Jlg 860SJ Parts Manual User Manual Page 1

Illustrated Parts ManualModels800S860SJSN 0300140000 to SN 0300182743 &SN B300000100 to PresentP/N3121270January 17, 2014

1-4 800S 860SJ 3121270SECTION 1 FRAME0272003 Ref STEERING INSTALLATIONS (2WS) ERef Note: Before ordering king pin kit, verify that machines is equippe

2-68 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-16. HOODS INSTALLATION (ABS)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref HOODS INSTALLATIONS0274762

3121270 800S 860SJ 2-69SECTION 2 TURNTABLE41 4160139 2 Spring, Gas (Tank Side)42 4160143 1 Spring, Gas (Engine Side)43 4740076 4 Washer, Fender44 4740

2-70 800S 860SJ 3121270SECTION 2 TURNTABLERef Note: Replacement Decals Must be Ordered Separately - See DECAL SECTION.112 1671230 1 Frame, Tubular113

3121270 800S 860SJ 2-71SECTION 2 TURNTABLEFIGURE 2-16. HOODS INSTALLATION (ABS) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-72 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-17. HOODS INSTALLATION (STEEL) 2838339242439164916233842439102838665738284215128382233838289

3121270 800S 860SJ 2-73SECTION 2 TURNTABLE543211135283838235116343823392410393924441714126122813827212737171434163485628233838283865302120921020420820

2-74 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-17. HOODS INSTALLATION (STEEL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref HOODS INSTALLATIONS10011

3121270 800S 860SJ 2-75SECTION 2 TURNTABLE41 1001113047 7ft/2.1m Seal (Adhesive Back)42 1001116280 1 Bracket, Hood Support43 1001116322 1 Door44 1 Doo

2-76 800S 860SJ 3121270SECTION 2 TURNTABLE105 3290601 1 Nut M6106 3311505 15 Locknut 5/16in-18NC107 3340877 4 Pad108 3900210 15 Screw, Button Head 5/1

3121270 800S 860SJ 2-77SECTION 2 TURNTABLEFIGURE 2-17. HOODS INSTALLATION (STEEL) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 1-5SECTION 1 FRAME2780229 Ref HUB ASSEMBLY (2WD ONLY) A401 7017052 2 Spindle (1 per Assembly)402 7017053 2 Housing (1 per Assembly)

2-78 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-18. ENGINE TRAY JACK INSTALLATION (OPTIONAL) 3A1615441111022677877713312759181719

3121270 800S 860SJ 2-79SECTION 2 TURNTABLEFIGURE 2-18. ENGINE TRAY JACK INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.0258728 Ref EN

2-80 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-19. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) 1010137105641314241623221

3121270 800S 860SJ 2-81SECTION 2 TURNTABLEFIGURE 2-19. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPT

2-82 800S 860SJ 3121270SECTION 2 TURNTABLE11 3574684 1 Plate, Box Mounting12 0701210 2 Bolt M12 x 20mm13 0962563 1 Bushing, Spacer14 3311605 1 Locknut

3121270 800S 860SJ 2-83SECTION 2 TURNTABLE108 4420060 3in/7cm Tape, Double-Sided109 4460234 3 Mount, Tie Strap110 4750800 1 Flatwasher #8 Regular111 4

2-84 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-20. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) 3535323741384036333432021222C2B

3121270 800S 860SJ 2-85SECTION 2 TURNTABLEFIGURE 2-20. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION RE

2-86 800S 860SJ 3121270SECTION 2 TURNTABLE16 0641508 1 Bolt 5/16in-18NC x 1in17 4751500 1 Flatwasher 5/16in Regular18 to 19 Not Used20 0721006 AR Bolt

3121270 800S 860SJ 2-87SECTION 2 TURNTABLEFIGURE 2-20. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. DESCRIPTION R

1-6 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE 106110106114102118107103103113113111109 105117

2-88 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-21. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)

3121270 800S 860SJ 2-89SECTION 2 TURNTABLEFIGURE 2-21. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.R

2-90 800S 860SJ 3121270SECTION 2 TURNTABLE25 4740397 1 Spacer (Not Shown - Located at Platform)26 4751000 2 Flatwasher #10 Regular27 4751500 4 Flatwas

3121270 800S 860SJ 2-91SECTION 2 TURNTABLEFIGURE 2-21. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-92 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-22. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES 2011039413041815

3121270 800S 860SJ 2-93SECTION 2 TURNTABLEFIGURE 2-22. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINESITEM # PART NUMBER QTY.

