Jlg 860SJ Parts Manual User Manual Page 1

Illustrated Parts ManualModels800S860SJSN 0300182743 to PresentP/N3121632January 17, 2014

1-4 800S 860SJ 3121632SECTION 1 FRAME208 4740256 AR Thrustwasher209 4740473 2 Washer, Special210 1001103813 AR Thrustwasher211 1001165657 4 Bearing212

2-68 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-15. HOODS INSTALLATION (ABS)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: REPLACEMENT DECALS M

3121632 800S 860SJ 2-69SECTION 2 TURNTABLE46 4751000 12 Flatwasher #10 Regular47 4751400 4 Flatwasher 1/4in Regular48 4751500 20 Flatwasher 5/16in Reg

2-70 800S 860SJ 3121632SECTION 2 TURNTABLE212 396043855in/1.4mSeal213 396046253in/1.35mSeal0272081 Ref NOISE REDUCTION INSTALLATION (DEUTZ ENGINE MACH

3121632 800S 860SJ 2-71SECTION 2 TURNTABLEFIGURE 2-15. HOODS INSTALLATION (ABS) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-72 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-16. HOODS (STEEL) & LIFTING PLATE INSTALLATIONSNOTE: REPLACEMENT DECALSMUST BE PURCHASED SEPARA

3121632 800S 860SJ 2-73SECTION 2 TURNTABLE NOTE: REPLACEMENT DECALSMUST BE PURCHASED SEPARATELY.50450150250348115106352253316121342591226332219

2-74 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-16. HOODS (STEEL) & LIFTING PLATE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOT

3121632 800S 860SJ 2-75SECTION 2 TURNTABLE39 1001117249 1 Plate, Seal40 1001116358 1 Bracket 41 1 Hood Options:1001116558 Standard Machines1001125502

2-76 800S 860SJ 3121632SECTION 2 TURNTABLE1001150243 Ref HOOD ENGINE SIDE WITH HINGES BRef Note: Customer must transfer Item 109 Heat Shield to Hood A

3121632 800S 860SJ 2-77SECTION 2 TURNTABLE310 1001157200 1 Hood Engine Side Replacement (See Items 351-361 for Breakdown) 1001157209 Ref HOOD ENGINE S

3121632 800S 860SJ 1-5SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION RE

2-78 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-17. ENGINE TRAY JACK INSTALLATION (OPTIONAL) 3A1615441111022677877713312759181719

3121632 800S 860SJ 2-79SECTION 2 TURNTABLEFIGURE 2-17. ENGINE TRAY JACK INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.0258728 Ref EN

2-80 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-18. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ ENGINES 1411211121414050205132891020124171

3121632 800S 860SJ 2-81SECTION 2 TURNTABLEFIGURE 2-18. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ ENGINESITEM # PART NUMBER QTY. DESCRIPTION REV.R

2-82 800S 860SJ 3121632SECTION 2 TURNTABLE28 1 Connector, Strain Relief4460071 60HzSee Note 50Hz (Note: Not Available - Purchase Locally.)29 1 Recepta

3121632 800S 860SJ 2-83SECTION 2 TURNTABLE39E 1 Shroud (was p/n 70002290)Use 70004169 2460048 Generator (was p/n 70002290)70004096 1001136988 Generato

2-84 800S 860SJ 3121632SECTION 2 TURNTABLE105 3311001 6 Nut #10-24NC106 4360070 1 Circuit Breaker - 15 Amp107 Not Used108 4460425 1 Connector, Strain

3121632 800S 860SJ 2-85SECTION 2 TURNTABLE301A cont’d 1001096134 1 Cover, Fuseholder (Deutz TD2.9L4 Engines) (Not Shown) 301B 4460967 1 Plug, Male - 3

2-86 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-19. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES 201301A301421214040272730212404204301

3121632 800S 860SJ 2-87SECTION 2 TURNTABLEFIGURE 2-19. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINESITEM # PART NUMBER QTY. DESCRIPTION REV.0275

1-6 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE 1151141061161011031021012032012042142042142152

2-88 800S 860SJ 3121632SECTION 2 TURNTABLE18G Use 70004169 1 Shroud (was p/n 70002290)19 2820031 1 Insulator20 3252764 1 Nameplate21 3311405 6 Locknut

3121632 800S 860SJ 2-89SECTION 2 TURNTABLE114 10702077 2 Screw #10-32NF x 3/8in115 10702082 2 Screw #10-32NF x 3/4in116 1001152525 1 Plug117 100115752

2-90 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-19. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINESITEM # PART NUMBER QTY. DESCRIPTION REV.

