Jlg 860SJ Parts Manual Manuel d'utilisateur Page 1

Illustrated Parts ManualModels800S860SJPrior to SN 03001400003121140January 17, 2014

1-2 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE 8121310111711211611521649141519119107210215

2-48 800S 860SJ 3121140SECTION 2 TURNTABLE315 7024565 1 Sensor, Speed (was p/n 7020481)70003931 1 Bolt70003931 1 Spacer316 See Note 1 Flywheel (Not Sh

3121140 800S 860SJ 2-49SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPT

2-50 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000)2642082542542382451112412212542352252

3121140 800S 860SJ 2-51SECTION 2 TURNTABLE 2322VENTRETURNFUEL PUMPSUPPLIEDWITHENGINE468A7562542082352542082352325721524416151191013122162162462

2-52 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION

3121140 800S 860SJ 2-53SECTION 2 TURNTABLE17C 7016803 1 Cable, Battery (Red) (SN 0300077586 to SN 0300138238)Not Required 1 Cable, Battery (Red) (SN 0

2-54 800S 860SJ 3121140SECTION 2 TURNTABLE45 1702943 1 Decal - Hydraulic Tank Heater (Located on bottom of Hydraulic Oil Tank)46 1702944 1 Decal - Hea

3121140 800S 860SJ 2-55SECTION 2 TURNTABLERef ENGINE AND PUMP ASSEMBLIES Ref Without Arctic Package2000219 Ref Tier II Engines (SN 0300077586 to SN 03

2-56 800S 860SJ 3121140SECTION 2 TURNTABLE2720434 SN 0300077586 to SN 03001364981001091179 SN 0300136498 to SN 0300140000228 2720449 1 Hose, Air Clean

3121140 800S 860SJ 2-57SECTION 2 TURNTABLE1001104308 SN 0300136498 to SN 0300140000250 4711600 AR Flatwasher 3/8in Thin251 AR Flatwasher Options:47119

3121140 800S 860SJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.0258286 Re

2-58 800S 860SJ 3121140SECTION 2 TURNTABLE307 3020021 AR Grease, Coupling2902065 Ref PUMP COUPLING INSTALLATION - TIER III ENGINES (SN 0300129454 TO S

3121140 800S 860SJ 2-59SECTION 2 TURNTABLE1 O-Seal Between Fuel Pump & Engine Block Options (Not Shown):7020411 7027238 Pump (SN 0300077586 to SN

2-60 800S 860SJ 3121140SECTION 2 TURNTABLE7027796 1 Harness. EMR2 Module (SN 0300085332 to SN 0300140000)420 70000345 4 Plug, Glow (SN 0300092776 to S

3121140 800S 860SJ 2-61SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077586 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION

2-62 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612) TOENGINERETURNTO TANKFUELRETURNVENTLIN

3121140 800S 860SJ 2-63SECTION 2 TURNTABLEFIGURE 2-12. FORD ENGINE INSTALLATION (PRIOR TO SN 0300079612)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref E

2-64 800S 860SJ 3121140SECTION 2 TURNTABLE109 3740067 1 Relay, Auxiliary Power Relay110 0080214 1 Adapter, Fan Spacer 111 2060025 1 Fan, Suction112 15

3121140 800S 860SJ 2-65SECTION 2 TURNTABLE154 2720436 1 Hose, Radiator (Upper)155 1641808 2 Bolt 1/2in-13NC x 1in156 2220430 1 Fitting, Reducer 157 21

2-66 800S 860SJ 3121140SECTION 2 TURNTABLE201 4771800 2 Starwasher 1/2in (SN 0300073336 to SN 0300079612)202 0100048 AR Grease, DielectricRef ENGINE C

3121140 800S 860SJ 2-67SECTION 2 TURNTABLE325 3 Relay Options:7023613 Prior to SN 0300073336 (2000174 Engines)7023695 SN 0300073336 to SN 0300079612 (

1-4 800S 860SJ 3121140SECTION 1 FRAME0272003 Ref STEERING INSTALLATIONS (2WS) BRef Note: Before ordering king pin kit, verify that machines is equippe

2-68 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) 2102642122642452731102492282642432281

3121140 800S 860SJ 2-69SECTION 2 TURNTABLE STARTERAUX.PWR.PUMPAUX.PWR.RELAYFRONT ENGINEMOUNTING BOLTBATTERY# 28 - BATTERY CABLE KIT(INCLUDES IT

2-70 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION R

3121140 800S 860SJ 2-71SECTION 2 TURNTABLE37 4751400 AR Flatwasher 1/4in Regular38 4751600 4 Flatwasher 3/8in Regular39 4752000 1 Flatwasher 5/8in Reg

2-72 800S 860SJ 3121140SECTION 2 TURNTABLE216 0701014 4 Bolt 10mm x 30mm217 0760606 4 Bolt 6mm x 12mm218 1 Bracket, Muffler Options:0902309 SN 0300079

3121140 800S 860SJ 2-73SECTION 2 TURNTABLE258 4640989 1 Valve, Oil Drain259 4711400 12 Flatwasher 1/4in Thin260 4711600 12 Flatwasher 3/8in Thin261 47

2-74 800S 860SJ 3121140SECTION 2 TURNTABLE321 Use 7019994 1 Sensor, EGR (was p/n 7027406)322 70002307 1 Gasket, Exhaust (Manifold to Pipe)7022143 1 Ga

3121140 800S 860SJ 2-75SECTION 2 TURNTABLEFIGURE 2-13. FORD ENGINE INSTALLATION (SN 0300079612 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION

2-76 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-14. DUAL FUEL INSTALLATIONS 221DUAL FUELENGINECOMPONENTS.1844531786185187216211201201202209

3121140 800S 860SJ 2-77SECTION 2 TURNTABLEFIGURE 2-14. DUAL FUEL INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DUAL FUEL ENGINE COMPONENTS

3121140 800S 860SJ 1-5SECTION 1 FRAME407 7010406 2 Seal, Lip (1 per Assembly)408 7000265 20 Stud (10 per Assembly)409 7017054 2 Dust Cap (1 per Assemb

2-78 800S 860SJ 3121140SECTION 2 TURNTABLE202 2720144 2 Hose203 0100020 AR Sealant, Pipe204 2221197 1 Fitting, Reducer 205 2180125 1 Fitting, Elbow206

3121140 800S 860SJ 2-79SECTION 2 TURNTABLEFIGURE 2-14. DUAL FUEL INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-80 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210) 25120825123322521723722721521621522820525023221

3121140 800S 860SJ 2-81SECTION 2 TURNTABLE 118118E118C118B118A118A118D216226216244216222C222ATO LP FUEL SHUT-OFF28222471429273744222B1614449303

2-82 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-15. GM ENGINE INSTALLATION (PRIOR TO SN 0300139210)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GM

3121140 800S 860SJ 2-83SECTION 2 TURNTABLE40 3422446 1 Pin41 3790012 1 O-Ring (Not Shown - Located in Console Box)42 3841143 1 Keeper43 4360336 1 Swit

2-84 800S 860SJ 3121140SECTION 2 TURNTABLERef GM ENGINE ASSEMBLIES2000375 Ref Tier I Engine (Prior to SN 0300109493) E1001091632 Ref Tier II Engine (S

3121140 800S 860SJ 2-85SECTION 2 TURNTABLE234 3311805 4 Locknut 1/2in-13NC235 3539872 1 Plate, Radiator Mounting236 3572280 1 Plate, Engine Mount237 3

2-86 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) 37413638393032115113113114NOTE: SEE GM

3121140 800S 860SJ 2-87SECTION 2 TURNTABLE 2934203B123472424635114025RETURN ON FUEL TANKTO ENGINE106FRONT ENGINEMTG BOLTAUX RELAYMTG BOLTBATTER

1-6 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE 106110106114102118501107103103113113111109 105

2-88 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION REV

3121140 800S 860SJ 2-89SECTION 2 TURNTABLE104 0641812 4 Bolt 1/2in-13NC x 1-1/2in105 1060637 1 Cable, Lanyard106 2902533 1 Battery Cable Kit B106A 702

2-90 800S 860SJ 3121140SECTION 2 TURNTABLE221 1703162 2 Decal - Caution Fan222 Not Used223 2060025 1 Fan224 Not Used225 27200585.5in/14cmHose226 10011