2-94 800S 860SJ 3121270SECTION 2 TURNTABLE18 2 Box, Switch Options:0860038 60Hz SpecSee Note 50Hz Spec (Note: Not Available - Purchase Locally.)19 064

3121270 800S 860SJ 2-95SECTION 2 TURNTABLE32B 70001966 1 Bearing, Ball Redial (Located in Belt Tensioner Endbell)70003708 1 Ring, Internal Retaining (

2-96 800S 860SJ 3121270SECTION 2 TURNTABLE43 0641618 1 Bolt 3/8in-16NC x 2-1/4in Options:44 4791400 AR Starwasher 1/4in45 4811900 4 Flatwasher M8 (Cat

3121270 800S 860SJ 2-97SECTION 2 TURNTABLE125 1671092 1 Cover (60Hz Spec Only)126 4460963 1 Connector (60Hz Spec Only)127 Not Used128 1001121340 1 Ter

3121270 800S 860SJ 1-7SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.0274572 Ref O

2-98 800S 860SJ 3121270SECTION 2 TURNTABLE1001121340 Ref TERMINAL BLOCK ASSEMBLY A501 70002818 2 Marker Strip #1502 70002819 4 Marker Strip #2503 7000

3121270 800S 860SJ 2-99SECTION 2 TURNTABLEFIGURE 2-22. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR & DEUTZ ENGINES (CONTINUED)ITEM # PART

2-100 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES 201107116105110117125126101204104109

3121270 800S 860SJ 2-101SECTION 2 TURNTABLEFIGURE 2-23. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref

2-102 800S 860SJ 3121270SECTION 2 TURNTABLE18C 70001953 1 Endbell (Front) 18D 70001100 1 Shaft/Rotor/Windings/Fan/Rear Bearing Assembly70001384 1 Bear

3121270 800S 860SJ 2-103SECTION 2 TURNTABLE104 1705376 1 Decal - Wiring Schematic105 3300396 1 Cover, Fuse106 3310601 2 Nut 6-32NC107 1060343 1.5ft/.4

2-104 800S 860SJ 3121270SECTION 2 TURNTABLE407 4240032 4 Strap, Tie408 4420060 3in/7cm Tape, Double-Sided409 4460234 3 Mount, Tie Strap410 4750800 1 F

3121270 800S 860SJ 3-1SECTION 3BOOM

3-2 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION NOTE: PLACE WASHER (41)ON TOWER BOOM ONSIDE OF L

3121270 800S 860SJ 3-3SECTION 3 BOOMFIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TOWER BOOM,

1-8 800S 860SJ 3121270SECTION 1 FRAME212 3422702 2 Pin, Tie-Rod213 3422972 4 Kingpin214 3422754 2 Pin, Attach215 3422813 1 Pin216 3422848 1 Pin, Hitch

3-4 800S 860SJ 3121270SECTION 3 BOOM35 3841287 AR Keeper, Pin 36 3841356 1 Keeper, Pin 37 3931624 2 Capscrew, Socket Head 3/8in-16NC x 1-1/2in38 41601

3121270 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 3121270SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800S 25253535918318201313135296342212233119121115108 118 1241121011021

3121270 800S 860SJ 3-7SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800SITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOM AND CYLINDERS INSTALLAT

3-8 800S 860SJ 3121270SECTION 3 BOOM106 0641620 1 Bolt 3/8in-16NC x 2-1/2in107 0641622 2 Bolt 3/8in-16NC x 2-3/4in108 0641652 2 Bolt 3/8in-16NC x 6-1/

3121270 800S 860SJ 3-9SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION - 800S (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-10 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ 25251035 35 35 193092014297734342424133121321110110110411311011

3121270 800S 860SJ 3-11SECTION 3 BOOMFIGURE 3-3. MAIN BOOM INSTALLATION - 860SJITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOM AND CYLINDERS INSTALL

3-12 800S 860SJ 3121270SECTION 3 BOOM109 3311605 5 Locknut 3/8in-16NC110 3422860 2 Pin111 3422861 2 Pin112 3422867 1 Pin113 3841143 3 Keeper, Pin114 3

3121270 800S 860SJ 3-13SECTION 3 BOOM221 4846553 1 Support, Push Tube222 4846555 1 Tube, Push223 4846558 1 Support, Track224 3311608 4 Locknut 3/8in-1

