 7 BOTH SIDES 29 BOTH SIDES 7 BOTH SIDES 8 32 32 24 23 30 49 2 62 8 31 8 22 2 32 49 54 24 34 38 BOTH SIDES BOTH SIDES 36 17 23 13 29 40 BOTH SIDES SIDES 55 BOTH 2 51 52 41 18 24 BOTH 8 SIDES 32 18 7 24 53 31 4 3 10 34 18 33 20 41 56 9 DECAL LOCATIONS FOR DUAL LANGUAGES ONLY! 24 38 56 31 50 23 57 22 52 37 59 9 23 25 47 20 33 21 51 5 43 45 46 47 48 60 SECTION 8 DECALS FIGURE 8-4.
PAGE 401
SECTION 8 DECALS FIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 PART NUMBER QTY.
PAGE 402
SECTION 8 DECALS FIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER 20 QTY. 2 1705967 1705968 1001116846 1705968 1704000 Not Required 1705969 1704001 21 1 1705895 1703925 1703924 1703926 1703927 1703923 22 1 1705896 1705348 1001116849 1705348 1705347 1705344 1705345 1705917 23 6 1705898 1703949 1703948 1703950 1703951 1703947 24 5 1705897 1703937 1001116851 1703937 1703936 1703938 1703939 1703935 8-18 DESCRIPTION REV.
PAGE 403
SECTION 8 DECALS FIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER 25 QTY.
PAGE 404
SECTION 8 DECALS FIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER 34 QTY. 1 1 4 1 1 1 5 2 Bolt 1/4in-20NC x 1in Box, Manual Storage Cable, Lanyard Locknut 1/4in Rivet 1707051 1707045 1707046 1707053 1707043 1707048 1704112 1707052 1707044 1707047 1707054 1707042 1707049 35 36 37 1 1 1 1705015 1001108496 38 39 40 41 to 42 43 44 45 46 47 8-20 1 1703808 1706941 3252781 1701691 Not Used 0641408 0860520 1060279 3311405 3820001 REV.
PAGE 405
SECTION 8 DECALS FIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER QTY.
PAGE 406
SECTION 8 DECALS FIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # 8-22 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
PAGE 407
SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODEL 800S/860SJ 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 408
SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODEL 800S/860SJ 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 409
SECTION 10 SPECIAL OPTIONS 3121140 800S 860SJ 10-1
PAGE 410
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. FIGURE 10-1. SPECIAL OPTIONS LIST ITEM # PART NUMBER QTY.
PAGE 411
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. FIGURE 10-1.
PAGE 412
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. FIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 413
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. FIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 414
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. FIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED) ITEM # PART NUMBER QTY. 1001140318 Ref Ref 1001140315 Ref 1001138772 Ref 1001138773 Ref 0273147 Ref Ref 0273146 Ref 0273149 Ref 0273145 Ref REV.
PAGE 415
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. FIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED) ITEM # PART NUMBER QTY.
PAGE 416
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. FIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED) ITEM # 10-8 PART NUMBER QTY.
PAGE 417
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. FIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED) ITEM # 3121140 PART NUMBER QTY. DESCRIPTION 800S 860SJ REV.
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SECTION 10 SPECIAL OPTIONS FIGURE 10-2.
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SECTION 10 SPECIAL OPTIONS 3121140 800S 860SJ 10-11
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SECTION 10 SPECIAL OPTIONS FIGURE 10-2. SKY WELDER INSTALLATION ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 22F 23 24 25 26 27 28 29 30 10-12 PART NUMBER QTY.
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SECTION 10 SPECIAL OPTIONS FIGURE 10-2. SKY WELDER INSTALLATION (CONTINUED) ITEM # PART NUMBER QTY.
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SECTION 10 SPECIAL OPTIONS FIGURE 10-2. SKY WELDER INSTALLATION (CONTINUED) ITEM # PART NUMBER 141 QTY. DESCRIPTION 1 Panel Assembly (Complete) Options: ANSI Spec (60Hz) ANSI Export Spec (50Hz) (Note: Not Available for Purchase.) Receptacle, Twistlock Options: ANSI Spec (60Hz) ANSI Export Spec (50Hz) (Note: Not Available for Purchase.) Control, Fine Light - AC Receptacle Options: ANSI Spec (60Hz) ANSI Export Spec (50Hz) (Note: Not Available for Purchase.