3121632 800S 860SJ 3-1SECTION 3BOOM

3-2 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION NOTE: PLACE WASHER (37)ON TOWER BOOM ONSIDE OF L

3121632 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 3121632SECTION 3 BOOM39 to 40 Not Used41 0641812 4 Bolt 1/2in-13NC x 1-1/2in (860SJ Only)42 4711800 8 Flatwasher 1/2in Thin (860SJ Only

3121632 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 3121632SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800S 39122223131918278173931252922921131201221071131241171121051131221

3121632 800S 860SJ 3-7SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800SITEM # PART NUMBER QTY. DESCRIPTION REV.1001155751 Ref BOOM AND CYLINDER

3121632 800S 860SJ 1-7SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.1001155194 Re

3-8 800S 860SJ 3121632SECTION 3 BOOM112 1320294 2 Bar, Clamping113 3311605 12 Locknut 3/8in-16NC114 3340764 2 Pad, Wear115 3340787 1 Pad, Wear116 3340

3121632 800S 860SJ 3-9SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800S (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-10 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ 7729292020263216231112141402110303030 2591724111011011041131101

3121632 800S 860SJ 3-11SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJITEM # PART NUMBER QTY. DESCRIPTION REV.1001155752 Ref BOOM AND CYLIND

3-12 800S 860SJ 3121632SECTION 3 BOOM114 3841340 1 Loop, Hose115 4740439 2 Thrustwasher116 4844816 1 Link, Jib (Upper)116A 0962335 4 Bushing 117 48448

3121632 800S 860SJ 3-13SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-14 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIES ABAB6453235162591137552020(TOP)(BOTTOM)12(TOP)(BOTTOM)1819661457413542398

3121632 800S 860SJ 3-15SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN BOOM ASSEMBLY OPTIONS:100115576

3-16 800S 860SJ 3121632SECTION 3 BOOM39 3422417 1 Pin, Extend Sheave40 3422424 2 Pin41 3580243 2 Sheave, Retract0961951 1 Bushing42 3580249 2 Guard, S

3121632 800S 860SJ 3-17SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-8 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS 302304307303306305301DETAIL OFVALVE STEM9614481331110120120

3-18 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY 1313118181521611123149860SJ800S1B1A101916817A17410210210319102103102101A101B1

3121632 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 3121632SECTION 3 BOOMRef KIT OPTIONS:100 1 Seal Kit Options: (Includes Items 9-13)100A 7017158 0060061 Rotators (Standard)100B 7000034

3121632 800S 860SJ 3-21SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-22 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS 109102120116125183761059240740540540340340

3121632 800S 860SJ 3-23SECTION 3 BOOM104120201301204205305306128203202304303307308309311310311302115101105121101

3-24 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATF

3121632 800S 860SJ 3-25SECTION 3 BOOM113 3900232 2 Screw 3/8in-16NC x 1-1/4in 114 3900283 4 Screw 3/8in-16NC x 3/4in115 4341264 1 Plate, Valve Mountin

3-26 800S 860SJ 3121632SECTION 3 BOOM0273695 Ref LEVEL SENSOR SWITCH INSTALLATION C401 0100011 AR Compound, Locking402 0100035 AR Compound, Locking403

3121632 800S 860SJ 3-27SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION R

3121632 800S 860SJ 1-9SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref WHEEL DRIVE INSTALLATI

3-28 800S 860SJ 3121632SECTION 3 BOOMFIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS 20 19 242522282126292728231516313435261675303132

3121632 800S 860SJ 3-29SECTION 3 BOOMFIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOM CABLE CLAMPS INSTALL

3-30 800S 860SJ 3121632SECTION 3 BOOM30 AR Bolt 1/4in-20NC x 1-1/4in Options:0641410 1 Machines Without 7500W GeneratorNot Required 0 Machines With 75

3121632 800S 860SJ 4-1SECTION 4PLATFORM

4-2 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIES 10810510323461110109B109C207207205204201106109A101107102401104104107107

3121632 800S 860SJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM ASSEMBLIES:1001144027 Ref

4-4 800S 860SJ 3121632SECTION 4 PLATFORMRef Note: When replacing 8ft/2.44m platform with Soft Touch option, new Soft Touch Rail p/n 4846673 must be pu

3121632 800S 860SJ 4-5SECTION 4 PLATFORMRef WORKLIGHTS INSTALLATIONS (OPTIONAL)0273472 Ref 800S D0273483 Ref 860SJ D1001128153 Ref 860SJ (Worklights /

4-6 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM) 63312854107131111427915

3121632 800S 860SJ 4-7SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.R

1-10 800S 860SJ 3121632SECTION 1 FRAMERef TIRE AND WHEEL INSTALLATIONS0270885 Ref 15-625 NHS Pneumatic (Available on All Specs Except Australian &

4-8 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLY 504502503501OPTIONAL GENERATORSWITCH LOCATED ONMOLDED PLATFORM PA

3121632 800S 860SJ 4-9SECTION 4 PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001141140 Ref PLATFORM CONSOLE

4-10 800S 860SJ 3121632SECTION 4 PLATFORM39 4460428 2 Connector, Strain Relief40 4460470 1 Nut, Terminal41 4460471 1 Lockwasher, Terminal42 4460496 1