3121270 800S 860SJ 1-9SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-14 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIES ABAB40566654386112375899(TOP)(BOTTOM)72(TOP)(BOTTOM)212223176841657241848

3121270 800S 860SJ 3-15SECTION 3 BOOMFIGURE 3-4. MAIN BOOM ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN BOOM ASSEMBLY OPTIONS:0801274 R

3-16 800S 860SJ 3121270SECTION 3 BOOM35 3312201 2 Nut 3/4in-10NC36 2 Pad, Wear Options;3340755 USA Built Machines SN 0300140000 to SN 0300169345 &

3121270 800S 860SJ 3-17SECTION 3 BOOM65 0641613 2 Screw 3/8in-16NC x 1-5/8in66 0811614 6 Screw 3/8in-16NC x 1-3/4in67 0811616 6 Screw 3/8in-16NC x 2in

3-18 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLIES 1313118181521611123149860SJ800S1B1A101916817A17410210210319102103102101A101

3121270 800S 860SJ 3-19SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref ROTATOR ASSEMBLIES0060061 Ref 800S I00

3-20 800S 860SJ 3121270SECTION 3 BOOMRef KIT OPTIONS:100 1 Seal Kit Options: (Includes Items 9-13)100A 7017158 0060061 Rotators (Standard)100B 7000034

3121270 800S 860SJ 3-21SECTION 3 BOOMFIGURE 3-5. ROTATOR ASSEMBLIES (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-22 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS 109103117127114183761059240740540540340340

3121270 800S 860SJ 3-23SECTION 3 BOOM126117201301204205305306128203202304303307308309311310311302120B117103312313101101OR106118101106118101120A

1-10 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS 102104107103106105101DETAIL OFVALVE STEM61448133911

3-24 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATF

3121270 800S 860SJ 3-25SECTION 3 BOOM110 to 113 Not Used114 1 Valve, Level/Rotate Options (See Items 301-313 for Breakdown):4641251 USA Built Machines

3-26 800S 860SJ 3121270SECTION 3 BOOMRef LEVEL/ROTATE VALVE ASSEMBLY4641251 Ref USA Built Machines SN 0300140000 to SN 0300141319 Only B1001118473 Ref

3121270 800S 860SJ 3-27SECTION 3 BOOMFIGURE 3-6. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION R

3-28 800S 860SJ 3121270SECTION 3 BOOMFIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS 20 19 242522282126292728231516313435261675303132

3121270 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 3121270SECTION 3 BOOM30 AR Bolt 1/4in-20NC x 1-1/4in Options:0641410 1 Machines Without 7500W GeneratorNot Required 0 Machines With 75

3121270 800S 860SJ 4-1SECTION 4PLATFORM

4-2 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIES 10810510323461110109B109C207207205204201106109A101107102401104104107107

3121270 800S 860SJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM ASSEMBLIES:Use 1001144027

3121270 800S 860SJ 1-11SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref WHEEL DRIVE INSTALLAT

4-4 800S 860SJ 3121270SECTION 4 PLATFORM1001111018 Ref Platform 36in x 6ft (91.5cm x 1.83m) Mesh to Mid Rail (Not Shown)ERef Note: For Platform with M

3121270 800S 860SJ 4-5SECTION 4 PLATFORM109 cont’d 1 Footswitch Assembly (Includes Footswitch, Electrical Cable, Strain Relief Connectors and Connecti

4-6 800S 860SJ 3121270SECTION 4 PLATFORM217 AR Hardware Options (Not Shown):2820035 9ft Loom, Vinyl (2 Work Lights)2820020 1ft Shrink, Heat (4 Work Li

3121270 800S 860SJ 4-7SECTION 4 PLATFORMFIGURE 4-1. PLATFORM ASSEMBLIES (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-8 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM) 63312854107131111427915

3121270 800S 860SJ 4-9SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.R

4-10 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLY 504502503501OPTIONAL GENERATORSWITCH LOCATED ONMOLDED PLATFORM P

3121270 800S 860SJ 4-11SECTION 4 PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM CONSOLE ASSEMBLIES

4-12 800S 860SJ 3121270SECTION 4 PLATFORM33 4360407 1 Controller, SpeedSee Note 1 Gasket “Top Hat” (Included With Switch) (Note: Not Available - Purch

