Jlg 800A_AJ ANSI Parts Manual User Manual

Illustrated Parts ManualModels800A800AJS/N 0300069000to S/N 0300140000P/N3121176April 30, 2014

1-2 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION

2-54 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION

3121176 800A 800AJ 2-55SECTION 2 TURNTABLE21B 1 Cable, Battery (Black) Options:7027012 SN 0300077500 to SN 03001382387027004 SN 0300138238 to SN 03001

2-56 800A 800AJ 3121176SECTION 2 TURNTABLERef Note: Arctic Package Items 51 - 62 Not Shown - Used on Arctic Machines Only51 1060625 1 Cable, Immersion

3121176 800A 800AJ 2-57SECTION 2 TURNTABLE109 (cont’d) 1001095354 1 Gear Pump (Sauer Danfoss) (SN 0300121643 to SN 0300140000)A2220415 1 Fitting100109

2-58 800A 800AJ 3121176SECTION 2 TURNTABLE224 1 Engine, Deutz Options:2000216 SN 0300077500 to SN 03000853312000274 SN 0300085331 to SN 03000927182000

3121176 800A 800AJ 2-59SECTION 2 TURNTABLE249 1 Tube, Tuning Options:4567815 SN 0300077500 to SN 03000853314569171 SN 0300085331 to SN 030012945610010

2-60 800A 800AJ 3121176SECTION 2 TURNTABLERef Note: Arctic Package Item 286 & 287 Not Shown - Used on Arctic Machines Only.286 2580062 1 Heater, E

3121176 800A 800AJ 2-61SECTION 2 TURNTABLE405 4 Pump, Injector Options:SN 0300077500 to SN 03001294567027246 Series A Injector (was p/n 7027242)702760

2-62 800A 800AJ 3121176SECTION 2 TURNTABLE411 cont’d 70002234 1 Bracket, Adjusting (Not Shown)412 7020479 1 Starter7026608 1 Solenoid70001498 1 Shield

3121176 800A 800AJ 2-63SECTION 2 TURNTABLE426 1 Timing Belt/Idler Kit Options (Not Shown):70000800 SN 0300077500 to SN 0300085331See NoteSN 0300085331

3121176 800A 800AJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0258286 Ref FIXED AXLE INSTALL

2-64 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-12. FORD ENGINE INSTALLATION - NON-UL SPEC MACHINES (SN 0300069000 TO SN 0300077500) TOENGIN

3121176 800A 800AJ 2-65SECTION 2 TURNTABLEFIGURE 2-12. FORD ENGINE INSTALLATION - NON-UL SPEC MACHINES (SN 0300069000 TO SN 0300077500)ITEM # PART NU

2-66 800A 800AJ 3121176SECTION 2 TURNTABLE104 0181727 1 Tie-Down105 0630498 2 Bolt, Tie-Down106 3620040 1 RadiatorUse 8180311 1 Cap, Radiator (was p/n

3121176 800A 800AJ 2-67SECTION 2 TURNTABLE147 3311505 6 Hex Nut 5/16in-18NC148 3900272 3 Bolt 5/16in-18NC x 1-3/4in149 0100020 AR Sealant, Pipe150 218

2-68 800A 800AJ 3121176SECTION 2 TURNTABLE187 3960468 1 Seal, Foam 188 3960469 1 Seal, Foam189 0641410 3 Bolt 1/4in-20NC x 1-1/4in190 4568158 4 Stando

3121176 800A 800AJ 2-69SECTION 2 TURNTABLE314 1660250 1 Coupling, Pump (was p/n 7016662)7019976 1 Flywheel7022180 1 Ring Gear315 7019993 1 Pressure Re

2-70 800A 800AJ 3121176SECTION 2 TURNTABLERef MUFFLER INSTALLATIONS0258390 Ref Standard Spark Arresting 10258391 Ref Optional Catalytic 1401 1 Muffler

3121176 800A 800AJ 2-71SECTION 2 TURNTABLEFIGURE 2-12. FORD ENGINE INSTALLATION - NON-UL SPEC MACHINES (SN 0300069000 TO SN 0300077500) (CONTINUED)IT

2-72 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-13. FORD ENGINE INSTALLATION - UL MACHINES (SN 0300069000 TO SN 0300077500) FUELRETURN256871

3121176 800A 800AJ 2-73SECTION 2 TURNTABLEFIGURE 2-13. FORD ENGINE INSTALLATION - UL MACHINES (SN 0300069000 TO SN 0300077500)ITEM # PART NUMBER QTY.

1-4 800A 800AJ 3121176SECTION 1 FRAME119 4640871 1 Valve, Lockout (SN 0300069000 to SN 0300083332 Only)7012693 1 Seal Kit - 4640871 Valve7002840 1 Pin

2-74 800A 800AJ 3121176SECTION 2 TURNTABLE112 2060025 1 Fan, Suction113 1580011 1 Container, Coolant Overflow Container114 3570133 1 Plate, Engine Mou

3121176 800A 800AJ 2-75SECTION 2 TURNTABLE158 0080201 1 Fitting, Elbow Reducing159 1320016 AR Clamp, Worm Gear160 3311801 1 Hex Nut 1/2in-13 UNC161 27

2-76 800A 800AJ 3121176SECTION 2 TURNTABLE210 0962450 2 Bushing, Spacer211 0181942 1 Angle, Alternator Mount212 4240099 2 Strap, Tie (Not Shown)213 35

3121176 800A 800AJ 2-77SECTION 2 TURNTABLE316 70002307 1 Gasket, Exhaust (Manifold to Pipe) (was p/n 7040050)7022143 1 Gasket, Exhaust (Manifold to Cy

2-78 800A 800AJ 3121176SECTION 2 TURNTABLE409 3574219 1 Housing, Fuel Pump Potting410 3574220 1 Plate, Pump Slide411 3574221 1 Plate, Pump Bottom412 3

3121176 800A 800AJ 2-79SECTION 2 TURNTABLEFIGURE 2-13. FORD ENGINE INSTALLATION - UL MACHINES (SN 0300069000 TO SN 0300077500) (CONTINUED)ITEM # PART

2-80 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-14. FORD ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000)21026421226424527324922826424322822623

3121176 800A 800AJ 2-81SECTION 2 TURNTABLE

2-82 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-14. FORD ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION R

3121176 800A 800AJ 2-83SECTION 2 TURNTABLE38 4751400 2 Flatwasher 1/4in Wide39 4751600 6 Flatwasher 3/8in Wide40 4751800 1 Flatwasher 1/2in Wide41 475

3121176 800A 800AJ 1-5SECTION 1 FRAME205 4 Bearing Options:2WS0962224 SN 0300069000 to SN 03000697750962448 SN 0300069775 to SN 03001400004WS0962224 S

2-84 800A 800AJ 3121176SECTION 2 TURNTABLE212 0641612 8 Bolt 3/8in-16NC x 1-1/2in213 0641828 4 Bolt 1/2in-13NC x 3-1/2in214 0641507 4 Bolt 5/16in-18NC

3121176 800A 800AJ 2-85SECTION 2 TURNTABLE257 3460398 1 Pipe, Exhaust258 4640989 1 Valve, Oil Drain259 4711400 12 Flatwasher 1/4in (Narrow)260 4711600

2-86 800A 800AJ 3121176SECTION 2 TURNTABLE320 7023698 1 Regulator, LP321 7019994 1 Sensor, EGR (was p/n 7027406)322 70002307 1 Gasket, Exhaust (Manifo

3121176 800A 800AJ 2-87SECTION 2 TURNTABLEFIGURE 2-14. FORD ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION

2-88 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-15. DUAL FUEL INSTALLATION (GAS MACHINES OPTIONS) 312321311301316315317319318310313302302302

3121176 800A 800AJ 2-89SECTION 2 TURNTABLEFIGURE 2-15. DUAL FUEL INSTALLATION (GAS MACHINES OPTIONS)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DUAL

2-90 800A 800AJ 3121176SECTION 2 TURNTABLE199 to 200 Not Used201 4641261 1 Valve, Solenoid - UL Machines202 4460897 1 Connector, Male- 2 Position - UL

3121176 800A 800AJ 2-91SECTION 2 TURNTABLEFIGURE 2-15. DUAL FUEL INSTALLATION (GAS MACHINES OPTIONS) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION R

2-92 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-16. GM ENGINE INSTALLATION (SN 0300069000 TO SN 0300140000) 21225422321724622922223420924823