3121140 800S 860SJ 2-91SECTION 2 TURNTABLEFIGURE 2-16. GM ENGINE INSTALLATION (SN 0300139210 TO SN 0300140000) (CONTINUED)ITEM # PART NUMBER QTY. DES

2-92 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-17. PISTON PUMP ASSEMBLY 150215101509150815111503155604120412031201A120112203041104165106166

3121140 800S 860SJ 2-93SECTION 2 TURNTABLEFIGURE 2-17. PISTON PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600295 Ref PISTON PUMP ASSEMBLIES

2-94 800S 860SJ 3121140SECTION 2 TURNTABLE159 7007454 1 Cover, Front160 to 162 Not Used163 7021207 6 Screw164 Not Used165 7021208 2 Spring (Part of It

3121140 800S 860SJ 2-95SECTION 2 TURNTABLE1004to1102Not Used1103 7010122 1 SCR Kit (Includes items 166, 106 & 165)1104 7010122 1 SCR Kit (Includes

2-96 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-18. LOAD SENSING PUMP ASSEMBLY

3121140 800S 860SJ 2-97SECTION 2 TURNTABLEFIGURE 2-18. LOAD SENSING PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600324 Ref LOAD SENSING PUM

3121140 800S 860SJ 1-7SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.Ref OSCILLATI

2-98 800S 860SJ 3121140SECTION 2 TURNTABLE404 7022318 1 Plug404A Use 7023967 1 O-Ring405 7023961 1 Pin— — — — — — — — — — 501 7023962 1 Ring, Retainin

3121140 800S 860SJ 2-99SECTION 2 TURNTABLEFIGURE 2-18. LOAD SENSING PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-100 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-19. TANK INSTALLATIONS 107A1071041058103102101PRIOR TOSN 0300071452101065124167211393011012

3121140 800S 860SJ 2-101SECTION 2 TURNTABLEFIGURE 2-19. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TANKS INSTALLATION 0270881 Ref

2-102 800S 860SJ 3121140SECTION 2 TURNTABLE7024445 1 Screen206 7024446 1 Plug, Magnetic207 7024374 1 Filter Assembly207A 7024375 1 Element, Filter208

3121140 800S 860SJ 2-103SECTION 2 TURNTABLEFIGURE 2-19. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-104 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-20. ROTARY COUPLING INSTALLATION (PRIOR TO SN 0300083331) 274274638851121171181161191211201

3121140 800S 860SJ 2-105SECTION 2 TURNTABLEFIGURE 2-20. ROTARY COUPLING INSTALLATION (PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-106 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) 112117126126 127125123124

3121140 800S 860SJ 2-107SECTION 2 TURNTABLEFIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPT

1-8 800S 860SJ 3121140SECTION 1 FRAME218 3841143 8 Shaft, Keeper 3/8in x 3in219 4130390 1 Spindle Weldment (LH)220 4130388 1 Spindle Weldment (RH)221

2-108 800S 860SJ 3121140SECTION 2 TURNTABLE115 2 Bearing Options:See Note p/n 1660257 (Note: No Longer Available.)Use 70001248 p/n 1660303 & 100

3121140 800S 860SJ 2-109SECTION 2 TURNTABLEFIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIP

2-110 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) 22231033023293A29303011112929101051041061023A

3121140 800S 860SJ 2-111SECTION 2 TURNTABLEFIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GROUND C

2-112 800S 860SJ 3121140SECTION 2 TURNTABLE6 1 Decal - Ground Control Display Options:1702610 Prior to SN 03000853321705753 SN 0300085332 to SN 030009

3121140 800S 860SJ 2-113SECTION 2 TURNTABLE32 (cont’d) Deutz Engine Machines4922654 Prior to SN 03000853324923239 SN 0300085332 to SN 0300129454100110

2-114 800S 860SJ 3121140SECTION 2 TURNTABLEContinued Ref GROUND CONTROL BOX INSTALLATION Ref GM Engine:0861792 Ref 800S - Prior to SN 0300099882 B1810

3121140 800S 860SJ 2-115SECTION 2 TURNTABLEFIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-116 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) 143231414030303019242328101822313711895526272925

3121140 800S 860SJ 2-117SECTION 2 TURNTABLEFIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GROUND CONT

3121140 800S 860SJ 1-9SECTION 1 FRAME501 Ref FRAME WELDMENT OPTIONS1 800S Options:2360568 2WD Prior to SN 03000833312360687 2WD SN 0300083331 to SN 03

2-118 800S 860SJ 3121140SECTION 2 TURNTABLE32 4761400 6 Lockwasher 1/4in33 0641506 4 Bolt 5/16in-18NC x 3/4in34 4922594 1 Harness, Valve (Not Shown -

3121140 800S 860SJ 2-119SECTION 2 TURNTABLEFIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-120 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-24. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS 800SAB36621210411588999E225226229228D2

3121140 800S 860SJ 2-121SECTION 2 TURNTABLEFIGURE 2-24. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref E

2-122 800S 860SJ 3121140SECTION 2 TURNTABLE0271999 Ref ALARM INSTALLATION 1201 0257887 1 Alarm/Harness Assembly0140032 1 Alarm2820035 6in/15cm Loom446

3121140 800S 860SJ 2-123SECTION 2 TURNTABLE231 3911040 4 Screw, Machine #10-24NC x 2-1/2in (0271552 Installation Only)232 3311005 4 Nut #10-24NC (0271

2-124 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982) 1818606049496060402404403405404505050505666

3121140 800S 860SJ 2-125SECTION 2 TURNTABLEFIGURE 2-25. HOODS INSTALLATION (PRIOR TO SN 0300089982)ITEM # PART NUMBER QTY. DESCRIPTION REV.0270880 Re

2-126 800S 860SJ 3121140SECTION 2 TURNTABLE23 (cont’d) 1671236 Ford Engine24 1 Cover Options:2680488 Cover, Storage Box (Prior to SN 0300087262)167120

3121140 800S 860SJ 2-127SECTION 2 TURNTABLE61 3960470 1 Seal, Latch62 0182077 1 Angle, Hood Support (SN 0300087262 to SN 0300089982)63 0641406 4 Bolt

1-10 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS 9611115416121082WDPRIOR TOSN 03000833311051131081061071121

2-128 800S 860SJ 3121140SECTION 2 TURNTABLE169 0641606 4 Bolt 3/8in-16NC x 3/4in170 2600209 1 Hinge171 396046465in/1.67mSeal172 396046261in/1.55mSeal2

3121140 800S 860SJ 2-129SECTION 2 TURNTABLE2680488 Ref HOOD ASSEMBLY (STORAGE COMPARTMENT) (PRIOR TO SN 0300087262)E401 Use 2680488 1 Hood402 2940088

2-130 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) 37483464747474747266303048154443344

3121140 800S 860SJ 2-131SECTION 2 TURNTABLE48203148311232384629539481640284573212485047492948324874832483214433444247304837774811483248114766473047473

2-132 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

3121140 800S 860SJ 2-133SECTION 2 TURNTABLE34 3380444 1 Panel, Adapter35 3380461 1 Cover, Top (Tank Side)36 3380575 1 Panel, Cover37 3380580 1 Panel,

2-134 800S 860SJ 3121140SECTION 2 TURNTABLE107 1 Shield, Heat Gasket Options:4061010 SN 0300089982 to SN 0300124624SN 0300124624 to SN 030012945410011

3121140 800S 860SJ 2-135SECTION 2 TURNTABLE125 1001117140 AR Tape, Aluminized Polyester (GM Engine Machines SN 03000139210 to SN 03000140000 Only)126

2-136 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-27. ENGINE TRAY JACK INSTALLATION (OPTIONAL) 3C16154411110226778777133D3A3B12759ORHAMMERBLO

3121140 800S 860SJ 2-137SECTION 2 TURNTABLEFIGURE 2-27. ENGINE TRAY JACK INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.0258728 Ref E

3121140 800S 860SJ 1-11SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref WHEEL DRIVE INSTALLAT

2-138 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) 101013710564131424162322

3121140 800S 860SJ 2-139SECTION 2 TURNTABLEFIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIP

2-140 800S 860SJ 3121140SECTION 2 TURNTABLE2B 1 Box, Control Options:7003657 110V/60Hz (Prior to SN 0300079612)7019680 110V/60Hz (SN 0300079612 to SN

3121140 800S 860SJ 2-141SECTION 2 TURNTABLE21 3520028 1 Plug, Hole22 0721006 AR Bolt #10-24NC x 3/4in23 3311005 AR Locknut #10-24NC24 4751000 AR Flatw

2-142 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) 3535323741384036333432021222C2

3121140 800S 860SJ 2-143SECTION 2 TURNTABLEFIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION R

2-144 800S 860SJ 3121140SECTION 2 TURNTABLE2A (cont’d) 7020110 1 End Bell, Front7020111 1 End Bell, Rear2B 1 Box, Control Options:7003657 110V/6

3121140 800S 860SJ 2-145SECTION 2 TURNTABLE7 0641610 1 Bolt 3/8in-16NC x 1-1/4in8 0100011 AR Compound, Locking9 0641772 1 Bolt 7/16in-14NC x 9in 10 47

2-146 800S 860SJ 3121140SECTION 2 TURNTABLE1001094475 Ref HOURMETER INSTALLATION (OPTIONAL) B101 Not Used102 0720808 1 Screw #8-32 x 1in103 2420165 1

3121140 800S 860SJ 2-147SECTION 2 TURNTABLEFIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) (CONTINUED)ITEM # PART NUMBER QTY. D

1-12 800S 860SJ 3121140SECTION 1 FRAME207 3020008 AR Lubricant (Not Shown)208 AR Drive Motor Assembly Options (See DRIVE MOTOR ASSEMBLY for Breakdown)

2-148 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO SN 03000079612) (OPTIONAL) USEEX

3121140 800S 860SJ 2-149SECTION 2 TURNTABLEFIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO SN 03000079612) (OPTIONAL)ITEM # PART

2-150 800S 860SJ 3121140SECTION 2 TURNTABLE5 1 V-Belt Options:110V/60Hz0480050 Prior to SN 03000660540480111 SN 0300066054 to SN 03000733800480134 SN

3121140 800S 860SJ 2-151SECTION 2 TURNTABLEFIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO SN 03000079612) (OPTIONAL) (CONTINUED)

2-152 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL)

3121140 800S 860SJ 2-153SECTION 2 TURNTABLEFIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL)ITEM

2-154 800S 860SJ 3121140SECTION 2 TURNTABLE16D 1 Pulley Options:3580324 110V/60Hz3580325 220V/50Hz7027887 1 Key, Woodruff17 2820031 AR Heatshrink (Not

3121140 800S 860SJ 2-155SECTION 2 TURNTABLEFIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (SN 0300079612 TO SN 0300140000) (OPTIONAL) (CON

2-156 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)

3121140 800S 860SJ 2-157SECTION 2 TURNTABLEFIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 1-13SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-158 800S 860SJ 3121140SECTION 2 TURNTABLE27 4751500 4 Flatwasher 5/16in Regular28 4811900 1 Flatwasher M829 4891600 1 Flatwasher 3/8in Hardened10010

3121140 800S 860SJ 2-159SECTION 2 TURNTABLEFIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. DESCRIPTION REV

2-160 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES 201103941304181

3121140 800S 860SJ 2-161SECTION 2 TURNTABLEFIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINESITEM # PART NUMBER QTY

2-162 800S 860SJ 3121140SECTION 2 TURNTABLE26 4 Bolt Options:0641404 Bolt 1/4in-20NC x 1/2in (Caterpillar Engine)0641405 Bolt 1/4in-20NC x 5/8in (Deut

3121140 800S 860SJ 2-163SECTION 2 TURNTABLE32E cont’d 7026188 1 Connector, Clamp (Not Shown)1 Panel, End Options (Not Shown):Use 70004170 Caterpillar

2-164 800S 860SJ 3121140SECTION 2 TURNTABLE0861542 Ref JUNCTION BOX ASSEMBLY D101 0861541 1 Box, Junction102 1060494 2ft/.6m Cable, Electrical 12/3103

3121140 800S 860SJ 2-165SECTION 2 TURNTABLE1001094475 Ref HOURMETER INSTALLATION (OPTIONAL) B401 Not Used402 0720808 1 Screw #8-32 x 1in403 2420165 1

2-166 800S 860SJ 3121140SECTION 2 TURNTABLE510 1 Rail, Relay Options:3640986 Prior to SN 03000729113641533 SN 0300072911 to SN 0300140000FIGURE 2-33.

3121140 800S 860SJ 2-167SECTION 2 TURNTABLEFIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED)ITEM # PAR

1-14 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) 191A1B1C1D1N1G1F1E1H211772189106A616161515151

2-168 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES 4227264630419215459819503948102319

3121140 800S 860SJ 2-169SECTION 2 TURNTABLEFIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINESITEM # PART NUMBER QTY. DESCRIPTION REV.0

2-170 800S 860SJ 3121140SECTION 2 TURNTABLE25C 70001953 1 Endbell (Front) 25D 70001100 1 Shaft/Rotor/Windings/Fan/Rear Bearing Assembly70001384 1 Bear

3121140 800S 860SJ 2-171SECTION 2 TURNTABLE0861542 Ref JUNCTION BOX ASSEMBLY C101 0861541 1 Box, Junction102 1060494 2ft/.6m Cable, Electrical 12/3103

2-172 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES 201107116105110117125126101204104109

3121140 800S 860SJ 2-173SECTION 2 TURNTABLEFIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINESITEM # PART NUMBER QTY. DESCRIPTION REV.027

2-174 800S 860SJ 3121140SECTION 2 TURNTABLE18G Use 70004169 1 Shroud Assy Endbell (Rear) (was p/n 70002290)19 2820031 1 Insulator20 3252764 1 Nameplat

3121140 800S 860SJ 2-175SECTION 2 TURNTABLE111 to 115 Not Used116 4460425 2 Strain Relief, Terminal117 4460426 2 Connector, Strain Relief118 to 120 No

2-176 800S 860SJ 3121140SECTION 2 TURNTABLE412 1001094375 1 Bracket, Hourmeter413 1001094509 1 Harness, Hourmeter414 4460018 1 Connector, Butt Splice

3121140 800S 860SJ 3-1SECTION 3BOOM

3121140 800S 860SJ 1-15SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTION REV.2780227 Ref

3-2 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION NOTE: PLACE WASHER (41)ON TOWER BOOM ONSIDE OF L

3121140 800S 860SJ 3-3SECTION 3 BOOMFIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TOWER BOOM,

3-4 800S 860SJ 3121140SECTION 3 BOOM38 4160187 2 Spring, Rubber39 4711600 AR Flatwasher 3/8in Thin40 Use 1001157180 1 Upright (was p/n 4846355)41 4740

3121140 800S 860SJ 3-5SECTION 3 BOOMFIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-6 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800S 25253535918318201313135296342212233119121115108 118 1241121011021

3121140 800S 860SJ 3-7SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800SITEM # PART NUMBER QTY. DESCRIPTION REV.0270876 Ref BOOM AND CYLINDERS I

3-8 800S 860SJ 3121140SECTION 3 BOOMRef POWER TRACK INSTALLATIONRef Note: These SN’s also use the 0271254 Installation: SN’s 0300065567,0300065568,030

3121140 800S 860SJ 3-9SECTION 3 BOOM124 1 Tube, Push Options:4846402 Prior to SN 0300065541 (See Note)4846554 SN 0300065541 to SN 0300140000 (See Note

3-10 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ 25251035 35 1930920147734342424133121321110135 2910110411311011

3121140 800S 860SJ 3-11SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJITEM # PART NUMBER QTY. DESCRIPTION REV.0270877 Ref BOOM AND CYLINDERS

1-16 800S 860SJ 3121140SECTION 1 FRAME16 7000288 2 Thrustwasher17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)18 Not Used19 7000290 1 Coupling20 701

3-12 800S 860SJ 3121140SECTION 3 BOOM108 1683609 1 Jib Lift Cylinder Assembly (See CYLINDER SECTION for Breakdown)109 3311605 5 Locknut 3/8in-16NC110