3121632 800S 860SJ 4-11SECTION 4 PLATFORM0271552 Ref HEAD & TAIL LIGHTS INSTALLATION (OPTIONAL) C301 4360522 1 Switch, Push Button302 1705170 1 D

4-12 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (LIFT AND SWING) 101102103110104105106107111112108109

3121632 800S 860SJ 4-13SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (LIFT AND SWING)ITEM # PART NUMBER QTY. DESCRIPTION REV.See Note Ref CONTROL

4-14 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE AND STEER) 2082082072092022022032032042042102052061061201101101

3121632 800S 860SJ 4-15SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE AND STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.1001118416 Ref CONT

4-16 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-6. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) 616616616616616616616616616616616616322122111810

3121632 800S 860SJ 4-17SECTION 4 PLATFORMFIGURE 4-6. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SOFT TOUCH

3121632 800S 860SJ 1-11SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-18 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-7. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) 7562862934

3121632 800S 860SJ 4-19SECTION 4 PLATFORMFIGURE 4-7. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.100111098

4-20 800S 860SJ 3121632SECTION 4 PLATFORMFIGURE 4-7. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION R

3121632 800S 860SJ 5-1SECTION 5CYLINDER

5-2 800S 860SJ 3121632SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY 918765543210

3121632 800S 860SJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001154258 Ref AXLE LOCKOUT

5-4 800S 860SJ 3121632SECTION 5 CYLINDERFIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) 688681 432181912 16175A1A511261414151510212210023

3121632 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 3121632SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM 18717271516121111132324242221202145861010292833301041041

3121632 800S 860SJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN LIFT CYLINDER

1-12 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY 10531111110112121102119122123104103103101109107108282911411311611511

5-8 800S 860SJ 3121632SECTION 5 CYLINDER— — — — — — — — — — 50 2901537 1 Seal Kit (Includes Items 15-24)1001157261 Ref MANUAL DESCENT INSTALLATION (OP

3121632 800S 860SJ 5-9SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

5-10 800S 860SJ 3121632SECTION 5 CYLINDERFIGURE 5-4. PLATFORM LEVEL (SLAVE) CYLINDER ASSEMBLY 1011 102726661916 72120124152215221717251418 923

3121632 800S 860SJ 5-11SECTION 5 CYLINDERFIGURE 5-4. PLATFORM LEVEL (SLAVE) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM LEV

5-12 800S 860SJ 3121632SECTION 5 CYLINDERFIGURE 5-5. STEER CYLINDER ASSEMBLY 161616161414341746571210111513 89

3121632 800S 860SJ 5-13SECTION 5 CYLINDERFIGURE 5-5. STEER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001150539 Ref STEER CYLINDER ASS

5-14 800S 860SJ 3121632SECTION 5 CYLINDERFIGURE 5-6. TELESCOPE CYLINDER ASSEMBLY 456781010111212131415161718192021252223126B123101126A126C12624

3121632 800S 860SJ 5-15SECTION 5 CYLINDERFIGURE 5-6. TELESCOPE CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TELESCOPE CYLINDER ASSEMB

5-16 800S 860SJ 3121632SECTION 5 CYLINDER126A 7026015 1 Cartridge7026004 1 Seal Kit - 7026015 Cartridge126B 7026016 1 Cartridge7011346 1 Seal Kit - 70

3121632 800S 860SJ 6-1SECTION 6HYDRAULIC

3121632 800S 860SJ 1-13SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.2780272 Ref DRIVE HUB/BRAKE ASSEMBL

6-2 800S 860SJ 3121632SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM 32792108465111OSCILLATINGAXLEPORT PFLOWDIVIDERPORT 11

3121632 800S 860SJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.1001157400 Ref AXLE LOCKOU

6-4 800S 860SJ 3121632SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD 840153621361835134142284828492322228272730388135853920173169

3121632 800S 860SJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WDITEM # PART NUMBER QTY. DESCRIPTION REV.1001157398 Ref DRIVE HYDRAU

6-6 800S 860SJ 3121632SECTION 6 HYDRAULIC48 2131616 2 Fitting, Elbow49 2131212 1 Fitting, Elbow50 2220811 1 Fitting, Straight51 2110810 1 Fitting, Str

3121632 800S 860SJ 6-7SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-8 800S 860SJ 3121632SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD 315434353133443320203155551340194017323643343131313123153731

3121632 800S 860SJ 6-9SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WDITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DRIVE HYDRAULIC DIAGRAM

6-10 800S 860SJ 3121632SECTION 6 HYDRAULIC38 1001095307 2 Hose39 2753685 1 Hose40 2753686 2 Hose41 2 Hose Options:2753628 Without Arctic Package275472