3121270 800S 860SJ 4-13SECTION 4 PLATFORM0861441 Ref CONSOLE BOX ASSEMBLY F101 See Note 1 Console Top (Note: Not Available for Purchase.)102 See Note

1-12 800S 860SJ 3121270SECTION 1 FRAME104 1 Rim, Wheel Options:4860224 13 x 24.5 Rim (Use with 15-625 Tires)4860225 15 x 24.5 Rim (Use with 18-625 Tir

4-14 800S 860SJ 3121270SECTION 4 PLATFORM201 cont’d 1001125010 800S - All Specs Except Australian & CE Specs800S - Australian Spec Only Options:10

3121270 800S 860SJ 4-15SECTION 4 PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-16 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (LIFT AND SWING) 222119185936145876391110122310121514131A1C1B102103110

3121270 800S 860SJ 4-17SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (LIFT AND SWING)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original E

4-18 800S 860SJ 3121270SECTION 4 PLATFORMUse 1001129555 Ref Controller Assembly:(Service Replacement - USA Built Machines SN 0300140000 to SN 03001463

3121270 800S 860SJ 4-19SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (LIFT AND SWING) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-20 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE AND STEER) 2082082072092022022032032042042102052061061201181719

3121270 800S 860SJ 4-21SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE AND STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original

4-22 800S 860SJ 3121270SECTION 4 PLATFORM103 70002725 2 Screw104 7019162 1 Spring105 70002726 1 Enclosure106 70002727 1 Handle Assembly (See Items 201

3121270 800S 860SJ 4-23SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE AND STEER) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 1-13SECTION 1 FRAMEFIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-24 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-6. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) 616616616616616616616616616616616616322122111810

3121270 800S 860SJ 4-25SECTION 4 PLATFORMFIGURE 4-6. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SOFT TOUCH

4-26 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-7. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) 7562862934

3121270 800S 860SJ 4-27SECTION 4 PLATFORMFIGURE 4-7. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.100111098

4-28 800S 860SJ 3121270SECTION 4 PLATFORMFIGURE 4-7. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION R

3121270 800S 860SJ 5-1SECTION 5CYLINDER

5-2 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY

3121270 800S 860SJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1683078 Ref AXLE LOCKOUT CY

5-4 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) 688681 432181912 16175A1A511261414151510212210023

3121270 800S 860SJ 5-5SECTION 5 CYLINDERFIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.1683609 Ref JIB

1-14 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY 10531111110112121102119122123104103103101109107108282911411311611511

5-6 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM 18717271516121111132324242221202145861010292833301021021

3121270 800S 860SJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref MAIN LIFT CYLINDER

5-8 800S 860SJ 3121270SECTION 5 CYLINDER— — — — — — — — — — 50 2901537 1 Seal Kit (Includes Items 15-24)0272750 Ref MANUAL DESCENT INSTALLATION (OPTIO

3121270 800S 860SJ 5-9SECTION 5 CYLINDERFIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

5-10 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-4. PLATFORM LEVEL CYLINDER ASSEMBLY 1011 102726661916 72120124152215221717251418 92356682421

3121270 800S 860SJ 5-11SECTION 5 CYLINDERFIGURE 5-4. PLATFORM LEVEL CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM LEVEL CYLIN

5-12 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-5. STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 0300140000 TO SN 0300142666) 14172489101312

3121270 800S 860SJ 5-13SECTION 5 CYLINDERFIGURE 5-5. STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 0300140000 TO SN 0300142666)ITEM # PART NUMBER QT

5-14 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-6. STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 03000142666 TO SN 0300182743 ONLY & CHINA BUIL

3121270 800S 860SJ 5-15SECTION 5 CYLINDERFIGURE 5-6. STEER CYLINDER ASSEMBLY (USA BUILT MACHINES SN 03000142666 TO SN 0300182743 ONLY & CHINA BUI

3121270 800S 860SJ 1-15SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.2780272 Ref DRIVE HUB/BRAKE ASSEMBL

5-16 800S 860SJ 3121270SECTION 5 CYLINDERFIGURE 5-7. TELESCOPE CYLINDER ASSEMBLY 456781010111212131415161718192021252223114B110114A114C11424262

3121270 800S 860SJ 5-17SECTION 5 CYLINDERFIGURE 5-7. TELESCOPE CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TELESCOPE CYLINDER ASSEMB