3121176 800A 800AJ 2-93SECTION 2 TURNTABLE

1-6 800A 800AJ 3121176SECTION 1 FRAMERef HUB INSTALLATION (2WD ONLY)0270209 Ref SN 0300069000 to SN 0300083332 B0273378 Ref SN 0300083332 to SN 030014

2-94 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-16. GM ENGINE INSTALLATION (SN 0300069000 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION REV

3121176 800A 800AJ 2-95SECTION 2 TURNTABLE36 3311605 AR Locknut 3/8in-16NC37 Not Used38 3380429 1 Panel, Rubber (SN 0300069000 to SN 0300098458)39 342

2-96 800A 800AJ 3121176SECTION 2 TURNTABLERef GM ENGINE AND PUMP SUB-ASSEMBLIES:Ref Without Arctic Package2000378 Ref Engine, GM 3.0L (SN 0300069000 t

3121176 800A 800AJ 2-97SECTION 2 TURNTABLERef GM ENGINE ASSEMBLIES:Ref Without Arctic Package2000375 Ref Engine, GM 3.0L (SN 0300069000 to SN 03001094

2-98 800A 800AJ 3121176SECTION 2 TURNTABLE2301Muffler, Insulation Options:2820180 Engine, GM 3.0L (SN 0300069000 to SN 0300109494)1001091794 Engine, G

3121176 800A 800AJ 2-99SECTION 2 TURNTABLEFIGURE 2-16. GM ENGINE INSTALLATION (SN 0300069000 TO SN 0300140000) (CONTINUED)ITEM # PART NUMBER QTY. DES

2-100 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-17. PISTON PUMP ASSEMBLY 150215101509150815111503155604120412031201A12011220122030411041651

3121176 800A 800AJ 2-101SECTION 2 TURNTABLEFIGURE 2-17. PISTON PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600295 Ref PISTON PUMP ASSEMBLY

2-102 800A 800AJ 3121176SECTION 2 TURNTABLE159 7007454 1 Cover, Front160 to 162 Not Used163 7021207 6 Screw164 Not Used165 7021208 2 Spring166 7021209

3121176 800A 800AJ 2-103SECTION 2 TURNTABLE1004 to 1102Not Used1103 7010122 1 SCR Kit (Includes Items 166, 106 & 165)1104 7010122 1 SCR Kit (Inclu

3121176 800A 800AJ 1-7SECTION 1 FRAMERef CSA Spec -Frame WeldmentRef SN 0300069000 to SN 03000833322360609 2WD/2WS with Pneumatic Tires2360610 2WD/2WS

2-104 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-18. TANK INSTALLATIONS 21041031021061011054412122111131113121212101315101 12111313112224242

3121176 800A 800AJ 2-105SECTION 2 TURNTABLEFIGURE 2-18. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TANKS INSTALLATION OPTIONS:0258

2-106 800A 800AJ 3121176SECTION 2 TURNTABLE20 4568119 1 Tube, Fuel 21 1320223 1 Clamp 22 3572423 1 Plate, Valve, Needle 23 0641508 AR Bolt 5/16in-18NC

3121176 800A 800AJ 2-107SECTION 2 TURNTABLEFIGURE 2-18. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-108 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-19. ROTARY COUPLING INSTALLATION (SN 0300069000 TO SN 0300083332) 464655773232118

3121176 800A 800AJ 2-109SECTION 2 TURNTABLEFIGURE 2-19. ROTARY COUPLING INSTALLATION (SN 0300069000 TO SN 0300083332)ITEM # PART NUMBER QTY. DESCRIPT

2-110 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-20. ROTARY COUPLING INSTALLATION (SN 0300083332 TO SN 0300137975) 112117118116119121120126A

3121176 800A 800AJ 2-111SECTION 2 TURNTABLEFIGURE 2-20. ROTARY COUPLING INSTALLATION (SN 0300083332 TO SN 0300137975)ITEM # PART NUMBER QTY. DESCRIPT

2-112 800A 800AJ 3121176SECTION 2 TURNTABLE103 See Note 2 O-Ring/Seal (Note: Use Item 126A, 126B, 126C or 126D)104 See Note 1 Housing (Note: Not Avail

3121176 800A 800AJ 2-113SECTION 2 TURNTABLE126 1 Seal Kit Options:1 SN 0300083332 to SN 0300114017126A 7026510 2WS (Includes Items 103,105,106,113,114

1-8 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL INSTALLATIONS 104101101103113114106108SN 0300069000TO SN 0300083332SN 030008333

2-114 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000) 1081071231031151051051061

3121176 800A 800AJ 2-115SECTION 2 TURNTABLEFIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPT

2-116 800A 800AJ 3121176SECTION 2 TURNTABLE116 7024404 1 Block Valve Assembly117 7026505 1 Plug118 7026506 1 Valve, Check119 7026507 1 Plug120 Use p/n

3121176 800A 800AJ 2-117SECTION 2 TURNTABLEFIGURE 2-21. ROTARY COUPLING INSTALLATION (SN 0300137975 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIP

2-118 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)

3121176 800A 800AJ 2-119SECTION 2 TURNTABLEFIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GROUND C

2-120 800A 800AJ 3121176SECTION 2 TURNTABLE9 1 Decal - Faceplate Options:1703467 800A - SN 0300069000 to SN 03000998841706912 800A - SN 0300099884 to

3121176 800A 800AJ 2-121SECTION 2 TURNTABLE30 4460471 1 Lockwasher, Terminal31 4460488 AR Mounting Base, Terminal32 4460526 1 Connector, Strain Relief

2-122 800A 800AJ 3121176SECTION 2 TURNTABLE43 (cont’d) Deutz Engine Machines4933232 SN 0300069000 to SN 03000853314933321 SN 0300085331 to SN 03000998

3121176 800A 800AJ 2-123SECTION 2 TURNTABLEFIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121176 800A 800AJ 1-9SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref WHEEL DRIVE INSTALLATIONS (S

2-124 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) 143332414031313131202524291021192331371189552827

3121176 800A 800AJ 2-125SECTION 2 TURNTABLEFIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GROUND CONT

2-126 800A 800AJ 3121176SECTION 2 TURNTABLE32 4751400 12 Flatwasher 1/4in33 4761400 6 Lockwasher 1/4in34 4922557 1 Harness, Valve (Not Shown - See ELE

3121176 800A 800AJ 2-127SECTION 2 TURNTABLEFIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-128 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-24. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) 333134323035324512526282729252616A1

3121176 800A 800AJ 2-129SECTION 2 TURNTABLEFIGURE 2-24. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

2-130 800A 800AJ 3121176SECTION 2 TURNTABLE31 3911040 4 Screw, Machine #10-24NC x 2-1/2in32 3311005 4 Nut #10-24NC33 4751000 4 Flatwasher #1034 474036

3121176 800A 800AJ 2-131SECTION 2 TURNTABLEFIGURE 2-24. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-132 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-25. HOODS INSTALLATION (SN 0300069000 TO SN 0300089982) 51323420420326353432444547462052062

3121176 800A 800AJ 2-133SECTION 2 TURNTABLEFIGURE 2-25. HOODS INSTALLATION (SN 0300069000 TO SN 0300089982)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

1-10 800A 800AJ 3121176SECTION 1 FRAME108 2 Drive Motor Assembly Options:Use 3160347 2 2WD Rear (SN 0300083332 to SN 0300098925 was p/n 3160308 - See

2-134 800A 800AJ 3121176SECTION 2 TURNTABLE23 4160143 1 Spring, Gas (Engine Side)24 3960389 3.5ft/1m Seal25 3960470 1 Seal, Latch26 3520033 2 Plug, Ho

3121176 800A 800AJ 2-135SECTION 2 TURNTABLE2680448 Ref HOOD ASSEMBLY (TANK SIDE) B201 2680437 1 Hood202 2600233 1 Hinge203 3311605 5 Locknut 3/8in-16N

2-136 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) 12412321121332342122073534324445474

3121176 800A 800AJ 2-137SECTION 2 TURNTABLEFIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

2-138 800A 800AJ 3121176SECTION 2 TURNTABLE28 4740171 AR Washer, Hardened29 3311805 AR Locknut 1/2in-13NC30 3900232 AR Screw, Button Head 3/8in-16NC x

3121176 800A 800AJ 2-139SECTION 2 TURNTABLE101 (cont’d) 1001101673 Deutz Engine SN 0300129456 to SN 0300140000See Note GM Engine SN 0300089982 to SN 0

2-140 800A 800AJ 3121176SECTION 2 TURNTABLE123 See Note 1 Insulation, Heat (GM Engine Only) (was p/ns 2820176 & 1001101323) (Note: Use Item 101)(N