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SECTION 10 SPECIAL OPTIONS 10-15 800S 860SJ 3121140
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SECTION 10 SPECIAL OPTIONS 10-16 800S 860SJ 3121140
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SECTION 11 PARTS NUMBER INDEX Part Number 0060048 0060061 0080163 0080181 0080201 0080214 0080241 0080243 0100009 0100010 0100011 0100019 0100020 0100035 0100038 0100040 0100048 0100062 0100063 0100074 0100081 0140001 0140011 3121140 Page .............. 3-11, 3-19 ................ 3-7, 3-19 .............. 2-48, 2-57 .............. 2-28, 2-38 2-64, 2-71, 2-84, 289 .............. 2-64, 2-71 ..................... 2-122 .............. 2-28, 2-38 ....................... 4-13 .........................
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SECTION 11 Part Number 0272561 0272562 0272566 0272567 0272568 0272589 0272590 0272599 0272607 0272643 0272725 0272733 0272750 0272796 0272817 0272842 0272873 0272955 0272970 0273145 0273146 0273147 0273149 0273251 0273308 0273309 0273353 0273376 0273378 0273472 0273483 0273507 0273511 0273518 0273527 0273538 0273539 0273540 0273541 0273542 0273575 0273596 0273687 0273695 0273701 0273704 0273706 0273800 0273824 0274081 0274082 0274086 0274087 0274090 0274091 0274173 0274174 0274237 0274244 11-2 PARTS NUM
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SECTION 11 Part Number 0641613 0641614 0641616 0641618 0641620 0641622 0641626 0641628 0641634 0641640 0641652 0641708 0641710 0641718 0641772 0641808 0641810 0641812 0641813 0641818 0641820 0641826 0641828 0642010 0642014 0642212 0642612 0642618 0642684 0651406 0681608 0681610 0681612 0681810 0681814 0681822 0681832 0682016 0682023 0682032 0682214 0682216 0700616 3121140 Page 169, 3-3, 4-27 .......3-3, 3-16, 3-17 ..................... 2-101 .2-125, 2-132, 3-15 ............ 2-163, 3-11 .........
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SECTION 11 Part Number PARTS NUMBER INDEX Page 0962449 .......... 2-141, 2-145 0962496 ......................... 5-3 0962520 2-162, 2-169, 2-173 0962521 .......... 2-169, 2-173 0962563 ..................... 2-140 0962653 ..................... 2-140 1001091179 ................. 2-56 1001091472 ................. 3-27 1001091563 ............... 2-101 1001091568 ............... 2-101 1001091583 ................. 2-84 1001091587 ........ 2-82, 2-88 1001091609 3-27, 7-21, 7-41 1001091618 ........
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SECTION 11 Part Number 1001114632 1001114633 1001114634 1001114896 1001114897 1001115388 1001115394 1001115398 1001115400 1001115404 1001115405 1001115409 1001115410 1001115413 1001115414 1001115930 1001115931 1001116287 1001116288 1001116544 1001116545 1001116595 1001116597 1001116598 1001116846 1001116849 1001116851 1001117040 1001117045 1001117139 1001117140 1001117251 1001117258 1001117320 1001117804 1001117805 1001118416 1001118417 1001119564 1001119939 1001119947 1001120206 1001120532 1001121340 1001
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SECTION 11 Part Number 1671230 1671231 1671232 1671236 1671237 1671248 1671311 1671332 1683053 1683059 1683077 1683078 1683609 1683740 1683818 1683976 1683986 1684041 1684042 1684043 1684045 1684046 1684049 1684050 1684078 1684080 1684089 1684090 1684123 1684124 1684133 1684135 1684136 1684184 1684188 1684189 1684191 1684198 1684199 1684202 1684267 1684269 1700584 1700818 1701499 1701500 1701501 1701502 1701503 1701504 1701505 1701509 11-6 PARTS NUMBER INDEX Page 132, 2-135 .......... 2-127, 2-134 ..