3121632 800S 860SJ 6-11SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-14 800S 860SJ 3121632SECTION 1 FRAME15 7000287 4 Thrustwasher16 7000288 2 Thrustwasher17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)18 Not Used19

6-12 800S 860SJ 3121632SECTION 6 HYDRAULICFIGURE 6-4. MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL) 13151310945678881111262664414

3121632 800S 860SJ 6-13SECTION 6 HYDRAULICFIGURE 6-4. MANUAL DESCENT HYDRAULIC DIAGRAM ( OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.2792597 Ref

6-14 800S 860SJ 3121632SECTION 6 HYDRAULICFIGURE 6-5. STANDARD HYDRAULIC DIAGRAM 23826369103771151195458153557171432411821244115342231120254511

3121632 800S 860SJ 6-15SECTION 6 HYDRAULICFIGURE 6-5. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref STANDARD HYDRAULIC DIAGRA

6-16 800S 860SJ 3121632SECTION 6 HYDRAULIC40 2753671 2 Hose41 1001157852 1 Hose42 2753674 1 Hose43 1 Hose Options:2753675 800S2753678 860SJ44 AR Hose

3121632 800S 860SJ 6-17SECTION 6 HYDRAULICFIGURE 6-5. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-18 800S 860SJ 3121632SECTION 6 HYDRAULICFIGURE 6-6. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Diagrams with ast

3121632 800S 860SJ 7-1SECTION 7ELECTRICAL

7-2 800S 860SJ 3121632SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LISTITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GENERATOR ELECTRICAL DIAGRAM

3121632 800S 860SJ 7-3SECTION 7 ELECTRICALFIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121632 800S 860SJ 1-15SECTION 1 FRAME201 AR Repair Kit Options:201A Use 7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural Colored Springs) (w

7-4 800S 860SJ 3121632SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION 346347J5J6J7J2J2J1J8J1J8218329328343P218D218E218C218BPLATFO

3121632 800S 860SJ 7-5SECTION 7 ELECTRICAL 4534474496109417347MAINCONTROLVALVE347B347B463347347A347E701701AFUELLEVELSENSORREARSTEERALARMHORN229AM

7-6 800S 860SJ 3121632SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001141140 Ref PLATFORM

3121632 800S 860SJ 7-7SECTION 7 ELECTRICAL105 4460879 1 Connector, Male 2 Position4460887 2 Terminal (12 Gauge)106 4460418 7 Connector, Female - 6 Pos

7-8 800S 860SJ 3121632SECTION 7 ELECTRICAL217 1 Harness Assembly - Main Boom (12/4 -18/8) Options:4922566 800S 2/B1001091618 800S (With Arctic Package

3121632 800S 860SJ 7-9SECTION 7 ELECTRICAL231 cont’d Use 1001121670 All Specs Except Australian, CE & Japanese Specs (Harness, 8/5 Cable - With 7

7-10 800S 860SJ 3121632SECTION 7 ELECTRICAL236 1 Harness, Limit Switch Lower Options (To Boom Capacity Length Switch) (All Specs Except Australian &am

3121632 800S 860SJ 7-11SECTION 7 ELECTRICAL343E 4120035 6 Base, Light4460634 7 Terminal (16 Gauge)4460635 5 Terminal (12 Gauge)343F 4460418 7 Connecto

7-12 800S 860SJ 3121632SECTION 7 ELECTRICAL348 1 Ground Control Box Wiring Diagram (Not Shown - See Items 501 to 513 for Breakdown)1001154329 Deutz D2

3121632 800S 860SJ 7-13SECTION 7 ELECTRICAL449 4461124 1 Receptacle, Female - 4 Position (GM Engine Only)4460693 4 Pin, Male (GM Engine Only)4460608 4

1-16 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY 3413401938303433323132311811411129107A1316151714786255222021232425262827

7-14 800S 860SJ 3121632SECTION 7 ELECTRICALRef STANDARD HARNESS COMPONENTS601 1 Battery Cable Kit Options:1001155143 Deutz D2011 Engines Machines C100

3121632 800S 860SJ 7-15SECTION 7 ELECTRICAL605 1001138491 1 Fuel Harness (Deutz TD2.9L4 Engines Only) C605A 4460897 1 Receptacle, Female - 2 Position

7-16 800S 860SJ 3121632SECTION 7 ELECTRICAL606J 4460930 1 Plug, Male - 8 Position4460465 1 Socket, Female4460466 7 Seal, Plug606K 4460884 1 Plug, Male

3121632 800S 860SJ 7-17SECTION 7 ELECTRICALRef OPTIONAL HARNESS COMPONENTS701 0257887 1 Alarm Harness (Includes Alarm)0140032 1 Alarm2820035 6in/15cm

7-18 800S 860SJ 3121632SECTION 7 ELECTRICAL707A 4460205 1 Plug, Male 707B 4460134 1 Receptacle, Female708 AC to Platform Receptacle Components Options