3121176 800A 800AJ 2-141SECTION 2 TURNTABLEFIGURE 2-26. HOODS INSTALLATION (SN 0300089982 TO SN 0300140000) (CONTINUED)ITEM # PART NUMBER QTY. DESCRI

2-142 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-27. ENGINE TRAY JACK INSTALLATION (OPTIONAL) 3C161817154411110226778777133D3A3B12759ORHAMME

3121176 800A 800AJ 2-143SECTION 2 TURNTABLEFIGURE 2-27. ENGINE TRAY JACK INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.0258728 Ref E

3121176 800A 800AJ 1-11SECTION 1 FRAME202 1 Tire Options:4520204 IN385/65D19.5 (15 x 19.5)4520242 IN385/65D19.5 Non-Marking (15 x 19.5)4520252 15-6254

2-144 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)

3121176 800A 800AJ 2-145SECTION 2 TURNTABLEFIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIP

2-146 800A 800AJ 3121176SECTION 2 TURNTABLE2B 1 Box, Control Options:110V/60Hz Replacement Box 7003657 SN 0300069000 to SN 03000825047019680 SN 030008

3121176 800A 800AJ 2-147SECTION 2 TURNTABLE16 3740080 1 Relay17 4460023 1 Connector, Strain Relief (SN 0300069000 to SN 0300082504)18 0641508 1 Bolt 5

2-148 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) 101013311010971012412D2A5USEEX

3121176 800A 800AJ 2-149SECTION 2 TURNTABLEFIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION R

2-150 800A 800AJ 3121176SECTION 2 TURNTABLE2C 1 Voltmeter Options:2420203 110V7020192 220V2D 1 Pulley Options:3580276 110V3580134 220V7027887

3121176 800A 800AJ 2-151SECTION 2 TURNTABLE40 Not Used41 1001100234 1 Light Red 42 0962449 1 BushingFIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ

2-152 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL)(SN 0300069000 TO SN 0300077500)

3121176 800A 800AJ 2-153SECTION 2 TURNTABLEFIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300069000 TO SN 0300077500)ITEM

1-12 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) 191A1B1C1D1N1G1F1E1H21177212589106A6161

2-154 800A 800AJ 3121176SECTION 2 TURNTABLE5 1 V-Belt Options:0480111 110V (SN 0300069000 to SN 0300073381)0480134 110V (SN 0300073381 to SN 030007750

3121176 800A 800AJ 2-155SECTION 2 TURNTABLEFIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300069000 TO SN 0300077500) (CON

2-156 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300077500 TO SN 0300140000)

3121176 800A 800AJ 2-157SECTION 2 TURNTABLEFIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300077500 TO SN 0300140000)ITEM

2-158 800A 800AJ 3121176SECTION 2 TURNTABLE16C 1 Voltmeter Options:2420203 110V7020192 220V16D 1 Pulley Options:3580324 110V3580325 220V702788

3121176 800A 800AJ 2-159SECTION 2 TURNTABLEFIGURE 2-31. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300077500 TO SN 0300140000) (CON

2-160 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)

3121176 800A 800AJ 2-161SECTION 2 TURNTABLEFIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-162 800A 800AJ 3121176SECTION 2 TURNTABLE21 4460906 3 Terminal (Not Shown)22 4568735 1 Spacer, Tube (Idler Pulley Grooved)23 4711400 1 Flatwasher 1/

3121176 800A 800AJ 2-163SECTION 2 TURNTABLEFIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. DESCRIPTION REV

3121176 800A 800AJ 1-13SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332)ITEM # PART NUMBER QTY. DESCRIPTION REV.278022

2-164 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (ANSI & CSA SPECS)

3121176 800A 800AJ 2-165SECTION 2 TURNTABLEFIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (ANSI & CSA SPECS)

2-166 800A 800AJ 3121176SECTION 2 TURNTABLE19 1 Generator Assembly Options:2460050 Caterpillar Engine2460048 Deutz Engine70001100 1 Rotor (Includes p/

3121176 800A 800AJ 2-167SECTION 2 TURNTABLE31 1 Bolt 1/4in-20NC Options:0641406 Bolt 3/8in Length - Caterpillar Engine 0641406 Bolt 3/8in Length - Deu

2-168 800A 800AJ 3121176SECTION 2 TURNTABLE0861542 Ref JUNCTION BOX ASSEMBLY C101 0861541 1 Box, Junction102 10604942ft/.6mCable, Electrical 12/3103 1

3121176 800A 800AJ 2-169SECTION 2 TURNTABLERef TERMINAL BLOCK ASSEMBLYNPN Ref Gray Terminal Block Assembly (Complete Assembly Not Available - Purchase

2-170 800A 800AJ 3121176SECTION 2 TURNTABLE511 4760600 2 Lockwasher #6512 1001094375 1 Bracket, Hourmeter513 1001094509 1 Harness, HourmeterFIGURE 2-3

3121176 800A 800AJ 2-171SECTION 2 TURNTABLEFIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ MACHINES (ANSI & CSA SPECS)

2-172 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD MACHINES (ANSI & CSA SPECS) 3041921819

3121176 800A 800AJ 2-173SECTION 2 TURNTABLEFIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD MACHINES (ANSI & CSA SPECS)ITEM # PART NUMBE

1-14 800A 800AJ 3121176SECTION 1 FRAME12 1 Spacer, Input Options:7017041 2WD7017045 4WD13 1 Gear, Sun Options:7017038 2WD7017043 4WD14 AR Spacer, Inpu

2-174 800A 800AJ 3121176SECTION 2 TURNTABLE25 (cont’d) 7026188 1 Clamp, Cable (Not Shown)7026597 1 Connector, W/Leads (Not Shown)70002088 1 Stator (No

3121176 800A 800AJ 2-175SECTION 2 TURNTABLE0861542 Ref JUNCTION BOX ASSEMBLY C101 0861541 1 Box, Junction102 1060494 2ft/.6m Cable, Electrical 12/3103

2-176 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES (ANSI & CSA SPECS) 231746441633

3121176 800A 800AJ 2-177SECTION 2 TURNTABLEFIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES (ANSI & CSA SPECS)ITEM # PART NUMBER

2-178 800A 800AJ 3121176SECTION 2 TURNTABLE18F 70001973 1 Decal - Warning Moving Parts19 2820031 1 Insulator20 3252764 1 Nameplate21 3311405 6 Locknut

3121176 800A 800AJ 2-179SECTION 2 TURNTABLE110 4360070 1 Circuit Breaker - 15 Amp111 to 115 Not Used116 4460425 2 Strain Relief, Terminal117 4460426 2

2-180 800A 800AJ 3121176SECTION 2 TURNTABLE403 2 Marker Strip #3 Options:4460413 Gray Terminal Block Assembly 70002820 Tan Terminal Block Assembly404

3121176 800A 800AJ 3-1SECTION 3BOOM

3-2 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800A 203111272537311125314033325269232450253326273722821253727

3121176 800A 800AJ 3-3SECTION 3 BOOMFIGURE 3-1. BOOM AND CYLINDER INSTALLATION - 800AITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOMS AND CYLINDERS

3121176 800A 800AJ 1-15SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB ASSEMBLIES (SN 0300069000 TO SN 0300083332) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTIO

3-4 800A 800AJ 3121176SECTION 3 BOOM37 0642214 5 Bolt 3/4in-10NC x 1-3/4in38 0642620 1 Bolt 1in-8NC x 2-1/2in39 3841340 1 Rod, Hose Loop40 1120510 1 C

3121176 800A 800AJ 3-5SECTION 3 BOOMRef PLATFORM SUPPORT INSTALLATION (SIDE ENTRY PLATFORM)0272070 Ref Machines without Load Sensing and without SkyGl

3-6 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJ LIFT CYLINDER(TOWER BOOM)4417354373111392939375444171544

3121176 800A 800AJ 3-7SECTION 3 BOOMFIGURE 3-2. BOOM AND CYLINDER INSTALLATION - 800AJITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOMS AND CYLINDERS

3-8 800A 800AJ 3121176SECTION 3 BOOM34 3422729 1 Pin35 3340835 1 Pad, Rest36 0561237 2 Clamp, Block37 0100011 AR Compound, Locking38 3841143 7 Keeper,

3121176 800A 800AJ 3-9SECTION 3 BOOM111 1 Support Weldment Options:4844790 Standard MachinesSee Note Machines with SkyGlazier (Note: Refer to JLG Supp

3-10 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-3. TOWER BOOM ASSEMBLY