3121140 800S 860SJ 3-13SECTION 3 BOOM211 3311605 4 Locknut 3/8in-16NC212 3340787 1 Pad, Wear213 3340936 2 Pad, Push Tube214 3340942 2 Pad, Rubber215 3

3-14 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLY ABAB40566654386112375899(TOP)(BOTTOM)72(TOP)(BOTTOM)21222317684165724184819

3121140 800S 860SJ 3-15SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN BOOM ASSEMBLY OPTIONS:0801274 Ref

3-16 800S 860SJ 3121140SECTION 3 BOOM34 3311605 4 Locknut 3/8in-16NC35 3312201 2 Nut 3/4in-10NC36 3340755 2 Pad, Wear37 3340757 2 Pad, Wear38 3340758

3121140 800S 860SJ 3-17SECTION 3 BOOM66 6 Screw 3/8in-16NC x 1-3/4in Options:0791614 Prior to SN 03000744310811614 SN 0300074431 to SN 030014000067 6

3-18 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY 131311815216111243149860SJ800S1B1A101916817A17101B102101A100C100B100A10210210

3121140 800S 860SJ 3-19SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref ROTATOR ASSEMBLIES0060061 Ref 800S I0060

3-20 800S 860SJ 3121140SECTION 3 BOOMRef KIT OPTIONS:100 1 Seal Kit Options: (Includes Items 9-13)100A 7017158 0060061 Rotators (Standard)100B 7000034

3121140 800S 860SJ 3-21SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 1-17SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO SN 0300083331) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-22 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS 106121201301204205305306115203202304303307

3121140 800S 860SJ 3-23SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATF

3-24 800S 860SJ 3121140SECTION 3 BOOM111 1670964 1 Cover112 to 114 Not Used115 3780117 2 O-Ring (860SJ Only)116 Not Used117 AR Valve, Jib (See Items 2

3121140 800S 860SJ 3-25SECTION 3 BOOM309 7023922 1 Valve, Solenoid (Platform Level)7017402 1 Seal Kit - 7023922 Valve310 7017452 1 Valve, Solenoid (Ro

3-26 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS 20 19 242522282126292728231516313435261675303132

3121140 800S 860SJ 3-27SECTION 3 BOOMFIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOM CABLE CLAMPS INSTALL

3-28 800S 860SJ 3121140SECTION 3 BOOMFIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 4-1SECTION 4PLATFORM

4-2 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORM 441020120220320420420520556113017912161817127106

3121140 800S 860SJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM AS

1-18 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) 1C1D1516 23B3C3F3D3E3G1766A6C6B6D6E 6F6

4-4 800S 860SJ 3121140SECTION 4 PLATFORM112 to 126 Not Used127 See Note 1 Footswitch (Note: See PLATFORM ASSEMBLIES - SIDE ENTRY PLATFORM for Service

3121140 800S 860SJ 4-5SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIES - FRONT ENTRY PLATFORM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-6 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-2. PLATFORM ASSEMBLIES - SIDE ENTRY (SN 0300067916 TO SN 0300140000) 1111071042345611789131010

3121140 800S 860SJ 4-7SECTION 4 PLATFORMFIGURE 4-2. PLATFORM ASSEMBLIES - SIDE ENTRY (SN 0300067916 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPT

4-8 800S 860SJ 3121140SECTION 4 PLATFORM103 0641408 3 Bolt 1/4in-20NC x 1in104 0641610 4 Bolt 3/8in-16NC x 1-1/4in105 1 Platform Console Assembly Opti

3121140 800S 860SJ 4-9SECTION 4 PLATFORM209 1 Connector, Strain Relief Options (Not Shown - Located at Console Box):4460598 SN 0300067916 to SN 030007

4-10 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM) 63312854107131111427915

3121140 800S 860SJ 4-11SECTION 4 PLATFORMFIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-12 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY 504502503501OPTIONAL GENERATORSWITCH LOCATED ONMOLDED PLATFORM P

3121140 800S 860SJ 4-13SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM CONSOLE ASSEMBLY08

3121140 800S 860SJ 1-19SECTION 1 FRAMEFIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTION REV.278025

4-14 800S 860SJ 3121140SECTION 4 PLATFORM31 4360331 1 Switch, Toggle32 4360387 1 Switch, Pushbutton33 4360407 1 Controller, Speed34 4360475 1 Switch,

3121140 800S 860SJ 4-15SECTION 4 PLATFORM103 3311601 1 Nut 3/8in-16NC104 2 Pin, Cotter Options:3450304 Prior to SN 03000737293420156 SN 0300073729 to

4-16 800S 860SJ 3121140SECTION 4 PLATFORM605 1 Connector, Strain Relief Options:4460598 Prior to SN 03000744254460426 SN 0300074425 to SN 030014000002

3121140 800S 860SJ 4-17SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-18 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) 2310121514131725201624222119185936145876391110121A1C1

3121140 800S 860SJ 4-19SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original E

4-20 800S 860SJ 3121140SECTION 4 PLATFORM108 70002734 4 Screw109 70002735 1 Can, Enclosure110 70002906 1 Cap111 Use 1001129555 1 Mechanical Assembly (

3121140 800S 860SJ 4-21SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-22 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER) 2082082072092022022032032042042102052061061201181719

3121140 800S 860SJ 4-23SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original

1-20 800S 860SJ 3121140SECTION 1 FRAME18 7024108 1 Plug, Pressure19 7024153 1 Coupling20 7017047 2 Pin, Dowel21 7017082 1 Plug, O-Ring22 7024138 1 Cou

4-24 800S 860SJ 3121140SECTION 4 PLATFORM109 Use 1001113961 1 Plug, Male - 8 Position (Black) (was p/n 7022825)4460871 7 Socket, FemaleRef HANDLE ASSE

3121140 800S 860SJ 4-25SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-26 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-7. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL)

3121140 800S 860SJ 4-27SECTION 4 PLATFORMFIGURE 4-7. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV

4-28 800S 860SJ 3121140SECTION 4 PLATFORM29 3010088 16 Link, Quick30 1260136 10ft/3m Chain31 4360387 1 Switch, Push Button32 1702938 1 Decal - Soft To

3121140 800S 860SJ 4-29SECTION 4 PLATFORMFIGURE 4-7. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL) (CONTINUED)ITEM # PART NUMBER QTY. DES

4-30 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) 14251722121813866744101020

3121140 800S 860SJ 4-31SECTION 4 PLATFORMFIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTI

4-32 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-9. PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) 778356422111210899

3121140 800S 860SJ 4-33SECTION 4 PLATFORMFIGURE 4-9. PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTIO

3121140 800S 860SJ 1-21SECTION 1 FRAMEFIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO SN 0300083331) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTIO

4-34 800S 860SJ 3121140SECTION 4 PLATFORMFIGURE 4-9. PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) (CONTINUED)ITEM # PART NUMBER QTY

3121140 800S 860SJ 5-1SECTION 5CYLINDER

5-2 800S 860SJ 3121140SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY

3121140 800S 860SJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1683078 Ref AXLE LOCKOUT CY

5-4 800S 860SJ 3121140SECTION 5 CYLINDERFIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) 6886781 432181912 1316175A1A511261414151510212210

3121140 800S 860SJ 5-5SECTION 5 CYLINDERFIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.1683609 Ref JIB

5-6 800S 860SJ 3121140SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM 18717271516121111132324242221202145861010292833301021021

3121140 800S 860SJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN LIFT CYLINDER

5-8 800S 860SJ 3121140SECTION 5 CYLINDER28 4641144 1 Cartridge, Restrictor/Check Valve7012967 1 Seal Kit - 4641144 Valve 29 4641234 1 Cartridge, Lift

3121140 800S 860SJ 5-9SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ AREVISION LOGNOTES:REVISION LOG:October 15, 2001 - Original Issue Of Manual (Edited to B/M 0010575 Revision 3)December 15, 2001 - R

1-22 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000) 10531111110112121102119122123104103

5-10 800S 860SJ 3121140SECTION 5 CYLINDERFIGURE 5-4. LEVEL CYLINDER ASSEMBLY - PLATFORM 1011 102726661916 72120124152215221717251418 9235668242