3121632 800S 860SJ 7-19SECTION 7 ELECTRICAL708B cont’d 4461198 1001091969, 1001100326 Installations4461201 1001091970, 1001100327 InstallationsUse 100

7-20 800S 860SJ 3121632SECTION 7 ELECTRICAL708H 1 Connector, Adapter Options:Not Required 0272259 & 0272260 InstallationsNot Required 0256202 Inst

3121632 800S 860SJ 7-21SECTION 7 ELECTRICAL709 Ref 7500W SkyPower Generator Installation 1001115394 Ref Deutz D2011 Engine E1001148563 Ref Deutz DT2.9

7-22 800S 860SJ 3121632SECTION 7 ELECTRICAL711D 4460742 1 Plug, Male - 2 Position (50Hz Deutz & 60Hz - GM Engines Only)4460743 2 Socket, Female (5

3121632 800S 860SJ 7-23SECTION 7 ELECTRICAL714B 0903697 1 Bracket, Circuit Breaker Mounting0641412 2 Bolt 1/4in-20NC x 1-1/2in3311405 2 Locknut 1/4in-

3121632 800S 860SJ 1-17SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DRIVE MOTOR ASSEMBLIES: 3160347 Ref

7-24 800S 860SJ 3121632SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121632 800S 860SJ 8-1SECTION 8DECALS

8-2 800S 860SJ 3121632SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) 20505695737569548474651254723233320224940BOTHSIDESBOTHSIDESBOT

3121632 800S 860SJ 8-3SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref STANDARD DECAL INSTALLATI

8-4 800S 860SJ 3121632SECTION 8 DECALS41 to 43 Not Used44 0860520 1 Box, Manual Storage45 Not Used46 3311405 1 Locknut 1/4in47 3820001 2 Rivet48 47514

3121632 800S 860SJ 8-5SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

8-6 800S 860SJ 3121632SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) 12DECAL LOCATIONS FORDUAL LANGUAGES ONLY!205056957375695484

3121632 800S 860SJ 8-7SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DECAL INSTALLATIONS027

8-8 800S 860SJ 3121632SECTION 8 DECALS21 1 Decal - Warning/Danger (PLF) Options:1705895 Brazil Spec (English/Portuguese)1703925 Chinese Spec1703924 CS

3121632 800S 860SJ 8-9SECTION 8 DECALS33 2 Decal Capacity Options:800S - Decal - 500LBS Unrestricted Capacity 1001121806 Brazil Spec (English/Portugue

1-18 800S 860SJ 3121632SECTION 1 FRAME25 2220883 1 Plug (Includes Item 26)26 Use 7022328 1 O-Ring27 2220888 2 Plug (Includes Item 28)28 Use 7022328 2

8-10 800S 860SJ 3121632SECTION 8 DECALS53 1 Decal - Fuel1701505 Diesel1701542 Gas54 to 55 Not Used56 1 Decal - Lanyard Attach (GM Spec)Not Required Br

3121632 800S 860SJ 8-11SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

8-12 800S 860SJ 3121632SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPEC) 2350419379548474651254723233360224940BOTHSIDES

3121632 800S 860SJ 8-13SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPEC)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DECAL INS

8-14 800S 860SJ 3121632SECTION 8 DECALS49 1702861 2 Decal - JLG Lift (8in Height)50 1702774 1 Decal - JLG Lift (3-1/2in Height)51 1702773 1 Decal - JL

3121632 800S 860SJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 800S/860SJThe following list will service one machine (built to current production

9-2 800S 860SJ 3121632SECTION 9 RECOMMENDED SERVICE PARTS STOCK70025161 Filter, Fuel (Deutz TD2.9L4 Engines) (Figure 2-6) 1 Dozen70025210 Module, Engi

3121632 800S 860SJ 10-1SECTION 10SPECIAL OPTIONS

10-2 800S 860SJ 3121632SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applic

3121632 800S 860SJ 10-3SECTION 10 SPECIAL OPTIONSContinued Ref Decal Installations 0274455 Ref Decal - FedEx (ANSI & CSA Specs)1001128989 Ref Deca

3121632 800S 860SJ 1-19SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

10-4 800S 860SJ 3121632SECTION 10 SPECIAL OPTIONSRef Filter Kits:1 Combined Filter Kit (Hydraulic/Air & Fuel/Engine Oil)Not Available Deutz Engine

3121632 800S 860SJ 10-5SECTION 10 SPECIAL OPTIONSRef Platform Cover Installations 0258703 Ref USA Built Machines1001112821 Ref China Built Machines100

10-6 800S 860SJ 3121632SECTION 10 SPECIAL OPTIONSRef Sky Accessory:0273596 Ref SkyAir Compressor Installation (Deutz D2011 - ANSI Export)1001148565 Re

3121632 800S 860SJ 10-7SECTION 10 SPECIAL OPTIONS4460510 1 Extractor - 12-14 Gauge (For Removal of Pin/Sockets from Deutsch Connectors)7002822 1 Screw