5-18 800S 860SJ 3121270SECTION 5 CYLINDER26 1 Spacer, Tube Options:800S4568264 USA Built Machines SN 0300140000 to SN 0300150027 & China Built Mac

3121270 800S 860SJ 6-1SECTION 6HYDRAULIC

6-2 800S 860SJ 3121270SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM 3810219475921

3121270 800S 860SJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.2792648 Ref AXLE LOCKOUT H

6-4 800S 860SJ 3121270SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD 840448214818351341622868284923222285050493881358539525335199

3121270 800S 860SJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WDITEM # PART NUMBER QTY. DESCRIPTION REV.2792714 Ref DRIVE HYDRAULIC

6-6 800S 860SJ 3121270SECTION 6 HYDRAULIC51 2754402 1 Hose52 2754242 1 Hose53 2754243 1 Hose54 Not Used55 2221084 1 Fitting, Tee3600410 Ref PISTON PUM

3121270 800S 860SJ 6-7SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-16 800S 860SJ 3121270SECTION 1 FRAME15 7000287 4 Thrustwasher16 7000288 2 Thrustwasher17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)18 Not Used19

6-8 800S 860SJ 3121270SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD 315434353133443320203155134019401732524334313131312315373101

3121270 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 3121270SECTION 6 HYDRAULIC41 2 Hose Options:2753628 Without Arctic Package2754720 With Arctic Package42 3 Hose Options:2753970 Without

3121270 800S 860SJ 6-11SECTION 6 HYDRAULICFIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-12 800S 860SJ 3121270SECTION 6 HYDRAULICFIGURE 6-4. MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL) 13151310945678881111262664414

3121270 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 3121270SECTION 6 HYDRAULICFIGURE 6-5. STANDARD HYDRAULIC DIAGRAM 23826369103771025154551041033510117143241182124411534223112025

3121270 800S 860SJ 6-15SECTION 6 HYDRAULICFIGURE 6-5. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref STANDARD HYDRAULIC DIAGRA

6-16 800S 860SJ 3121270SECTION 6 HYDRAULIC17 1 Fitting Options:2131210 Fitting, Elbow (USA Built Machines SN 0300140000 to SN 0300176302 Only & Ch

3121270 800S 860SJ 6-17SECTION 6 HYDRAULIC46 2753681 1 Hose47 2753682 1 Hose48 2753683 1 Hose49 2753684 1 Hose50 2110608 1 Fitting, Straight51 2753590

3121270 800S 860SJ 1-17SECTION 1 FRAME201 AR Repair Kit Options:201A Use 7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural Colored Springs) (w

6-18 800S 860SJ 3121270SECTION 6 HYDRAULICFIGURE 6-6. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Diagrams with ast

3121270 800S 860SJ 7-1SECTION 7ELECTRICAL

7-2 800S 860SJ 3121270SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LISTITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GENERATOR ELECTRICAL DIAGRAM

3121270 800S 860SJ 7-3SECTION 7 ELECTRICALFIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

7-4 800S 860SJ 3121270SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION 335334J5J6J7J2J2J1J8J1J8218327326336P218D218E218C218BPLATFO

3121270 800S 860SJ 7-5SECTION 7 ELECTRICAL 453BOSCH FUELREGULATOR(GM) FUELREGULATOR(GM HARNESS)447449610335418335438423433602B602A602C602D334MAIN

7-6 800S 860SJ 3121270SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM CONSOLE BOX

3121270 800S 860SJ 7-7SECTION 7 ELECTRICALRef PLATFORM BOX HARNESS ASSEMBLY1001107796 Ref USA Built Machines SN 0300140000 to SN 0300161730 & Chin

7-8 800S 860SJ 3121270SECTION 7 ELECTRICAL1001117400 Ref Australian & CE Specs Only With 7500W Generator and Without Arctic PackageB0275586 Ref Al

3121270 800S 860SJ 7-9SECTION 7 ELECTRICAL229A 4460880 2 Connector, DIN229B 4460320 1 Plug, Male - 2 Position4460226 2 Socket, Female229C 4460424 1 Co

1-18 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) 3413401938303433323132311811411129107A1316151714786255

7-10 800S 860SJ 3121270SECTION 7 ELECTRICAL234 (cont’d) 4923466 With Arctic Package4460464 2 Pin, Male 4460897 1 Receptacle, Female - 2 Position235 AR