3121140 800S 860SJ 5-11SECTION 5 CYLINDERFIGURE 5-4. LEVEL CYLINDER ASSEMBLY - PLATFORMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SLAVE CYLINDER ASS

5-12 800S 860SJ 3121140SECTION 5 CYLINDERFIGURE 5-5. STEER CYLINDER ASSEMBLY 1417248910131214146113514100

3121140 800S 860SJ 5-13SECTION 5 CYLINDERFIGURE 5-5. STEER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1683740 Ref STEER CYLINDER ASSEMB

5-14 800S 860SJ 3121140SECTION 5 CYLINDERFIGURE 5-6. TELESCOPE CYLINDER ASSEMBLY 456781010111212131415161718192021252223114B110114A114C11424262

3121140 800S 860SJ 5-15SECTION 5 CYLINDERFIGURE 5-6. TELESCOPE CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TELESCOPE CYLINDER ASSEMB

5-16 800S 860SJ 3121140SECTION 5 CYLINDER0272750 Ref MANUAL DESCENT INSTALLATION (SN 0300068651 TO SN 0300140000)A101 to 109 Not Used110 3931480 4 Cap

3121140 800S 860SJ 6-1SECTION 6HYDRAULIC

6-2 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM 63810219475921

3121140 800S 860SJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref AXLE LOCKOUT HYDRAULIC

3121140 800S 860SJ 1-23SECTION 1 FRAMEFIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (SN 0300083331 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION REV.27

6-4 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331)

3121140 800S 860SJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTION REV.27

6-6 800S 860SJ 3121140SECTION 6 HYDRAULIC46 2753667 2 Hose47 2753685 1 Hose48 2753652 2 Hose49 2753687 2 Hose50 2753688 2 Hose51 2753689 1 Hose52 4641

3121140 800S 860SJ 6-7SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO SN 0300083331) (CONTINUED)ITEM # PART NUMBER QTY. DESCRI

6-8 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000) 840448214818351341622868284

3121140 800S 860SJ 6-9SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTIO

6-10 800S 860SJ 3121140SECTION 6 HYDRAULIC40 1 Hose Options:2754245 SN 0300083331 to SN 03000854662753685 SN 0300085466 to SN 030014000041 1 Hose Opti

3121140 800S 860SJ 6-11SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083331 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPT

6-12 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331) 3210493329285315493250515277931371

3121140 800S 860SJ 6-13SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTION REV.2

1-24 800S 860SJ 3121140SECTION 1 FRAME15 7000287 4 Thrustwasher16 7000288 2 Thrustwasher17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)18 Not Used19

6-14 800S 860SJ 3121140SECTION 6 HYDRAULIC46 2753634 1 Hose47 2753635 1 Hose48 Not Used49 2753659 2 Hose50 2753660 1 Hose51 2753661 1 Hose52 2753664 1

3121140 800S 860SJ 6-15SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO SN 0300083331) (CONTINUED)ITEM # PART NUMBER QTY. DESCR

6-16 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300083331 TO SN 0300140000) 31543435313344332020315513

3121140 800S 860SJ 6-17SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300083331 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTI

6-18 800S 860SJ 3121140SECTION 6 HYDRAULIC34 2754044 1 Hose35 3 Hose Options:2753622 Without Arctic PackageUse 2754719 With Arctic Package (SN 0300083

3121140 800S 860SJ 6-19SECTION 6 HYDRAULIC57 2220811 4 Fitting, Reducer (SN 0300138515 to SN 0300140000)3600410 Ref PISTON PUMP ASSEMBLY C101 2111010

6-20 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-6. MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL) 13151310945678881111262664414

3121140 800S 860SJ 6-21SECTION 6 HYDRAULICFIGURE 6-6. MANUAL DESCENT HYDRAULIC DIAGRAM ( OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.2792597 Ref

6-22 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-7. STANDARD HYDRAULIC DIAGRAM 23826369103771025154551041033510117143241182124411534223112025

3121140 800S 860SJ 6-23SECTION 6 HYDRAULICFIGURE 6-7. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref STANDARD HYDRAULIC DIAGRA

3121140 800S 860SJ 1-25SECTION 1 FRAMERef KIT OPTIONS:200 AR Seal Kit Options:200A 7017068 1 Seal Kit - Hub (Includes Items 1B,5,6F,6G & 8)200B 70

6-24 800S 860SJ 3121140SECTION 6 HYDRAULIC38 1 Hose Options:2753693 800S2753692 860SJ39 2753670 2 Hose 40 2753671 2 Hose41 2753672 1 Hose42 2753674 1

3121140 800S 860SJ 6-25SECTION 6 HYDRAULICFIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-26 800S 860SJ 3121140SECTION 6 HYDRAULICFIGURE 6-8. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Diagrams with ast

3121140 800S 860SJ 7-1SECTION 7ELECTRICAL

7-2 800S 860SJ 3121140SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LISTITEM # PART NUMBER QTY. DESCRIPTION REV.4933243 Ref ADE SYSTEM POWER-DOW

3121140 800S 860SJ 7-3SECTION 7 ELECTRICALRef PLATFORM WORKLIGHTS ELECTRICAL DIAGRAM0270814 Ref 800S/860SJ - Prior to SN 03000744250273472 Ref 800S -

7-4 800S 860SJ 3121140SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332)

3121140 800S 860SJ 7-5SECTION 7 ELECTRICAL 218333J7HEADLIGHTSANDTAILLIGHTSSPEEDPICKUP(DEUTZENGINE)RECEPTACLEAT PLATFORM(OPTIONAL) J1J2J3J4GROUNDC

7-6 800S 860SJ 3121140SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332)ITEM # PART NUMBER QTY. D

3121140 800S 860SJ 7-7SECTION 7 ELECTRICAL59A 4460761 1 Connector, Female - 4 Position4460227 4 Pin, Male60 4460708 2 Receptacle - 15 Position4922595

1-26 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD PRIOR TO SN 0300083331)

7-8 800S 860SJ 3121140SECTION 7 ELECTRICAL204 1060902 AR Cable, Electrical - 18/2 (Prior to SN 0300071452)134ft/41m 800S138ft/42m 860SJ AR To Boom Cap

3121140 800S 860SJ 7-9SECTION 7 ELECTRICAL218E 4460466 8 Seal, Plug219 to 232 Not Used233 4922660 1 Holding Valve/Lift Dump Harness Assembly (Note: Th

7-10 800S 860SJ 3121140SECTION 7 ELECTRICALRef GROUND CONTROL BOX COMPONENTS301 to 320 Not Used321 4460426 AR Connector, Strain Relief322 4460470 1 Nu

3121140 800S 860SJ 7-11SECTION 7 ELECTRICAL334G 4460871 9 Socket, Female334H 4460434 2 Plug, Male - 15 Position4460227 22 Pin, Male335 1 Ground Contro

7-12 800S 860SJ 3121140SECTION 7 ELECTRICAL463 Not Used464 4460887 1 Terminal, Molex465 to 467 Not Used468 3730120 1 Resistor Assembly (SN 0300073347

3121140 800S 860SJ 7-13SECTION 7 ELECTRICAL606 7022824 1 Controller Harness/Circuit Board Assembly (Drive and Steer)606A 7022825 1 Connector, Female -

7-14 800S 860SJ 3121140SECTION 7 ELECTRICAL701G (cont’d)106049418in/46cm ANSI Spec106046130in/76cm ANSI Export Spec701H 1 Plug, Male Options:4

3121140 800S 860SJ 7-15SECTION 7 ELECTRICAL704A 4460320 1 Connector, Female - 2 Position4460267 2 Pin, Male705 0257887 1 Alarm Harness (Includes Alarm

7-16 800S 860SJ 3121140SECTION 7 ELECTRICAL707J 2400070 1 Fuse (Platform Worklights Only)707K 2400066 1 Holder, Fuse (Platform Worklights Only)708 See

3121140 800S 860SJ 7-17SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO SN 0300085332) (CONTINUED)ITEM # PART

3121140 800S 860SJ 1-27SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTION REV.3160268 Re

7-18 800S 860SJ 3121140SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) 341339J5J6J

3121140 800S 860SJ 7-19SECTION 7 ELECTRICAL 455BOSCH FUELREGULATOR(GM) FUELREGULATOR(GM HARNESS)446447427615STROBELIGHT34141834142244044942343360