10-8 800S 860SJ 3121632SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applica

PagePart Number PagePart Number PagePart NumberPagePart Number3121632 800S 860SJ 11-1SECTION 11 PARTS NUMBER INDEX0060048 ...3-11, 3-1900

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 800S 860SJ 3121632SECTION 11 PARTS NUMBER INDEX0641640 ... 3-

PagePart Number PagePart Number PagePart NumberPagePart Number3121632 800S 860SJ 11-3SECTION 11 PARTS NUMBER INDEX1001109475 ...7-23, 9-21001

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 800S 860SJ 3121632SECTION 11 PARTS NUMBER INDEX1001141968 ... 7-191

PagePart Number PagePart Number PagePart NumberPagePart Number3121632 800S 860SJ 11-5SECTION 11 PARTS NUMBER INDEX1001159854 ... 6-5

1-20 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS ORVALVE ROTATED FOR CLARITYVALVE ROTATED FOR CLARITY

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 800S 860SJ 3121632SECTION 11 PARTS NUMBER INDEX1705980 ... 8-

PagePart Number PagePart Number PagePart NumberPagePart Number3121632 800S 860SJ 11-7SECTION 11 PARTS NUMBER INDEX2902312 ... 8-

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 800S 860SJ 3121632SECTION 11 PARTS NUMBER INDEX3900316 2-74, 2-75, 2-76, 3-8, 3-1

PagePart Number PagePart Number PagePart NumberPagePart Number3121632 800S 860SJ 11-9SECTION 11 PARTS NUMBER INDEX4460959 ... 7-

PagePart Number PagePart Number PagePart NumberPagePart Number11-10 800S 860SJ 3121632SECTION 11 PARTS NUMBER INDEX70000795 ... 1-

PagePart Number PagePart Number PagePart NumberPagePart Number3121632 800S 860SJ 11-11SECTION 11 PARTS NUMBER INDEX70024915 ... 2-

PagePart Number PagePart Number PagePart NumberPagePart Number11-12 800S 860SJ 3121632SECTION 11 PARTS NUMBER INDEX7023948 ... 2

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

3121632 800S 860SJ 1-21SECTION 1 FRAMEFIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.1001157015 Ref DRIV

1-22 800S 860SJ 3121632SECTION 1 FRAME207to 208 Not Used209 8580420 2 Nut, Well210 0641410 2 Bolt 1/4in-20NC x 1-1/4in211 4751400 2 Flatwasher 1/4in R

3121632 800S 860SJ 1-23SECTION 1 FRAMEFIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121632 800S 860SJ AREVISION LOGNOTES:Note: S/N 0300174290, 030180894 & 0300181347 also built to the same specs as machines built S/N 0300182743 t

1-24 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-7. TOW PACKAGE INSTALLATION 10212111311311411411711211211511512010310510510410911010610610610610

3121632 800S 860SJ 1-25SECTION 1 FRAMEFIGURE 1-7. TOW PACKAGE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001158436 Ref TOW BAR INSTALLATION

1-26 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-7. TOW PACKAGE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121632 800S 860SJ 2-1SECTION 2TURNTABLE

2-2 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-1.70 CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS 81919137191910155162721421322820220621

3121632 800S 860SJ 2-3SECTION 2 TURNTABLE FIGURE 2-1. 70 CONTROL VALVES & AUXILIARY PUMP INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTI

2-4 800S 860SJ 3121632SECTION 2 TURNTABLE154 70003612 2 O-Ring155 70004267 1 O-Ring1001157261 Ref MANUAL DESCENT INSTALLATION (OPTIONAL) A201 Not Used

3121632 800S 860SJ 2-5SECTION 2 TURNTABLEFIGURE 2-1. 70 CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPT

2-6 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY 18936825471613151115121410141718517A

3121632 800S 860SJ 2-7SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.4641432 Ref MAIN CONTROL VALV

B 800S 860SJ 3121632REVISION LOG

2-8 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE BEARING & SWING DRIVE INSTALLATION 201202203204FRAME REF.2786530130210310510

3121632 800S 860SJ 2-9SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE BEARING & SWING DRIVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.10010948

2-10 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-4. SWING MOTOR/HUB ASSEMBLY11G1A1B1E1H1I1C233A4481111545A612201J24253B3B3E3G3C3C3F3D13

3121632 800S 860SJ 2-11SECTION 2 TURNTABLE 318K8J30352122233212011911711811611411511311211010910810710610510310410410410410410210128292829200A2

2-12 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-4. SWING MOTOR/HUB ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001101060 Ref SWING MOTOR/HUB

3121632 800S 860SJ 2-13SECTION 2 TURNTABLE23 7017023 2 Plug, Pipe24 See Note 1 Plate, ID (Note: Not Available for Purchase.)25 7000281 2 Screw, Drive2