3121176 800A 800AJ 3-11SECTION 3 BOOMFIGURE 3-3. TOWER BOOM ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.0801132 Ref TOWER BOOM ASSEMBLY E1 1 Bas

3-12 800A 800AJ 3121176SECTION 3 BOOM107 0641605 4 Bolt 3/8in-16NC x 5/8in108 0641606 2 Bolt 3/8in-16NC x 3/4in109 0641622 2 Bolt 3/8in-16NC x 2-3/4in

3121176 800A 800AJ 3-13SECTION 3 BOOMFIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-16 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000) 10531111110112121102119122123104103103101

3-14 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIES 800AJ800A1413122017181713129101121171617237810111110911010311091101101181

3121176 800A 800AJ 3-15SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN BOOM ASSEMBLY OPTIONS:0801135 R

3-16 800A 800AJ 3121176SECTION 3 BOOMRef POWER TRACK INSTALLATION OPTIONS:0258076 Ref 800A J0258077 Ref 800AJ H101 1 Carrier Options:101A Gemco Brand

3121176 800A 800AJ 3-17SECTION 3 BOOM121 2 Screw, Button Head Options:3900232 Screw, Button Head 3/8in-16NC x 1-1/4in (SN 0300069000 to SN 0300080132)

3-18 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) 72131527A27A25262727A27A271616117A192051717B3121114134

3121176 800A 800AJ 3-19SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref ROTATOR ASSEMBLIE

3-20 800A 800AJ 3121176SECTION 3 BOOM17 1 Valve Assembly Options:Use 7017183 0060041 & 0060031 Rotators (was p/n 7017101)7017183 0060077 & 006

3121176 800A 800AJ 3-21SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-22 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-6. ROTATOR ASSEMBLY (SIDE ENTRY PLATFORM) 876800A52141411123910785134115252616800AJSEE BOOMINSTAL

3121176 800A 800AJ 3-23SECTION 3 BOOMFIGURE 3-6. ROTATOR ASSEMBLY (SIDE ENTRY PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref ROTATOR ASSEMBLIES

3121176 800A 800AJ 1-17SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300083332 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION REV.2780272

3-24 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED)

3121176 800A 800AJ 3-25SECTION 3 BOOMFIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED)ITEM # PART NUMBER QTY. DESCRIPTION REV.0258217 R

3-26 800A 800AJ 3121176SECTION 3 BOOM0258338 Ref LIMIT SWITCHES INSTALLATION - 800A DUAL CAPACITY H201 0100011 AR Compound, Locking202 0100035 AR Comp

3121176 800A 800AJ 3-27SECTION 3 BOOM404 3930606 3 Screw #6-32 NC405 3311405 2 Locknut 1/4in-20NC406 4751400 2 Flatwasher 1/4in407 1001094400 1 Sensor

3-28 800A 800AJ 3121176SECTION 3 BOOMFIGURE 3-7. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION R

3121176 800A 800AJ 4-1SECTION 4PLATFORM

4-2 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) 10510510510110210410410311121018131

3121176 800A 800AJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

4-4 800A 800AJ 3121176SECTION 4 PLATFORM11 3911008 4 Screw #10-24NC x 1in12 4751000 4 Flatwasher #1013 3311005 4 Locknut #10-24NC14 0641524 4 Bolt 5/1

3121176 800A 800AJ 4-5SECTION 4 PLATFORMFIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-18 800A 800AJ 3121176SECTION 1 FRAME15 7000287 4 Thrustwasher16 7000288 2 Thrustwasher17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)18 Not Used19

4-6 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM)

3121176 800A 800AJ 4-7SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref

4-8 800A 800AJ 3121176SECTION 4 PLATFORM104 1 Platform Console Box Assembly Options:0861517 SN 0300069000 to SN 0300137975 (See PLATFORM CONSOLE ASSEM

3121176 800A 800AJ 4-9SECTION 4 PLATFORM206 4240099 10 Tie-Strap (Not Shown)207 2820035 9 Loom, Vinyl (Not Shown)208 Not Used209 1 Connector, Strain R

4-10 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM)

3121176 800A 800AJ 4-11SECTION 4 PLATFORMFIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION R

4-12 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975)

3121176 800A 800AJ 4-13SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975)ITEM # PART NUMBER QTY. DESCRIPTION RE

4-14 800A 800AJ 3121176SECTION 4 PLATFORM32 4360407 1 Controller, SpeedSee Note 1 Gasket “Top Hat” (Included W/Switch) (Note: Not Available - Purchase

3121176 800A 800AJ 4-15SECTION 4 PLATFORMRef DUAL FUEL SWITCH INSTALLATIONS201 4360336 1 Switch, Toggle3790012 1 O-RingRef HEAD & TAIL LIGHTS INST

3121176 800A 800AJ 1-19SECTION 1 FRAME127 7024193 1 Friction Disc Kit - Brake (Includes Items 103, 104, 106 & 107)128 7024197 1 Bearing Kit - Brak

4-16 800A 800AJ 3121176SECTION 4 PLATFORM505 1 Connector, Strain Relief Options:4460598 ANSI Spec Machines (SN 0300069000 to SN 0300074427)4460426 ANS

3121176 800A 800AJ 4-17SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (SN 0300069000 TO SN 0300137975) ITEM # PART NUMBER QTY. DESCRIPTION R

4-18 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-5. PLATFORM CONSOLE ASSEMBLY (SN 0300137975 TO SN 0300140000)

3121176 800A 800AJ 4-19SECTION 4 PLATFORMFIGURE 4-5. PLATFORM CONSOLE ASSEMBLY (SN 0300137975 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION RE

4-20 800A 800AJ 3121176SECTION 4 PLATFORM35 4460234 3 Mount, Tie-Strap (Not Shown)36 4460428 2 Connector, Strain Relief37 4460470 1 Nut, Terminal38 44

3121176 800A 800AJ 4-21SECTION 4 PLATFORMRef SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) 0273824 Ref 6Ft/1.8m Platforms B0272427 Ref 8Ft/2.4m Platforms

4-22 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (SWING & LIFT) 222119185936145876391110121A1C1B1021031101041051061

3121176 800A 800AJ 4-23SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (SWING & LIFT)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original

4-24 800A 800AJ 3121176SECTION 4 PLATFORM108 70002734 4 Screw109 70002735 1 Can, Enclosure110 70002906 1 Cap111 Use 1001129555 1 Mechanical Assembly (

3121176 800A 800AJ 4-25SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (SWING & LIFT) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-20 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY (SN 0300069000 TO SN 0300083332) 232221203031191817161514131211109876543

4-26 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER) 20820820720920220220320320420421020520610612011817

3121176 800A 800AJ 4-27SECTION 4 PLATFORMFIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Origina

4-28 800A 800AJ 3121176SECTION 4 PLATFORM109 Use 1001113961 1 Plug, Male - 8 Position (Black) (was p/n 7022825)4460871 7 Socket, FemaleRef HANDLE ASSE

3121176 800A 800AJ 4-29SECTION 4 PLATFORMFIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-30 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)

3121176 800A 800AJ 4-31SECTION 4 PLATFORMFIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SOFT TOUCH

4-32 800A 800AJ 3121176SECTION 4 PLATFORMFIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121176 800A 800AJ 5-1SECTION 5CYLINDER

5-2 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY 302019173171859112511110161514423131222A721228

3121176 800A 800AJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1683078 Ref AXLE LOCKOUT CY

3121176 800A 800AJ 1-21SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY (SN 0300069000 TO SN 0300083332)ITEM # PART NUMBER QTY. DESCRIPTION REV.316020

5-4 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-2. UPRIGHT LEVEL CYLINDER ASSEMBLY 72661415151417161712121 320 2122 18242519112101030812129 51

3121176 800A 800AJ 5-5SECTION 5 CYLINDERFIGURE 5-2. UPRIGHT LEVEL CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original Equipme

5-6 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - JIB (800AJ ONLY) 688681 432181912 13916175A1A511261414151510212022

3121176 800A 800AJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - JIB (800AJ ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.1683609 Ref JIB

5-8 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM 511919262112252913630181611111017164223132419 19 2 40823

3121176 800A 800AJ 5-9SECTION 5 CYLINDERFIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN BOOMITEM # PART NUMBER QTY. DESCRIPTION REV.1683547 Ref MAIN BOOM L

5-10 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-5. LIFT CYLINDER ASSEMBLY - TOWER BOOM 711010866910104212617161715145141518192012132222323242