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SECTION 11 Part Number 1706712 1706914 1706915 1706941 1707015 1707016 1707042 1707043 1707044 1707045 1707046 1707047 1707048 1707049 1707051 1707052 1707053 1707054 1707055 1707056 1707057 1707058 1707059 1707060 1810098 1810099 1810101 1810103 1810104 1810106 1870133 1870195 1870221 2000174 2000178 2000193 2000194 2000211 2000216 2000219 2000233 2000271 2000272 2000274 2000279 2000285 2000296 2000323 2000339 2000342 2000354 2000365 2000375 2000379 2000386 2000391 2030010 2060025 3121140 Page ........
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SECTION 11 Part Number 2460032 2460034 2460039 2460041 2460044 2460048 2460049 2460050 2460051 2460052 2460055 2460056 2460057 2540035 2560122 2560123 2560136 2560173 2573001 2580024 2580050 2580055 2580062 2600209 2600216 2600219 2600233 2600244 2600281 2600287 2680451 2680488 2680490 2680492 2720058 2720144 2720271 2720314 2720351 2720392 2720398 2720434 2720435 2720436 2720449 2720472 2720509 2720510 2720514 2720515 2720532 2720563 11-8 PARTS NUMBER INDEX Page 2-139, 2-143, 2-149 ..........
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SECTION 11 Part Number 2902310 2902311 2902312 2902322 2902354 2902394 2902401 2902429 2902443 2902445 2902460 2902461 2902462 2902533 2910799 2910871 2910928 2910950 2915014 2915140 2915195 2915196 2920028 2920029 2920110 2920113 2920129 2920140 2920154 2920157 2920162 2920215 2940074 2940088 2940188 3010088 3020008 3020016 3020021 3020044 3124114 3160266 3160268 3160280 3160286 3160294 3160308 3160347 3160348 3200362 3200406 3121140 Page ....................... 8-21 ....................... 8-21 .....
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SECTION 11 Part Number 3422932 3422972 3430816 3440410 3450304 3450404 3460398 3460399 3460544 3460552 3470003 3480176 3480210 3480265 3480266 3480267 3480275 3510772 3510816 3510817 3510821 3510822 3510830 3510831 3510833 3510837 3510868 3510884 3520028 3520034 3520035 3520072 3520172 3520189 3520198 3530072 3536089 3537416 3537420 3537445 3537446 3538047 3539219 3539281 3539622 3539662 3539685 3539719 3539872 3539877 3539878 3539934 3539971 3539972 3570103 11-10 PARTS NUMBER INDEX Page .............
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SECTION 11 Part Number Page 2-85, 2-90 3960470 .......... 2-127, 2-133 3960548 2-33, 2-40, 2-54, 264, 2-71, 2-83, 2-89 3960549 2-32, 2-40, 2-45, 247, 2-54, 2-65, 2-71, 2-83, 2-89 3960591 ....................... 2-72 3980007 .............. 2-30, 2-41 3990010 7-10, 7-13, 7-14, 725, 7-44, 9-2 4031608 .......... 2-141, 2-145 4031911 .............. 2-29, 2-39 4032015 ..................... 2-161 4060092 .....7-13, 7-33, 7-50 4060700 .....2-161, 2-170, 2174, 7-13, 7-33 4060802 .....
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SECTION 11 Part Number 4460426 4460428 4460434 4460457 4460458 4460459 4460460 4460464 4460465 4460466 4460467 4460470 4460471 4460473 4460476 4460488 4460496 4460497 4460508 4460509 4460510 4460526 4460536 11-12 PARTS NUMBER INDEX Page 7-15, 7-16, 7-34, 7-35, 7-51 .....2-112, 2-117, 2164, 2-171, 2175, 4-9, 4-16, 7-10, 7-25, 7-34, 7-35, 7-43, 7-51 4-14, 7-6, 7-20, 7-40 ..7-7, 7-11, 7-21, 726, 7-41, 7-44 7-11, 7-27, 7-28, 745 2-175, 7-11, 7-12, 727, 7-28, 7-30, 7-32, 7-45, 7-46, 7-49 ...........
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SECTION 11 Part Number 4640750 4640751 4640774 4640858 4640902 4640930 4640932 4640952 4640989 4641033 4641062 4641108 4641144 4641162 4641183 4641184 4641185 4641186 4641188 4641194 4641198 4641201 4641209 4641232 4641234 4641237 4641251 4641262 4641263 4641300 4641303 4641317 4641432 4711000 4711400 4711500 4711600 4711700 4711800 3121140 Page ....................... 2-30 .............. 2-45, 2-56 ....................... 6-21 ......................... 5-3 ......................... 2-5 .............