7-20 800S 860SJ 3121140SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000)ITEM # PART NUMB

3121140 800S 860SJ 7-21SECTION 7 ELECTRICALRef PLATFORM BOX HARNESS ASSEMBLY4922595 Ref SN 0300085332 to SN 0300137913 10/I1001107796 Ref SN 030013791

7-22 800S 860SJ 3121140SECTION 7 ELECTRICAL217 (cont’d)4922567 860SJ 3/C4923595 860SJ (With Arctic Package) 1/AAR Cable, Electrical - 12/4&18/8 Op

3121140 800S 860SJ 7-23SECTION 7 ELECTRICAL235 (cont’d) 4923466 With Arctic Package (SN 0300107594 to SN 0300140000)4460464 2 Pin, Male 4460897 1 Rece

7-24 800S 860SJ 3121140SECTION 7 ELECTRICAL240 4460959 1 Terminal, Turnlok Plug (With 7500W Generator and Arctic Package)1671092 1 Cover, Female Conne

3121140 800S 860SJ 7-25SECTION 7 ELECTRICALRef GROUND CONTROL BOX COMPONENTS301 0100048 AR Grease, Dielectric302 to 327 Not Used328 4460426 1 Connecto

7-26 800S 860SJ 3121140SECTION 7 ELECTRICAL340G 4460871 AR Socket, Female340H 4460434 2 Plug, Male - 15 Position4460227 AR Pin, Male340J 4460761 1 Con

3121140 800S 860SJ 7-27SECTION 7 ELECTRICAL423 4461070 1 Receptacle, Female With Resistor (3 Position) (Deutz Engine Only)4461095 1 Plug, Male - 3 Pos

1-28 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 & ALL 4WD MACHINES) (4 BOLT ASSEMBLY)

7-28 800S 860SJ 3121140SECTION 7 ELECTRICAL453 4460374 1 Plug, Sealed Relay (Deutz Engine Tier III) (SN 0300129454 to SN 0300140000)4460375 4 Terminal

3121140 800S 860SJ 7-29SECTION 7 ELECTRICAL511 4922771 1 Harness, Angle Sensor (Boom Proximity Sensor)1060902 9.5ft/2.9m Cable - 18/2511A 4460226 2 So

7-30 800S 860SJ 3121140SECTION 7 ELECTRICAL601B (cont’d)7027018 GM Engine Machines601C 7016824 1 Cable (Red)601D 1 Cable (Red) Options:7016803 Caterpi

3121140 800S 860SJ 7-31SECTION 7 ELECTRICAL610 See Note 1 Pump Harness (Note: Not Available for Purchase.)610A 7007497 1 Plug (Pump End)610B 7007498 1

7-32 800S 860SJ 3121140SECTION 7 ELECTRICAL706 AR 2500W Generator Electrical Components4933300 ANSI Export Specs - Caterpillar/Deutz (SN 0300085332 to

3121140 800S 860SJ 7-33SECTION 7 ELECTRICAL708B 1 Receptacle Options (ANSI Spec Only):4460346 110V GFI4460125 220V GFI708C 1 Shield, Cover Options (AN

7-34 800S 860SJ 3121140SECTION 7 ELECTRICAL709D 1 Cover, Receptacle Options:4061043 60Hz Spec (Side Hinged Cover) (SN 0300085332 to SN 0300138287)1001

3121140 800S 860SJ 7-35SECTION 7 ELECTRICAL711D 2400060 AR Fuseholder Options:1 Caterpillar, Deutz & GM Engine Machines2 Ford Engine Machines24000

7-36 800S 860SJ 3121140SECTION 7 ELECTRICAL802 7002823 1 Extractor (For Removal of Pin/Socket from Connectors) (Not Shown)803 4460467 1 Extractor, Pin

3121140 800S 860SJ 7-37SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 TO SN 0300140000) (CONTINUED)ITEM

3121140 800S 860SJ 1-29SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 & ALL 4WD MACHINES) (4 BOLT ASSEMBLY)I

7-38 800S 860SJ 3121140SECTION 7 ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM) 335334J5J6J7J2J2J1J8J1J8218327326336P218D218E21

3121140 800S 860SJ 7-39SECTION 7 ELECTRICAL 453BOSCH FUELREGULATOR(GM) FUELREGULATOR(GM HARNESS)447449610STROBELIGHT335418335438423433602B602A602

7-40 800S 860SJ 3121140SECTION 7 ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: FO

3121140 800S 860SJ 7-41SECTION 7 ELECTRICAL107 4460225 4 Plug, Male - 6 Position4460226 18 Terminal (16 Gauge)108 4460225 1 Plug, Male - 6 Position446

7-42 800S 860SJ 3121140SECTION 7 ELECTRICAL218 (cont’d) 20ft/6.1m Cable, Electrical - 12/4&18/8 Options:1060896 Standard & Sky Welder 4923462

3121140 800S 860SJ 7-43SECTION 7 ELECTRICAL234 1 Harness, Limit Switch Upper Options (To Boom Transport Length Limit Switch):4922871 Standard & Sk

7-44 800S 860SJ 3121140SECTION 7 ELECTRICAL334D 4460834 1 Connector, Female - 2 Position4460842 2 Terminal, Female334E 4460871 22 Socket, Female334F 4

3121140 800S 860SJ 7-45SECTION 7 ELECTRICAL337 1 Ground Control Box Wiring Diagram (Not Shown - See Items 501 to 513 for Breakdown)1001110344 Caterpil

7-46 800S 860SJ 3121140SECTION 7 ELECTRICAL446 4461157 1 Receptacle, Female - 2 Position4460979 2 Pin, Male4460458 2 Seal, Terminal447 4461121 1 Plug,

3121140 800S 860SJ 7-47SECTION 7 ELECTRICAL511B 4460424 1 Receptacle, Female - 2 Position512 Not Used513 4460894 1 Plug, Male - 6 Position4460892 1 Co

1-30 800S 860SJ 3121140SECTION 1 FRAME25 7022321 1 Plug (Includes Item 26)26 Use 7022328 1 O-Ring27 7007420 1 Plug (Includes Item 28)28 Use 7022328 1

7-48 800S 860SJ 3121140SECTION 7 ELECTRICAL604A 4460894 1 Plug, Male - 6 Position4460465 5 Socket, Female4460466 1 Seal, Plug604B 4460891 1 Plug, Male

3121140 800S 860SJ 7-49SECTION 7 ELECTRICAL704A 4460320 1 Connector, Female - 2 Position4460267 2 Pin, Male705 See Note 1 Headlight & Taillight/Ch

7-50 800S 860SJ 3121140SECTION 7 ELECTRICAL708C 1 Shield, Cover Options (ANSI Spec Only):1001110873 110V GFI (Top Hinged Cover)4060092 220V GFI708D 44

3121140 800S 860SJ 7-51SECTION 7 ELECTRICAL710A 2ft/.6m Cable, Electrical 12/31060494 60Hz SpecSee Note 50Hz Spec (Note: Not Available - Purchase Loca

7-52 800S 860SJ 3121140SECTION 7 ELECTRICAL713D 1 Harness, Console Box to Connector Options:4922873 800S Harness (85ft/25.9m of 10/3 Cable P/N 1060708

3121140 800S 860SJ 8-1SECTION 8DECALS

8-2 800S 860SJ 3121140SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) 4101294912121534131123283132293031321

3121140 800S 860SJ 8-3SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref

8-4 800S 860SJ 3121140SECTION 8 DECALS34 3252347 1 Decal - Footswitch (Part of 4360031 Footswitch)35 4 Decal - Max Tire Load Options:1703475 800S17034

3121140 800S 860SJ 8-5SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300088933) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPT

3121140 800S 860SJ 1-31SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD SN 0300083331 TO SN 0300098641 & ALL 4WD MACHINES) (4 BOLT ASSEMBLY)

8-6 800S 860SJ 3121140SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) 20504156957375956954847464543

3121140 800S 860SJ 8-7SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION

8-8 800S 860SJ 3121140SECTION 8 DECALS34 1 Decal Capacity Options:800S - Decal - 500LBS Unrestricted Capacity:1705089 SN 0300088933 to SN 030010061417

3121140 800S 860SJ 8-9SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION

8-10 800S 860SJ 3121140SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) 410129491212153934131123283132293

3121140 800S 860SJ 8-11SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933)ITEM # PART NUMBER QTY. DESCRIPTION REV.