3121176 800A 800AJ 5-11SECTION 5 CYLINDERFIGURE 5-5. LIFT CYLINDER ASSEMBLY - TOWER BOOMITEM # PART NUMBER QTY. DESCRIPTION REV.1683537 Ref TOWER LIF

5-12 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-6. MASTER CYLINDER ASSEMBLY - 800A 1219137121722023211418 615161511221011122439544 830

3121176 800A 800AJ 5-13SECTION 5 CYLINDERFIGURE 5-6. MASTER CYLINDER ASSEMBLY - 800AITEM # PART NUMBER QTY. DESCRIPTION REV.1683608 Ref MASTER CYLIND

3121176 800A 800AJ AREVISION LOGSeptember 30, 2002 - Original Issue Of Manual (Manual edited to 0010580 Revision 21)February 7, 2003 - Revised (Manual

1-22 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN 0300140000) (4 BOLT ASSEMBLY)

5-14 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-7. MASTER CYLINDER ASSEMBLY - 800AJ 55308341221102112141614221713117192202315121896

3121176 800A 800AJ 5-15SECTION 5 CYLINDERFIGURE 5-7. MASTER CYLINDER ASSEMBLY - 800AJITEM # PART NUMBER QTY. DESCRIPTION REV.1683682 Ref MASTER CYLIN

5-16 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-8. SLAVE CYLINDER ASSEMBLIES 910 92425551814 62212622114122012201616231317 55812193015733

3121176 800A 800AJ 5-17SECTION 5 CYLINDERFIGURE 5-8. SLAVE CYLINDER ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original Equipment Cy

5-18 800A 800AJ 3121176SECTION 5 CYLINDER19 3931620 8 Capscrew 3/8in-16NC x 1-1/4in20 See Note 2 Seal (Note: Use Item 30)21 See Note 1 Wiper (Note: Us

3121176 800A 800AJ 5-19SECTION 5 CYLINDERFIGURE 5-8. SLAVE CYLINDER ASSEMBLIES (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

5-20 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-9. STEER CYLINDER ASSEMBLY 141724891013121414206113514

3121176 800A 800AJ 5-21SECTION 5 CYLINDERFIGURE 5-9. STEER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1683740 Ref STEER CYLINDER ASSEMB

5-22 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-10. TELESCOPE CYLINDER ASSEMBLY - MAIN 719101096302626A18111122222242733121581417221352116161

3121176 800A 800AJ 5-23SECTION 5 CYLINDERFIGURE 5-10. TELESCOPE CYLINDER ASSEMBLY - MAINITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TELESCOPE CYLINDE

3121176 800A 800AJ 1-23SECTION 1 FRAMEFIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN 0300140000) (4 BOLT ASSEMBLY)ITEM #

5-24 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY - TOWER 15541716316171415672828282829312929131211109333219192

3121176 800A 800AJ 5-25SECTION 5 CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY - TOWERITEM # PART NUMBER QTY. DESCRIPTION REV.1683606 Ref TELESCOP

5-26 800A 800AJ 3121176SECTION 5 CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY - TOWER (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121176 800A 800AJ 6-1SECTION 6HYDRAULIC

6-2 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM 910191011061031110751023109410510431095102711010861581416FL

3121176 800A 800AJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.2792367 Ref AXLE LOCKOUT H

6-4 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332) 736444548429449737374747471

3121176 800A 800AJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332)ITEM # PART NUMBER QTY. DESCRIPTIO

6-6 800A 800AJ 3121176SECTION 6 HYDRAULIC48 2751017 1 Hose49 2752498 1 Hose50 2751500 1 Hose51 2752365 1 Hose52 2752366 1 Hose53 2751399 1 Hose54 2753

3121176 800A 800AJ 6-7SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300069000 TO SN 0300083332) ITEM # PART NUMBER QTY. DESCRIPTI

1-24 800A 800AJ 3121176SECTION 1 FRAME22 1 Cap, End - Axial Options:See Note 2WD (Note: Not Available - Purchase Complete Assy.)7022367 4WD23 7022368

6-8 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000) 404545443952485851595750616

3121176 800A 800AJ 6-9SECTION 6 HYDRAULIC4045454439524858515957506160494952395851444045596045424614475354454363433845566217464143434141311111920217222

6-10 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTI

3121176 800A 800AJ 6-11SECTION 6 HYDRAULIC21 1 Hose Options:2752366 SN 0300083332 to SN 03001373261001110033 SN 0300137326 to SN 030014000022 2751399

6-12 800A 800AJ 3121176SECTION 6 HYDRAULIC64 2130606 5 Fitting, Elbow65 2150606 2 Fitting, Elbow66 2170506 2 Fitting, Tee67 2753625 2 Hose68 2753626 2

3121176 800A 800AJ 6-13SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPT

6-14 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332) 123C CCLEFT REARDRIVE

3121176 800A 800AJ 6-15SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332)ITEM # PART NUMBER QTY. DESCR

6-16 800A 800AJ 3121176SECTION 6 HYDRAULIC48 2752363 2 Hose49 2752498 1 Hose50 2752592 2 Hose51 2753035 2 Hose52 2752516 1 Hose53 2752514 1 Hose54 275

3121176 800A 800AJ 6-17SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300069000 TO SN 0300083332) ITEM # PART NUMBER QTY. DESC

3121176 800A 800AJ 1-25SECTION 1 FRAMEFIGURE 1-6. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) (SN 0300083332 TO SN 0300140000) (4 BOLT ASSEMBLY) (CONTI

6-18 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000) 6470681874697373716672

3121176 800A 800AJ 6-19SECTION 6 HYDRAULIC647068187469737371667271656773667265671439683275394261616123355857609363774334011344130477819205431177745513

6-20 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCR

3121176 800A 800AJ 6-21SECTION 6 HYDRAULIC24 2131616 1 Fitting, Elbow25 2130604 1 Fitting, Elbow26 2130406 2 Fitting, Elbow27 2150406 2 Fitting, Elbow

6-22 800A 800AJ 3121176SECTION 6 HYDRAULIC56 1 Hose Options:2753633 Without Arctic Package (SN 0300083332 to SN 0300121643)2754040 Without Arctic Pack

3121176 800A 800AJ 6-23SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY. DESC

6-24 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP)

3121176 800A 800AJ 6-25SECTION 6 HYDRAULICFIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP)ITEM # PART NUMBER QT

6-26 800A 800AJ 3121176SECTION 6 HYDRAULIC45 2752721 1 Hose46 2752438 1 Hose47 2753192 1 Hose48 2752494 1 Hose49 2753008 1 Hose50 1 Hose Options:27526

3121176 800A 800AJ 6-27SECTION 6 HYDRAULIC81 2 Hose Options:Not Required 800A2753128 800AJ82 4100062 4 Protection, Nylon Hose (24in/61cm per piece)83

1-26 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO SN 0300140000) (5 BOLT ASSEMBLY)

6-28 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) TOWERLIFTUP39121110162728VC

3121176 800A 800AJ 6-29SECTION 6 HYDRAULICFIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP)ITEM # PART NUMBER QTY. DESCRIPTIO

6-30 800A 800AJ 3121176SECTION 6 HYDRAULIC45 2752721 1 Hose46 2752438 1 Hose47 2753192 1 Hose48 2752494 1 Hose49 2753008 1 Hose50 2752671 1 Hose51 464

3121176 800A 800AJ 6-31SECTION 6 HYDRAULIC84 2220947 1 Fitting, Straight85 2221036 1 Fitting, Elbow86 2220950 1 Fitting, Elbow87 to 88 Not Used89 2220

6-32 800A 800AJ 3121176SECTION 6 HYDRAULICFIGURE 6-8. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Diagrams with ast

3121176 800A 800AJ 6-33SECTION 6 HYDRAULICRef Tilt Sensor Installation Options:1001093187 Ref SN 0300069000 to SN 0300112885 C1001094557 Adapter, Pres

6-34 800A 800AJ 3121176SECTION 6 HYDRAULICITEM # PART NUMBER QTY. DESCRIPTION REV.