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SECTION 11 Part Number 4922567 4922569 4922570 4922594 4922595 4922619 4922620 4922636 4922641 4922643 4922654 4922655 4922660 4922666 4922690 4922737 4922741 4922742 4922743 4922749 4922757 4922764 4922771 4922790 4922808 4922809 4922871 4922872 4922873 4922874 4922877 4922883 4922905 4922922 4922925 4922968 4922970 4922978 4923213 4923239 4923277 4923278 4923279 4923292 4923379 4923420 4923445 11-14 PARTS NUMBER INDEX Page .......7-8, 7-22, 7-41 .......7-8, 7-22, 7-41 .....................
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SECTION 11 Part Number Page 70002416 ............ 2-48, 2-60 70002417 ............ 2-48, 2-60 7000246 .....2-13, 2-18, 2-24 70002460 ...2-162, 2-169, 2173 7000248 .............. 2-18, 2-24 7000253 .....2-13, 2-18, 2-24 7000255 .....2-13, 2-18, 2-24 7000256 .............. 2-13, 2-18 70002567 ..................... 2-67 7000257 .....2-13, 2-18, 2-24 7000258 .............. 2-13, 2-18 7000263 .....2-13, 2-18, 2-24 7000265 1-5, 1-8, 1-15, 1-19, 1-23 7000269 .............. 2-13, 2-18 7000270 ..............
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SECTION 11 Part Number PARTS NUMBER INDEX Page 7011346 ....................... 5-16 7012513 .....2-139, 2-143, 2149, 2-153, 2157 7012514 .....2-139, 2-143, 2149, 2-153, 2157 7012518 ................ 2-4, 3-24 7012540 ......................... 2-7 7012558 .....2-139, 2-143, 2149, 2-153, 2157 7012664 2-29, 2-38, 2-45, 255, 2-64, 2-72, 2-84, 2-89, 9-1 7012679 ....................... 2-73 7012694 ......................... 2-5 7012699 ......................... 2-5 7012766 .........................
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SECTION 11 Part Number 7020463 7020464 7020465 7020468 7020471 7020478 7020479 7020480 7020481 7020484 7020487 7021200 7021201 7021202 7021203 7021205 7021206 7021207 7021208 7021209 7021212 7021213 7021214 7021218 7021219 7021220 7021221 7021222 7021223 7021226 7021227 7021228 7021229 7021230 7021231 7021232 7021249 7021275 7021276 7021277 7021612 7021616 7021625 7021639 7021868 7022133 7022134 7022135 7022139 7022140 7022143 7022144 7022146 7022147 7022148 7022149 7022150 7022151 7022153 3121140 Page
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SECTION 11 Part Number 7023982 7023983 7023984 7023985 7023986 7023987 7024100 7024106 7024108 7024137 7024138 7024139 7024140 7024141 7024142 7024143 7024144 7024145 7024146 7024147 7024148 7024149 7024150 7024151 7024152 7024153 7024154 7024155 7024156 7024182 7024185 7024189 7024190 7024191 7024192 7024193 7024194 7024195 7024196 7024197 7024313 7024314 7024315 7024316 7024317 7024318 7024369 7024370 7024373 7024374 7024375 7024379 7024380 7024381 7024389 7024390 11-18 PARTS NUMBER INDEX Page ......
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SECTION 11 Part Number Page Part Number Page Part Number PARTS NUMBER INDEX Page Part Number Page 7027790 7027791 7027792 7027793 7027794 7027795 7027796 7027799 7027887 ....................... 2-59 ....................... 2-59 ....................... 2-59 .....2-60, 7-30, 7-47 .............. 2-60, 7-30 ................ 2-59, 9-1 .....2-60, 7-30, 7-47 2-162, 2-169, 2-173 .....2-140, 2-149, 2154, 2-157 7027965 .......2-84, 2-89, 9-1 7027972 .......2-84, 2-89, 9-1 7027991 ..............
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SECTION 11 Part Number 11-20 PARTS NUMBER INDEX Page Part Number Page Part Number 800S 860SJ Page Part Number Page 3121140
PAGE 445
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3121140 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.