2-14 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-5. DEUTZ D2011 ENGINE INSTALLATION21820121120121220130420130322124621922040941142041240140221942342

3121632 800S 860SJ 2-15SECTION 2 TURNTABLE 2082092372372552323725223722521721723722537373849751110712620404406402423417414233416407 415 4032012

2-16 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-5. DEUTZ D2011 ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DEUTZ D2011 ENGINE I

3121632 800S 860SJ 2-17SECTION 2 TURNTABLE37 3960548 44in/1.1m Seal38 396054911in/28cmSeal39 4922737 1 Harness, Engine Ground40 to 48 Not Used49 1 Dec

3121632 800S 860SJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18 800S 860SJ 3121632SECTION 2 TURNTABLERef ENGINE ASSEMBLIES 1001153396 Ref Without Arctic Package (All Specs except CE Spec) B1001160965 Ref Witho

3121632 800S 860SJ 2-19SECTION 2 TURNTABLE242 1001146273 1 Adapter, Air Intake243 1001147812 1 Clamp244 1001147813 1 Air Cleaner Assembly Including Fi

2-20 800S 860SJ 3121632SECTION 2 TURNTABLE401 cont’d 1 Tube, Dipstick Options:70001002 1001147823 Engine (All Specs except CE Specs)See Note 100114431

3121632 800S 860SJ 2-21SECTION 2 TURNTABLE410 AR Exhaust Manifold Components (Not Shown)70001835 1 Gasket, Exhaust Adapter to Exhaust Rail70001841 1 V

2-22 800S 860SJ 3121632SECTION 2 TURNTABLE420 1 Muffler Options:7000695 1001147823 Engine (Standard on All Specs except CE Specs)1001099051 1001144319

3121632 800S 860SJ 2-23SECTION 2 TURNTABLE510 4812200 3 Flatwasher M14511 1 Support, Engine (Right Front)511A 1001149703 Machines without Generator511

2-24 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-6. DEUTZ TD2.9L4 ENGINE INSTALLATION 9011530233426926825323822731720133121924530028728122020720124

3121632 800S 860SJ 2-25SECTION 2 TURNTABLE POWERMODULERELAYBOLTONENGINETRAYPIVOTAUX PUMPSTARTERAUXRELAYBATTERY47A47D47B47E47F47E47C47CAA505045025

2-26 800S 860SJ 3121632SECTION 2 TURNTABLE 152535405191627110116108102NOTE:HITCH PIN (110)SHOWN HERE FOR CLARITY.71SUPPLYVENT1532512RETURN48361533217

3121632 800S 860SJ 2-27SECTION 2 TURNTABLEFIGURE 2-6. DEUTZ TD2.9L4 ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DEUTZ ENGINE INSTA

ii 800S 860SJ 3121632FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-28 800S 860SJ 3121632SECTION 2 TURNTABLE46 1001138491 1 Harness, Fuel (Not Shown - See ELECTRICAL SECTION for Breakdown)47 1001143736 1 Battery Cabl

3121632 800S 860SJ 2-29SECTION 2 TURNTABLE111 1001152522 1 Hydrostatic Pump Assembly with Fittings (See HYDROSTATIC PUMP ASSEMBLY for Breakdown)112 10

2-30 800S 860SJ 3121632SECTION 2 TURNTABLE230 3580320 1 Pulley231 3931432 1 Capscrew 1/4in-20NC x 2in232 3931512 4 Capscrew 5/16in-18NC x 3/4in233 393

3121632 800S 860SJ 2-31SECTION 2 TURNTABLE280 1001139813 1 Engine, Deutz TD2.9L4 (See Items 501-535 for Serviced Components)281 1001155384 1 Radiator2

2-32 800S 860SJ 3121632SECTION 2 TURNTABLE327 8406102 1 Clip328 1001138718 1 Bracket329 1001142501 1 Fitting, Elbow Barbed330 1001148641 1 Bracket331

3121632 800S 860SJ 2-33SECTION 2 TURNTABLE509 7016331 1 Filter, Oil 510 70004276 1 Cooler, Oil70024925 1 Gasket511 70024924 1 Pump, High Pressure (Not

2-34 800S 860SJ 3121632SECTION 2 TURNTABLE532 70024504 1 Sensor, Pressure (Not Shown - Located Left Side Front)70024920 1 Seal533 70024507 1 Sensor, P

3121632 800S 860SJ 2-35SECTION 2 TURNTABLEFIGURE 2-6. DEUTZ TD2.9L4 ENGINE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-36 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-7. GM ENGINE INSTALLATION 219228204216226256244216216215215 (NOT SHOWN)2152212272372172252052502322

3121632 800S 860SJ 2-37SECTION 2 TURNTABLE 2934203B123472424635114025RETURN ON FUEL TANKTO ENGINE106FRONT ENGINEMTG BOLTAUX RELAYMTG BOLTBATTER