3121176 800A 800AJ 7-1SECTION 7ELECTRICAL

7-2 800A 800AJ 3121176SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LISTITEM # PART NUMBER QTY. DESCRIPTION REV.1282571 Ref COLD WEATHER START E

3121176 800A 800AJ 7-3SECTION 7 ELECTRICAL0274207 Ref SLOPE SENSOR ELECTRICAL DIAGRAMRef STANDARD ELECTRICAL DIAGRAMS:Ref Caterpillar Engine without U

3121176 800A 800AJ 1-27SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO SN 0300140000) (5 BOLT ASSEMBLY)ITEM #

7-4 800A 800AJ 3121176SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGM201J201K201L201M201P201Q201R437437713438J5J6J7J2J1J82

3121176 800A 800AJ 7-5SECTION 7 ELECTRICAL 532JIBVALVE4WSVALVESTROBELIGHT438437519550520551437549706B706A706D521550551541544542545543548437

7-6 800A 800AJ 3121176SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION WITHOUT UGMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: FO

3121176 800A 800AJ 7-7SECTION 7 ELECTRICAL153 4922666 1 Harness, Analyzer Cable 2/B4460226 4 Socket, Female (Not Shown - Located at J2)153A 4460761 1

7-8 800A 800AJ 3121176SECTION 7 ELECTRICAL202 1 Harness Assembly - Tower Boom (12/4 - 18/8) Options:4922576 Without Arctic Package4923489 With Arctic

3121176 800A 800AJ 7-9SECTION 7 ELECTRICAL207 (cont’d) 800AJ:4922216 (10/3) (Without Arctic Package)4922775 (8/5) (Without Arctic Package & With 7

7-10 800A 800AJ 3121176SECTION 7 ELECTRICALRef GROUND CONTROL BOX WIRING DIAGRAMSRef Caterpillar Engine Machines4933296 Ref SN 0300069000 to SN 030008

3121176 800A 800AJ 7-11SECTION 7 ELECTRICAL417 3740049 AR Relay Options:3 Caterpillar Engine2 Deutz, Ford & GM Engines418 to 425 Not Used426 44604

7-12 800A 800AJ 3121176SECTION 7 ELECTRICAL439A 4460418 9 Connector, Female- 6 Position4460419 27 Socket, Female439B 4460876 1 Connector, 35- Position

3121176 800A 800AJ 7-13SECTION 7 ELECTRICAL441 1 Ground Control Box Wiring Diagram (Not Shown - See Items 301 to 316 for Breakdown)Caterpillar Engine

1-28 800A 800AJ 3121176SECTION 1 FRAME24 Use 7022328 1 O-Ring25 2220883 1 Plug (Includes Item 26)26 Use 7022328 1 O-Ring27 2220888 2 Plug (Includes It

7-14 800A 800AJ 3121176SECTION 7 ELECTRICAL525 4460539 1 Connector, Male - 3 Position (Deutz & GM Engine SN 0300085331 to SN 0300140000 Only)44609

3121176 800A 800AJ 7-15SECTION 7 ELECTRICAL543 4460726 2 Connector Wedge Lock, Side (Ford Engine Only)544 4460800 32 Connector, Plug (Ford Engine Only

7-16 800A 800AJ 3121176SECTION 7 ELECTRICALRef STANDARD HARNESS COMPONENTS701 1 Battery Cable Kit Options:2901609 Caterpillar & Deutz Engines SN 0

3121176 800A 800AJ 7-17SECTION 7 ELECTRICAL706B See Note 1 Receptacle, Female - 25 Position (SN 0300085331 to SN 0300140000 Only) (Note: Not Available

7-18 800A 800AJ 3121176SECTION 7 ELECTRICAL717G 4460908 1 Connector - 12 Position (Gray)4460915 1 Wedge Lock - 12 Position4460928 5 Socket, Female717H

3121176 800A 800AJ 7-19SECTION 7 ELECTRICAL802A 4460326 1 Plug, Male - 3 Position802B 4460267 3 Pin, Male802C 4460499 2 Connector, DIN with Diode803 0

7-20 800A 800AJ 3121176SECTION 7 ELECTRICAL806 AR Generator Electrical Components4933215 110V (SN 0300069000 to SN 0300082504) 2/C4933216 220V (SN 030

3121176 800A 800AJ 7-21SECTION 7 ELECTRICAL809D 1 Cover, Receptacle Options:Use 1001110872 60Hz Spec (was p/n 4061043)See Note 50Hz Spec (Note: Not Av

7-22 800A 800AJ 3121176SECTION 7 ELECTRICAL811E 4922641 1 Switch Harness811F 4460226 2 Socket, Female811G 4460742 1 Plug, Male - 2 Position (GM Engine

3121176 800A 800AJ 7-23SECTION 7 ELECTRICAL813J AR Connector, Male - 3 Position Options (Platform Worklights Only):4460476 1 SN 0300069000 to SN 03001

3121176 800A 800AJ 1-29SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (SERVICE REPLACEMENT) (SN 0300083332 TO SN 0300140000) (5 BOLT ASSEMBLY) (CONT

7-24 800A 800AJ 3121176SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGM714A714BSOFT TOUCHLIMIT SWITCH203A204A204BOOM LENGTHLIM

3121176 800A 800AJ 7-25SECTION 7 ELECTRICAL JIBVALVEGENERATORHOURMETER4WSVALVESTROBELIGHTDRIVEORIENTATIONSWITCH334335517517550518552605A605

7-26 800A 800AJ 3121176SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION WITH UGMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: FOR

3121176 800A 800AJ 7-27SECTION 7 ELECTRICAL121 4460875 1 Plug, Male 35 Position (Gray)4460871 24 Socket, Female122 4460873 1 Plug, Male 35 Position (B

7-28 800A 800AJ 3121176SECTION 7 ELECTRICAL201A 4460865 1 Connector - 19 Position4460465 11 Socket, Female4460509 4 Socket, Female4460466 4 Seal, Plug

3121176 800A 800AJ 7-29SECTION 7 ELECTRICAL207 1 Harness Assembly - Main Boom Options:800A:4922215 (10/3) (Without Arctic Package)4922773 (8/5) (Witho

7-30 800A 800AJ 3121176SECTION 7 ELECTRICAL334C 4460424 1 Connector, Male- 2 Position4460268 5 Pin, Female334D 4460871 11 Socket, Female334E 4460326 1

3121176 800A 800AJ 7-31SECTION 7 ELECTRICAL336S 4460874 1 Connector, Natural4460871 10 Socket, Female4460905 AR Plug, Seal336T 4460875 1 Connector, Gr

7-32 800A 800AJ 3121176SECTION 7 ELECTRICAL528 4460460 1 Plug, Male - 4 Position4460457 4 Terminal, Female4460458 4 Seal, Terminal529 to 532 Not Used5

3121176 800A 800AJ 7-33SECTION 7 ELECTRICALRef STANDARD HARNESS COMPONENTS601 1 Battery Cable Kit Options:1001112762 Caterpillar Engines A2902401 Deu

1-30 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-8. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300069000 TO SN 0300083332)

7-34 800A 800AJ 3121176SECTION 7 ELECTRICAL602F See Note 1 Connector 5 Position (Note: Not Available for Purchase.)See Note 5 Terminal (Note: Not Avai

3121176 800A 800AJ 7-35SECTION 7 ELECTRICAL702 4921927 1 Jib Valve Harness (800AJ Only) F702A 4460326 1 Plug, Male - 3 Position702B 4460267 3 Pin, Mal

7-36 800A 800AJ 3121176SECTION 7 ELECTRICAL706A 4922641 1 Harness - On/Off Switch A706B 4460226 2 Socket, Female706C 1 Harness, Powermite Control Box

3121176 800A 800AJ 7-37SECTION 7 ELECTRICAL709E 1 Receptacle Options:4460346 60Hz SpecSee Note 50Hz Spec (Note: Not Available - Purchase Locally.)709F

7-38 800A 800AJ 3121176SECTION 7 ELECTRICAL712B 4922643 1 Harness, Bagged (Located at Ground Control Box) (Not Shown)713 Ref Platform Worklights Compo

3121176 800A 800AJ 8-1SECTION 8DECALS

8-2 800A 800AJ 3121176SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (SN 0300069000 TO SN 0300089982) 8342729324143720638 242620140

3121176 800A 800AJ 8-3SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (SN 0300069000 TO SN 0300089982)ITEM # PART NUMBER QTY. DESCRIPTION

8-4 800A 800AJ 3121176SECTION 8 DECALS33 3820001 4 Rivet34 3252347 1 Decal - Footswitch (Part of 4360031 Footswitch)35 1703960 4 Decal - Max Tire Load

3121176 800A 800AJ 8-5SECTION 8 DECALS324 1001095809 1 Decal - Legend (MTB Control)FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (SN 0300069000 TO SN 03

3121176 800A 800AJ 1-31SECTION 1 FRAMEFIGURE 1-8. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300069000 TO SN 0300083332)ITEM # PART NUMBER QTY. DE