8-12 800S 860SJ 3121140SECTION 8 DECALS3 (cont’d) 1703935 Latin American Spec4 3 Decal - Warning/Crushing1703952 Brazil Spec (Spanish/Portuguese)17039

3121140 800S 860SJ 8-13SECTION 8 DECALS18 1701504 2 Decal - Hydraulic Oil19 1 Decal - Inspection Options:1704008 Brazil Spec1704006 CSA Spec1704007 La

8-14 800S 860SJ 3121140SECTION 8 DECALS44 1701499 4 Decal - No Lift 45 3252781 1 Decal - Lift Capacity46 1704412 1 Decal - Hydraulic Oil Chart47 17045

3121140 800S 860SJ 8-15SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300088933) ITEM # PART NUMBER QTY. DESCRIPTION REV

B 800S 860SJ 3121140REVISION LOGNovember 4, 2009 - Revised Manual (Edited to B/M 0010575 Revision 104)May 3, 2010 - Revised Manual (Edited to B/M 0010

1-32 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) 3413401938303433323132311811411129107A1316151714786255

8-16 800S 860SJ 3121140SECTION 8 DECALSFIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) 4735323082545517363924187

3121140 800S 860SJ 8-17SECTION 8 DECALSFIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPT

8-18 800S 860SJ 3121140SECTION 8 DECALS20 2 Decal - No Hands Options:1705967 Brazil Spec (English/Portuguese)Chinese Spec (Traditional)1705968 USA Bui

3121140 800S 860SJ 8-19SECTION 8 DECALS25 1 Decal - Foot Switch Options:1705902 Brazil Spec (English/Portuguese)1703982 Chinese Spec1703984 CSA Spec17

8-20 800S 860SJ 3121140SECTION 8 DECALS34 1 Decal Capacity Options:800S - Decal - 500LBS Unrestricted Capacity SN 0300088933 to SN 0300100614:1706381

3121140 800S 860SJ 8-21SECTION 8 DECALS48 4751400 10 Flatwasher 1/4in Regular49 1702861 2 Decal - JLG Lift (8in Height)50 1702774 1 Decal - JLG Lift (

8-22 800S 860SJ 3121140SECTION 8 DECALSFIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300088933 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIP

3121140 800S 860SJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 800S/860SJThe following list will service one machine (built to current production

9-2 800S 860SJ 3121140SECTION 9 RECOMMENDED SERVICE PARTS STOCK3740080 Relay (Machine with Generator Option) (Figures 2-28, 2-29, 2-31, 2-32, 2-33 2-3

3121140 800S 860SJ 10-1SECTION 10SPECIAL OPTIONS

3121140 800S 860SJ 1-33SECTION 1 FRAMEFIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DRIVE MOTOR ASSEM

10-2 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applic

3121140 800S 860SJ 10-3SECTION 10 SPECIAL OPTIONSRef Cold Weather Start Kits0273575 Ref Caterpillar Engine Machines0256060 Ref Deutz Engine Machines (

10-4 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONS0257157 Ref Ether Start Installation (Deutz Engine Machines)1001093389 Ref Fan, CoverRef Filter Kits:

3121140 800S 860SJ 10-5SECTION 10 SPECIAL OPTIONSCont’d Ref Fluids:Ref Hydraulic Fluids Options:2300014 Ref Mobil 4242300027 Ref Mobil 224H Bio2300029

10-6 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONSRef Platform Mesh To Mid Rail Installation (Side Entry Platform)1001140318 Ref 800S/860SJ - 2.5ftx4ft

3121140 800S 860SJ 10-7SECTION 10 SPECIAL OPTIONSContinued Ref Sky Accessory:Ref SkyGlazier (ANSI Export Spec 800S Only) (Spanish) Options:Use 1001099

10-8 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONSRef Tools for Service2901443 1 Analyzer Kit (SN 0300062045 to SN 0300140000)8896941 1 Wire Stripper70

3121140 800S 860SJ 10-9SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applica

10-10 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONSFIGURE 10-2. SKY WELDER INSTALLATION

3121140 800S 860SJ 10-11SECTION 10 SPECIAL OPTIONS

1-34 800S 860SJ 3121140SECTION 1 FRAME25 2220883 1 Plug (Includes Item 26)26 Use 7022328 1 O-Ring27 2220888 2 Plug (Includes Item 28)28 Use 7022328 2

10-12 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONSFIGURE 10-2. SKY WELDER INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SKY WELDER INSTALLA

10-13 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONS31 4711500 4 Flatwasher 5/16in Thin32 4711800 8 Flatwasher 1/2in Thin33 4740397 1 Spacer34 4751400 2

10-14 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONS141 1 Panel Assembly (Complete) Options:7023420 ANSI Spec (60Hz)See Note ANSI Export Spec (50Hz) (No

10-15 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONS

10-16 800S 860SJ 3121140SECTION 10 SPECIAL OPTIONS

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-1SECTION 11 PARTS NUMBER INDEX0060048 ...3-11, 3-1900

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX0272561 ... 8-

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-3SECTION 11 PARTS NUMBER INDEX169, 3-3, 4-270641613 ...3-3,

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX0962449 ... 2-141, 2-145096

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-5SECTION 11 PARTS NUMBER INDEX1001114632 ... 2-891

3121140 800S 860SJ 1-35SECTION 1 FRAMEFIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX132, 2-1351671230 ... 2-127

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-7SECTION 11 PARTS NUMBER INDEX1706712 ...2-112, 2-1171706

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX2460032 2-139, 2-143, 2-1492460034

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-9SECTION 11 PARTS NUMBER INDEX2902310 ... 8-

PagePart Number PagePart Number PagePart NumberPagePart Number11-10 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX3422932 ... 3

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-11SECTION 11 PARTS NUMBER INDEX2-85, 2-903960470 ...2-127

PagePart Number PagePart Number PagePart NumberPagePart Number11-12 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX7-15, 7-16, 7-34, 7-35, 7-514460426

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-13SECTION 11 PARTS NUMBER INDEX4640750 ... 2

PagePart Number PagePart Number PagePart NumberPagePart Number11-14 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX4922567 ...7-8, 7-22, 7-41492

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-15SECTION 11 PARTS NUMBER INDEX70002416 ...2-48, 2-6070

1-36 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-10. FRAME VALVES & SHIELDS INSTALLATIONS (PRIOR TO SN 0300083331) 1010A10A10B113119B99B9AMOU

PagePart Number PagePart Number PagePart NumberPagePart Number11-16 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX7011346 ... 5

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-17SECTION 11 PARTS NUMBER INDEX7020463 ... 2

PagePart Number PagePart Number PagePart NumberPagePart Number11-18 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX7023982 ...

PagePart Number PagePart Number PagePart NumberPagePart Number3121140 800S 860SJ 11-19SECTION 11 PARTS NUMBER INDEX7027790 ... 2

PagePart Number PagePart Number PagePart NumberPagePart Number11-20 800S 860SJ 3121140SECTION 11 PARTS NUMBER INDEX

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

3121140 800S 860SJ 1-37SECTION 1 FRAMEFIGURE 1-10. FRAME VALVES & SHIELDS INSTALLATIONS (PRIOR TO SN 0300083331)ITEM # PART NUMBER QTY. DESCRIPTI

1-38 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-11. FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO SN 0300140000) ORVALVE ROTATED FO

3121140 800S 860SJ 1-39SECTION 1 FRAMEFIGURE 1-11. FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO SN 0300140000)ITEM # PART NUMBER QTY. D

1-40 800S 860SJ 3121140SECTION 1 FRAME0274267 Ref FRAME SHIELDS INSTALLATIONS A201 0100011 6 Compound, Locking202 0641608 6 Bolt, 3/8in - 16NC x 1in20

3121140 800S 860SJ 1-41SECTION 1 FRAMEFIGURE 1-11. FRAME VALVES & SHIELDS INSTALLATIONS (SN 0300083331 TO SN 0300140000) (CONTINUED)ITEM # PART N