3121632 800S 860SJ 1-1SECTION 1 FRAME

2-38 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-7. GM ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001156470 Ref GM 3.0L TIER III/i

3121632 800S 860SJ 2-39SECTION 2 TURNTABLE104 0641812 4 Bolt 1/2in-13NC x 1-1/2in105 1060637 1 Cable, Lanyard106 2902533 1 Battery Cable Kit B106A 702

2-40 800S 860SJ 3121632SECTION 2 TURNTABLE221 1703162 2 Decal - Caution Fan222 0100020 AR Locking Compound223 2060025 1 Fan224 Not Used225 27200585.5i

3121632 800S 860SJ 2-41SECTION 2 TURNTABLEFIGURE 2-7. GM ENGINE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-42 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-8. HYDROSTATIC PUMP ASSEMBLY

3121632 800S 860SJ 2-43SECTION 2 TURNTABLEFIGURE 2-8. HYDROSTATIC PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001142522 Ref PUMP ASSEMBLY B

2-44 800S 860SJ 3121632SECTION 2 TURNTABLE53 70004346 1 Orifice54 Not Used55 70004347 1 Coupler56 Not Used57 See Note 2 Plug (Note: Not Available for

3121632 800S 860SJ 2-45SECTION 2 TURNTABLEFIGURE 2-8. HYDROSTATIC PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-46 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-9. VARIABLE PUMP ASSEMBLY 600501502504504A570570A4521503401254045405455445435425415465475495

3121632 800S 860SJ 2-47SECTION 2 TURNTABLEFIGURE 2-9. VARIABLE PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001094595 Ref PUMP ASSEMBLY A1 7

1-2 800S 860SJ 3121632SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE FIXED AXLEOSCILLATING AXLE11511410611610110

2-48 800S 860SJ 3121632SECTION 2 TURNTABLE301 to 399 Not Used401 7023958 1 Shaft402 70001957 1 Cap, End403 7023960 4 Screw404 7022318 1 Plug404A Use 7

3121632 800S 860SJ 2-49SECTION 2 TURNTABLEFIGURE 2-9. VARIABLE PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-50 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-10. TANK INSTALLATIONS 22089511166714141STANDARDMACHINESONLY3141821144151510111220319191313O

3121632 800S 860SJ 2-51SECTION 2 TURNTABLEFIGURE 2-10. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TANKS INSTALLATION 1001157258 Re

2-52 800S 860SJ 3121632SECTION 2 TURNTABLE1001158290 Ref HYDRAULIC TANK ASSEMBLY B101 7024374 1 Filter Assembly7024375 1 Element, Filter102 7023306 1

3121632 800S 860SJ 2-53SECTION 2 TURNTABLEFIGURE 2-10. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-54 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-11. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) 1611292022101317181519867543333311121214

3121632 800S 860SJ 2-55SECTION 2 TURNTABLEFIGURE 2-11. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.1001151

2-56 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-12. ROTARY COUPLING INSTALLATION 112117126126 1271251231241241181161191211201131141041011010

3121632 800S 860SJ 2-57SECTION 2 TURNTABLEFIGURE 2-12. ROTARY COUPLING INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001107531 Ref ROTARY COUP

3121632 800S 860SJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.1001151037

2-58 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-13. GROUND CONTROL BOX ASSEMBLY 393837427452829332711718156163620191383231412537383936143026

3121632 800S 860SJ 2-59SECTION 2 TURNTABLEFIGURE 2-13. GROUND CONTROL BOX ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GROUND CONTROL BOX ASSE

2-60 800S 860SJ 3121632SECTION 2 TURNTABLE31 4460496 1 Lockwasher, Terminal32 4460497 1 Nut, Terminal33 4460526 1 Connector, Strain Relief 34 4740397

3121632 800S 860SJ 2-61SECTION 2 TURNTABLEFIGURE 2-13. GROUND CONTROL BOX ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-62 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-14. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS 800SAB36621210411588999191919860SJC6688

3121632 800S 860SJ 2-63SECTION 2 TURNTABLEFIGURE 2-14. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref LI

2-64 800S 860SJ 3121632SECTION 2 TURNTABLERef ALARM INSTALLATION (CONTINUED)1001158364 Ref Deutz TD2.9L4 Engines A205 0100011 AR Compound, Locking206

3121632 800S 860SJ 2-65SECTION 2 TURNTABLE262 Not Used263 4240032 AR Tie-Strap (Not Shown)264 4460234 AR Mount, Tie-Strap (Not Shown)265 4360522 1 Swi

2-66 800S 860SJ 3121632SECTION 2 TURNTABLEFIGURE 2-15. HOODS INSTALLATION (ABS) 374936648484848482663131491544534441314841314810134949332032464

3121632 800S 860SJ 2-67SECTION 2 TURNTABLE492032493212333847305394916402946733124935482121049334974933493314440140240340434454249537749493349524866485