8-6 800A 800AJ 3121176SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300089982 TO SN 0300140000)

3121176 800A 800AJ 8-7SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI SPEC) (SN 0300089982 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION

8-8 800A 800AJ 3121176SECTION 8 DECALS35 1704885 2 Decal - Website 36 See Note 1 Nameplate, Manufactures (Note: Not Available for Purchase.)37 1001096

3121176 800A 800AJ 8-9SECTION 8 DECALS217 1001096141 1 Decal - Upright Level Over Ride218 to 223 Not Used224 1001095809 1 Decal - Legend (MTB Control)

8-10 800A 800AJ 3121176SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300069000 TO SN 0300089982) 83427292241437 38 24 2640

3121176 800A 800AJ 8-11SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300069000 TO SN 0300089982)ITEM # PART NUMBER QTY. DESCRIPT

8-12 800A 800AJ 3121176SECTION 8 DECALS5 (cont’d) Not Required Japanese DecalsNot Required Korean Decals6 1 Decal - Legend Options:Not Required Dual L

3121176 800A 800AJ 8-13SECTION 8 DECALS14 (cont’d) 1704111 800A Korean Decals1704112 800AJ Korean Decals15 1 Decal - USA Options:Not Required Dual Lan

8-14 800A 800AJ 3121176SECTION 8 DECALS31 3 Decal - Warning/Crushing Options:1703943 Dual Language English/Chinese Decals1703942 Dual Language English

3121176 800A 800AJ 8-15SECTION 8 DECALS0258671 Ref MANUAL STORAGE BOX INSTALLATION BRef Note: Located on Hydraulic Tank SN 0300069000 to SN 030006920

B 800A 800AJ 3121176REVISION LOGMay 31, 2012 - Revised ManualJuly 31, 2012 - Revised ManualDecember 14, 2012 - Revised ManualMarch 26, 2013 - Revised

1-32 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-9. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO SN 0300140000) ORVALVE ROTATED FOR

8-16 800A 800AJ 3121176SECTION 8 DECALSFIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300089982 TO SN 0300140000)

3121176 800A 800AJ 8-17SECTION 8 DECALSFIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300089982 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPT

8-18 800A 800AJ 3121176SECTION 8 DECALS18 3 Decal - Warning/Crushing Options:1703943 Dual Language English/Chinese Decals1703942 Dual Language English

3121176 800A 800AJ 8-19SECTION 8 DECALS25 1 Decal - Footswitch Options:1703982 Dual Language English/Chinese Decals1703984 Dual Language English/Frenc

8-20 800A 800AJ 3121176SECTION 8 DECALS34 1 Decal - 500LBS Max Capacity Options:SN 0300089982 to SN 0300100380:1704109 800A Dual Language English/Chin

3121176 800A 800AJ 8-21SECTION 8 DECALS51 2 Decal - LP Gas (Liquid) (GM Engine Machines Only) Options:1700818 ANSI Spec1702720 ANSI Export1704271 CSA

8-22 800A 800AJ 3121176SECTION 8 DECALSFIGURE 8-4. DECAL INSTALLATION (COUNTRY SPEC) (SN 0300089982 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIP

3121176 800A 800AJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 800A/800AJThe following list will service one machine (built to current production

9-2 800A 800AJ 3121176SECTION 9 RECOMMENDED SERVICE PARTS STOCK3740080 Relay (Machines with Generator Option) (Figures 2-28, 2-29, 2-31, 2-32, 2-33, 2

3121176 800A 800AJ 10-1SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applic

3121176 800A 800AJ 1-33SECTION 1 FRAMEFIGURE 1-9. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY. D

10-2 800A 800AJ 3121176SECTION 10 SPECIAL OPTIONSCold Weather Package Installation Options:0273575 Ref Caterpillar Engine0256060 Ref Deutz without Glo

3121176 800A 800AJ 10-3SECTION 10 SPECIAL OPTIONS2300040 Ref Diesel Fuel - Anti-Gel2902396 Ref Drive/Steer Cutout Kit0274619 Ref Dual AC 110V GFI Inst

10-4 800A 800AJ 3121176SECTION 10 SPECIAL OPTIONSContinued Ref Hydraulic/Air Filter Options:Ref Ford Engine Machines 1001109693 1 SN 0300069000 to SN

3121176 800A 800AJ 10-5SECTION 10 SPECIAL OPTIONSRef Side Entry Platform, Mesh to Top Rail0273147 Ref 2.5ft x 4ft Platforms0273149 Ref 3ft x 6ft Platf

10-6 800A 800AJ 3121176SECTION 10 SPECIAL OPTIONSContinued Ref SkyAccessory:0275257 Ref SkyPower - 7500W 60Hz (GM Engine)See Note Ref SkyCutter Plasma

3121176 800A 800AJ 10-7SECTION 10 SPECIAL OPTIONS0258918 Ref Utility Rack InstallationRef Weld Leads to Platform Installation Options:0258826 Ref 800A

10-8 800A 800AJ 3121176SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applica

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-1SECTION 11 PART NUMBER INDEX0060031 ...3-7, 3-1900

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX0272448 ... 10-

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-3SECTION 11 PART NUMBER INDEX2-35, 2-40, 2-41, 2-43, 2-49, 2-54, 2

1-34 800A 800AJ 3121176SECTION 1 FRAMERef FRAME SHIELDS INSTALLATIONS0274267 Ref 2WS A0274266 Ref 4WS A201 0100011 AR Compound, Locking 202 0641608 AR

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX0962270 ... 4-1

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-5SECTION 11 PART NUMBER INDEX1001112077 ...2-41, 2-43100111

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX1683539 ... 5-1

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-7SECTION 11 PART NUMBER INDEX1705902 ... 8-1

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX2220811 ..2-103, 6-3, 6-5, 6-10, 6-

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-9SECTION 11 PART NUMBER INDEX2753540 ... 6-2

PagePart Number PagePart Number PagePart NumberPagePart Number11-10 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX3311508 ... 2-16

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-11SECTION 11 PART NUMBER INDEX3730120 ... 7-

PagePart Number PagePart Number PagePart NumberPagePart Number11-12 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX4360549 ... 3-25, 3-264

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-13SECTION 11 PART NUMBER INDEX4461060 ...7-14, 7-3244

3121176 800A 800AJ 1-35SECTION 1 FRAMEFIGURE 1-9. DRIVE VALVES & SHIELDS INSTALLATIONS (SN 0300083332 TO SN 0300140000) ITEM # PART NUMBER QTY. D

PagePart Number PagePart Number PagePart NumberPagePart Number11-14 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX4844928 ...

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-15SECTION 11 PART NUMBER INDEX70001100 ...2-166, 2-173, 2-177700

PagePart Number PagePart Number PagePart NumberPagePart Number11-16 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX7002821 ...7-23, 7-38, 10-670028

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-17SECTION 11 PART NUMBER INDEX7017048 ...1-13, 1-1770

PagePart Number PagePart Number PagePart NumberPagePart Number11-18 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX7022167 ... 2-

PagePart Number PagePart Number PagePart NumberPagePart Number3121176 800A 800AJ 11-19SECTION 11 PART NUMBER INDEX7026836 ... 2-

PagePart Number PagePart Number PagePart NumberPagePart Number11-20 800A 800AJ 3121176SECTION 11 PART NUMBER INDEX

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

1-36 800A 800AJ 3121176SECTION 1 FRAMEFIGURE 1-10. TOW PACKAGE INSTALLATION (2WS ONLY) 11412112110410410311611510412212612112110710711711012012

3121176 800A 800AJ 1-37SECTION 1 FRAMEFIGURE 1-10. TOW PACKAGE INSTALLATION (2WS ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.0271352 Ref STEERING IN

1-38 800A 800AJ 3121176SECTION 1 FRAME206 1705090 1 Decal - Towing Instructions207 Not Used208 3250872 1 Nameplate - Steer/Tow Valve209 3311401 2 Nut

3121176 800A 800AJ 2-1SECTION 2TURNTABLE

2-2 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONS

3121176 800A 800AJ 2-3SECTION 2 TURNTABLEFIGURE 2-1. CONTROL VALVES & HORN INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref VALVES INSTAL

3121176 800A 800AJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 800A 800AJ 3121176SECTION 2 TURNTABLE12 4640866 1 Valve Assembly (Level)12A 7017466 1 Cartridge2900708 1 Seal Kit - Cartridge12B 7012959 1 Knob13

