Parts Manual Instruction Manual
3121140 800S 860SJ i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE. . . . . . . . . . . . . 1-2
1-2 AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . 1-6
1-3 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) . . . . . . . . . . . . 1-18
1-6 DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000) . . . . . . . . . 1-22
1-7 DRIVE MOTOR ASSEMBLY (2WD PRIOR TO SN 0300083331) . . . . . . . . . . . . . . . . 1-26
1-8 DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 &
ALL 4WD MACHINES) (4 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1-9 DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1-10 FRAME VALVES & SHIELDS INSTALLATIONS (PRIOR TO SN 0300083331) . . . . . 1-36
1-11 FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO
SN 0300140000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1-12 TOW PACKAGE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-4 SWING HUB ASSEMBLY (PRIOR TO SN 0300066417) . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-5 SWING MOTOR ASSEMBLY (PRIOR TO SN 0300066417) . . . . . . . . . . . . . . . . . . . . 2-14
2-6 SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) . . . . . . . . 2-16
2-7 SWING MOTOR/HUB ASSEMBLY (SN 0300134352 TO SN 0300140000) . . . . . . . . 2-22
2-8 CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398) . . . . . . . . . . 2-26
2-9 CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000) . . . 2-36
2-10 DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) . . . . . . . . . . . . . . . . . 2-44
2-11 DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) . . . . . . . . . 2-50
2-12 FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612). . . . . . . . . . . . . . . . . . 2-62
2-13 FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) . . . . . . . . . . 2-68
2-14 DUAL FUEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
2-15 GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) . . . . . . . . . . . . . . . . . . . 2-80
2-16 GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) . . . . . . . . . . . . 2-86
2-17 PISTON PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
2-18 LOAD SENSING PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
2-19 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
2-20 ROTARY COUPLING INSTALLATION (PRIOR TO SN 0300083331). . . . . . . . . . . . . 2-104
2-21 ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) . . . . . 2-106
2-22 GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM). . . . . . . . . . . . . . . . . . . . . 2-110
2-23 GROUND CONTROL BOX ASSEMBLY (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . 2-116
2-24 LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 2-120
2-25 HOODS INSTALLATION (PRIOR TO SN 0300089982) . . . . . . . . . . . . . . . . . . . . . . . 2-124
2-26 HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) . . . . . . . . . . . . . . . . 2-130
2-27 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136
2-28 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-138
2-29 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-142
2-30 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO
SN 03000079612) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-148
2-31 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO
SN 0300140000) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152
2-32 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) . . . . . . . . . . . 2-156