3121140 800S 860SJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-42 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-12. TOW PACKAGE INSTALLATION 1021211131131141141171121121151151201031051051041091101061061061061

3121140 800S 860SJ 1-43SECTION 1 FRAMEFIGURE 1-12. TOW PACKAGE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0271354 Ref TOW BAR INSTALLATION E

1-44 800S 860SJ 3121140SECTION 1 FRAMEFIGURE 1-12. TOW PACKAGE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121140 800S 860SJ 2-1SECTION 2TURNTABLE

2-2 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-1. CONTROL VALVES INSTALLATIONS 2420201392323168232526272320201313552020SN 0300083331TO SN 03

3121140 800S 860SJ 2-3SECTION 2 TURNTABLEFIGURE 2-1. CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref VALVES INSTALLATIONS0270

2-4 800S 860SJ 3121140SECTION 2 TURNTABLE19 4641317 1 Dual Select Valve Assembly C7012944 2 Coil7012941 2 Cartridge Less Coil7010543 2 Seal Kit - 7012

3121140 800S 860SJ 2-5SECTION 2 TURNTABLE0272750 Ref MANUAL DESCENT INSTALLATION (OPTIONAL) (SN 0300068651 TO SN 0300140000)A201 0641420 2 Bolt 1/4in-

2-6 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY 18936825471613151115121410141718517A

3121140 800S 860SJ 2-7SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN CONTROL VALVE ASSEMB

ii 800S 860SJ 3121140FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS2-33 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES . . . .

2-8 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION

3121140 800S 860SJ 2-9SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TURNTABLE WELD

2-10 800S 860SJ 3121140SECTION 2 TURNTABLE0259147 Ref TURNTABLE LOCK INSTALLATION B201 4844958 1 Pin202 3421565 1 Pin, Snap203 3760170 2 Ring, Quick R

3121140 800S 860SJ 2-11SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-12 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-4. SWING HUB ASSEMBLY (PRIOR TO SN 0300066417) 986573421101112242325262621131714181921A20222

3121140 800S 860SJ 2-13SECTION 2 TURNTABLEFIGURE 2-4. SWING HUB ASSEMBLY (PRIOR TO SN 0300066417)ITEM # PART NUMBER QTY. DESCRIPTION REV.2780205 Ref

2-14 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-5. SWING MOTOR ASSEMBLY (PRIOR TO SN 0300066417) 1917141614151413419876542133022231011124343

3121140 800S 860SJ 2-15SECTION 2 TURNTABLEFIGURE 2-5. SWING MOTOR ASSEMBLY (PRIOR TO SN 0300066417)ITEM # PART NUMBER QTY. DESCRIPTION REV.3160280 Re

2-16 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352)9124251J1G1A1B1D1E1F1H1I1C23B3B3E3G3C3C

3121140 800S 860SJ 2-17SECTION 2 TURNTABLE 3631205211210212221202219222223204203206206201209207208214213216215218217203272203035192122233212011

3121140 800S 860SJ iiiTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352)ITEM # PART NUMBER QTY. DESCRIPTION RE

3121140 800S 860SJ 2-19SECTION 2 TURNTABLE31 7024707 1 Motor Assembly (See Items 101-120 for Breakdown)32 7024784 1 Valve Assembly - Complete (No Serv

2-20 800S 860SJ 3121140SECTION 2 TURNTABLE219 7024190 2 Pin, Dowel220 See Note 1 Plug (Note: Not Available - Purchase Locally.)221 See Note 1 Plug (No

3121140 800S 860SJ 2-21SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300066417 TO SN 0300134352) ITEM # PART NUMBER QTY. DESCRIPTION R

2-22 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134352 TO SN 0300140000)11G1A1B1E1H1I1C233A4481111545A612201J24

3121140 800S 860SJ 2-23SECTION 2 TURNTABLE 318K8J30352122233212011911711811611411511311211010910810710610510310410410410410410210128292829200A2

2-24 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134352 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION RE

3121140 800S 860SJ 2-25SECTION 2 TURNTABLE23 7017023 2 Plug, Pipe24 See Note 1 Plate, ID (Note: Not Available for Purchase.)25 7000281 2 Screw, Drive2

2-26 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398)6767104431466856116681553A29293727274036

3121140 800S 860SJ 2-27SECTION 2 TURNTABLE VENTSUPPLY161646466868110111121114112252510410512111511513713412010654545467441155356721231301311391

iv 800S 860SJ 3121140FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS

2-28 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (PRIOR TO SN 0300139398)ITEM # PART NUMBER QTY. DESCRIPTION REV

3121140 800S 860SJ 2-29SECTION 2 TURNTABLE30 1340060 1 Air Cleaner Assembly7012664 1 Element, Air Cleaner31 1580011 1 Container, Coolant Overflow32 16

2-30 800S 860SJ 3121140SECTION 2 TURNTABLE63 1 Tube, Air Intake Weldment Options:4568788 1 Prior to SN 03000872624569177 1 SN 0300087262 to SN 0300104

3121140 800S 860SJ 2-31SECTION 2 TURNTABLERef CATERPILLAR ENGINE INSTALLATIONSRef Machines Without Arctic Package0273527 Ref Tier II Engines (Prior to

2-32 800S 860SJ 3121140SECTION 2 TURNTABLE110 0642010 1 Bolt 5/8in-11NC x 1-1/4in111 4752000 1 Flatwasher 5/8in Regular112 1320223 AR J-Clip 1/2in113

3121140 800S 860SJ 2-33SECTION 2 TURNTABLE143 4751500 3 Flatwasher 5/16in Regular (Prior to SN 0300075346)144 396054842in/1mSeal, Hood145 0641812 4 Bo

2-34 800S 860SJ 3121140SECTION 2 TURNTABLE209 7026822 1 Thermostat7026821 1 Gasket (Between Regulator & Thermostat Housing)7026820 1 Gasket (Betwe

3121140 800S 860SJ 2-35SECTION 2 TURNTABLE228 70002766 1 Head, Cylinder (Not Shown)7026801 1 Gasket, Valve Cover (Not Shown)70002764 1 Gasket, Rear He

2-36 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000)70357064395638557476322321327606

3121140 800S 860SJ 2-37SECTION 2 TURNTABLE SUPPLYTANK REF.10711540472737161215A215B215B215C215D614426214426210612135827242453531171191041011110

3121140 800S 860SJ 1-1SECTION 1 FRAME

2-38 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIP

3121140 800S 860SJ 2-39SECTION 2 TURNTABLE42 3311605 AR Locknut 3/8in-16NC43 3311801 1 Nut 1/2in-13NC44 3311805 4 Locknut 1/2in-13NC45 3574206 1 Plate

2-40 800S 860SJ 3121140SECTION 2 TURNTABLE105 0641808 1 Bolt 1/2in-13NC x 1in106 0642010 1 Bolt 5/8in-11NC x 1-1/4in107 1320022 7 Clamp, Hose108 13201

3121140 800S 860SJ 2-41SECTION 2 TURNTABLE213 4891800 2 Flatwasher 1/2in Hardened 214 Not Used215 1001112762 1 Battery Cable Kit B215A 7027028 1 Cable

2-42 800S 860SJ 3121140SECTION 2 TURNTABLE328 1001112070 1 Switch, Oil Pressure329 1001112071 1 Harness, Engine (Not Shown - See Section 7 for Breakdo

3121140 800S 860SJ 2-43SECTION 2 TURNTABLE413 7026811 1 Filter, OilNote: Machines with SkyPower use Remote Mounted Oil Filter - See Section 10. The sa

2-44 800S 860SJ 3121140SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586)

3121140 800S 860SJ 2-45SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077586)ITEM # PART NUMBER QTY. DESCRIPTION REV.0270

2-46 800S 860SJ 3121140SECTION 2 TURNTABLE42 2180536 1 Fitting, Straight43 2220313 1 Fitting, Elbow44 27505327ft./2.2mHose 3/8in45 2220250 1 Fitting,

3121140 800S 860SJ 2-47SECTION 2 TURNTABLE83 3311801 1 Nut 1/2in-13NC84 4751800 1 Flatwasher 1/2in Regular85 4567815 1 Tuning Tube Weldment 86 0641826