3121176 800A 800AJ 2-5SECTION 2 TURNTABLE27 4420060 2in/5cm Tape, Double Sided (SN69000 to SN83332 Only)28 0140001 1 Horn (SN 0300103765 to SN 0300140

2-6 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY 169536343115191827293340101128302638233923B22202125228A29A3614

3121176 800A 800AJ 2-7SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN CONTROL VALVE ASSEMB

2-8 800A 800AJ 3121176SECTION 2 TURNTABLE22 70002946 1 Flow Control Manifold Assembly (Main) (Includes Items 24 & 25)23 7018994 1 Control Valve As

3121176 800A 800AJ 2-9SECTION 2 TURNTABLE33 7021310 AR Valve, Sandwich (Platform Rotate) 7018945 2 O-Rings, Replacement - 7021310 Valve34 7017478 1 Ca

2-10 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-3. ACCESSORY VALVE ASSEMBLY 16210238471041011011032B102B1061052C102C2A102ANOTE: TORQUE ITEMS

3121176 800A 800AJ 2-11SECTION 2 TURNTABLEFIGURE 2-3. ACCESSORY VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref ACCESSORY VALVE ASSEMBLIES4

2-12 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-4. AUXILIARY PUMP ASSEMBLY (SN 03000109067 TO SN 0300140000) FENNER BRAND(ORIGINAL EQUIPMENT

3121176 800A 800AJ 2-13SECTION 2 TURNTABLEFIGURE 2-4. AUXILIARY PUMP ASSEMBLY (SN 03000109067 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION RE

ii 800A 800AJ 3121176FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS2-31 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300077500 TO S

2-14 800A 800AJ 3121176SECTION 2 TURNTABLE135 See Note 1 Label (Note: Not Available for Purchase.)136 See Note 2 Pin, Shear (Note: Not Available for P

3121176 800A 800AJ 2-15SECTION 2 TURNTABLEFIGURE 2-4. AUXILIARY PUMP ASSEMBLY (SN 03000109067 TO SN 0300140000) ITEM # PART NUMBER QTY. DESCRIPTION R

2-16 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-5. TURNTABLE BEARING AND SWING DRIVE INSTALLATION

3121176 800A 800AJ 2-17SECTION 2 TURNTABLEFIGURE 2-5. TURNTABLE BEARING AND SWING DRIVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TURNT

2-18 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353)

3121176 800A 800AJ 2-19SECTION 2 TURNTABLE 3631205211210212221202219222223204203206206201209207208214213216215218217203272203035192122233212011

2-20 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353)ITEM # PART NUMBER QTY. DESCRIPTION RE

3121176 800A 800AJ 2-21SECTION 2 TURNTABLE25 7000281 2 Screw, Drive26 7024705 1 O-Ring27 7017082 1 Plug, Pipe28 See Note 2 Lug, Lifting (Note: Not Ava

2-22 800A 800AJ 3121176SECTION 2 TURNTABLE208 7024191 1 Cylinder209 7024192 1 Piston210 Use 7024197 1 Bearing, Ball211 Use 7024197 1 Ring, Retaining21

3121176 800A 800AJ 2-23SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR/HUB ASSEMBLY (SN 0300069000 TO SN 0300134353) ITEM # PART NUMBER QTY. DESCRIPTION R

3121176 800A 800AJ iiiTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.6-7 STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) . . . 6-286-8 HYD

2-24 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134353 TO SN 0300140000)11G1A1B1E1H1I1C234481111545A612201J2425

3121176 800A 800AJ 2-25SECTION 2 TURNTABLE 318K8J30352122233212011911711811611411511311211010910810710610510310410410410410410210128292829200A2

2-26 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-7. SWING MOTOR/HUB ASSEMBLY (SN 0300134353 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIPTION RE

3121176 800A 800AJ 2-27SECTION 2 TURNTABLE29 70002069 2 Bolt 1/2in-13NC x 2in (Grade 8)30 7017085 2 Elbow31 70002075 1 Motor Assembly (See Items 101-1

2-28 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400)6767104632486858681555A282838303

3121176 800A 800AJ 2-29SECTION 2 TURNTABLE VENTSUPPLYRETURN161648486868110111113114112262610410514112112111511513613613456568856674611248789573

2-30 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (SN 0300069000 TO SN 0300139400)ITEM # PART NUMBER QTY. DESCRIP

3121176 800A 800AJ 2-31SECTION 2 TURNTABLE32 1580011 1 Container, Coolant Overflow33 1660239 1 Coupling, Pump34 1703162 2 Decal - Fan Blade35 1 Caterp

2-32 800A 800AJ 3121176SECTION 2 TURNTABLE66 4740274 4 Washer, Snubbing67 4751400 28 Flatwasher 1/4in68 4751600 AR Flatwasher 3/8in69 4751800 1 Flatwa

3121176 800A 800AJ 2-33SECTION 2 TURNTABLERef CATERPILLAR ENGINE INSTALLATION0273526 Ref Without Arctic Package (SN 0300069000 to SN 0300087266) 5/D02

iv 800A 800AJ 3121176FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS

2-34 800A 800AJ 3121176SECTION 2 TURNTABLE107D 1 Cable (Red) Options:7016803 1 SN 0300069000 to SN 0300138238Not Required 1 SN 0300138238 to SN 030013

3121176 800A 800AJ 2-35SECTION 2 TURNTABLE136 3311505 AR Locknut 5/16in-18NC137 0641407 1 Bolt 1/4in-20NC x 7/8in138 0641808 1 Bolt 1/2in-13NC x 1in13

2-36 800A 800AJ 3121176SECTION 2 TURNTABLE206 1 Dipstick Oil Level Options:7026834 SN 0300087000 to SN 03001050487026888 SN 0300105048 to SN 030013475

3121176 800A 800AJ 2-37SECTION 2 TURNTABLE226 7026807 1 Seal, Front Main (Not Shown - Located on Front of Engine Block)227 Not Used228 7026810 1 Belt2

2-38 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000)70357064395638385574763223213276

3121176 800A 800AJ 2-39SECTION 2 TURNTABLE VENT102111107SUPPLY101102107110107120114119114401115103103RETURN11410710211272737161215A215B215B215C

2-40 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139400 TO SN 0300140000)ITEM # PART NUMBER QTY. DESCRIP

3121176 800A 800AJ 2-41SECTION 2 TURNTABLE42 3311605 16 Locknut 3/8in-16NC43 3311801 1 Nut 1/2in-13NC44 3311805 4 Locknut 1/2in-13NC45 3574206 1 Plate

2-42 800A 800AJ 3121176SECTION 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

3121176 800A 800AJ 2-43SECTION 2 TURNTABLE208 1001095354 1 Load Sensing Pump Assembly with Fittings2220415 1 Fitting1001094595 1 Pump, Displacement Le

3121176 800A 800AJ 1-1SECTION 1 FRAME

2-44 800A 800AJ 3121176SECTION 2 TURNTABLE319 4812100 2 Flatwasher 12mm320 4811600 1 Flatwasher 5mm321 1001097553 1 Washer, Coolant Sensor322 10011090

3121176 800A 800AJ 2-45SECTION 2 TURNTABLE418 70001051 1 Valve, Shutoff419 7026826 1 Gasket, Exhaust Manifold to Engine Block (Not Shown)70002852 4 St

2-46 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500)

3121176 800A 800AJ 2-47SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500)ITEM # PART NUMBER QTY. DESCRIPTION

2-48 800A 800AJ 3121176SECTION 2 TURNTABLE44 3311405 AR Locknut 1/4in-20NC45 to 47 Not Used48 1320022 6 Clamp, Hose49 2220273 2 Fitting, Reducer50 218

3121176 800A 800AJ 2-49SECTION 2 TURNTABLE89 3200362 2 Mount, Rubber Engine (Front)90 4711400 1 Flatwasher 1/4in Narrow91 3960468 1 Seal, Foam Gasket9

2-50 800A 800AJ 3121176SECTION 2 TURNTABLE305 7020479 1 Starter See Note 1 Relay (Note: Not Available for Purchase.) 7026608 2 Bolt, Starter Mounting7

3121176 800A 800AJ 2-51SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (SN 0300069000 TO SN 0300077500) ITEM # PART NUMBER QTY. DESCRIPTION

2-52 800A 800AJ 3121176SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ ENGINE INSTALLATION (SN 0300077500 TO SN 0300140000)2742102572572392471112432232572362262

3121176 800A 800AJ 2-53SECTION 2 TURNTABLE 22727273025228280VENTRETURNFUEL PUMPSUPPLIEDWITHENGINE6314523312572102362572102361132612172469281232