3121270 800S 860SJ 7-11SECTION 7 ELECTRICAL334D 4460834 1 Connector, Female - 2 Position4460842 2 Terminal, Female334E 4460871 22 Socket, Female334F 4

7-12 800S 860SJ 3121270SECTION 7 ELECTRICAL337 1 Ground Control Box Wiring Diagram (Not Shown - See Items 501 to 513 for Breakdown)1001110344 Caterpil

3121270 800S 860SJ 7-13SECTION 7 ELECTRICAL446 4461157 1 Receptacle, Female - 2 Position4460979 2 Pin, Male4460458 2 Seal, Terminal447 4461121 1 Plug,

7-14 800S 860SJ 3121270SECTION 7 ELECTRICAL511B 4460424 1 Receptacle, Female - 2 Position512 Not Used513 4460894 1 Plug, Male - 6 Position4460892 1 Co

3121270 800S 860SJ 7-15SECTION 7 ELECTRICAL604B 4460891 1 Plug, Male - 2 Position4460465 2 Socket, Female604C 4460891 1 Plug, Male - 2 Position4460465

7-16 800S 860SJ 3121270SECTION 7 ELECTRICAL703 0257887 1 Alarm Harness (Includes Alarm)0140032 1 Alarm2820035 6in/15cm Loom703A 4460424 1 Plug, Male -

3121270 800S 860SJ 7-17SECTION 7 ELECTRICAL707A 4460205 1 Plug, Male 707B 4460134 1 Receptacle, Female708 AC to Platform Receptacle Components Options

7-18 800S 860SJ 3121270SECTION 7 ELECTRICAL708B cont’d 4461198 1001091969, 1001100326 Installations4461201 1001091970, 1001100327 InstallationsUse 100

3121270 800S 860SJ 7-19SECTION 7 ELECTRICAL708H 1 Connector, Adapter Options:Not Required 0272259 & 0272260 InstallationsNot Required 0256202 Inst

3121270 800S 860SJ 1-19SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DRIVE MOTOR ASSEM

7-20 800S 860SJ 3121270SECTION 7 ELECTRICAL708L 2 Cover, Connector Options (ANSI Export, Australian & CE Specs):1671092 USA Built Machines SN 0300

3121270 800S 860SJ 7-21SECTION 7 ELECTRICAL710B 2.5ft/.76m Cable, Electrical 10/31060708 60Hz SpecSee Note 50Hz Spec (Note: Not Available - Purchase L

7-22 800S 860SJ 3121270SECTION 7 ELECTRICAL713E 1 Harness, Connector to Aux Relay Options:4922873 800S Harness (85ft/25.9m of 10/3 Cable P/N 1060708)

3121270 800S 860SJ 7-23SECTION 7 ELECTRICAL803 4460467 1 Extractor, Pin (Blue 16-18 Gauge) (For Removal of Pin/Socket from Connectors) (Not Shown)804

7-24 800S 860SJ 3121270SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 8-1SECTION 8DECALS

8-2 800S 860SJ 3121270SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) 20505695737569548474651254752232333204735323082545536392418749

3121270 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 3121270SECTION 8 DECALS33 Continued 2 Decal Capacity Options:860SJ - Decal - 500LBS Maximum Capacity1704995 USA Built Machines SN 03001

3121270 800S 860SJ 8-5SECTION 8 DECALS53 1 Decal - Fuel1701505 Diesel1701542 Gas54 1701543 1 Decal - LP Gas (GM Engine Machines Only)55 1700818 2 Deca

1-20 800S 860SJ 3121270SECTION 1 FRAME25 2220883 1 Plug (Includes Item 26)26 Use 7022328 1 O-Ring27 2220888 2 Plug (Includes Item 28)28 Use 7022328 2

8-6 800S 860SJ 3121270SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC) 4735323082545517363924187493124231326111262224940BOTHSIDES3

3121270 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 3121270SECTION 8 DECALS19 Not Used20 2 Decal - No Hands Options:1705967 Brazil Spec (English/Portuguese)1001116846 Chinese Spec (Tradit

3121270 800S 860SJ 8-9SECTION 8 DECALS26 1 Decal - USA Options:3251813 Brazil/Chinese/CSA/Japanese/Korean/Latin American Spec (USA Built Machines SN

8-10 800S 860SJ 3121270SECTION 8 DECALSContinued 860SJ - Decal - 500LBS Maximum Capacity1001122509 Korean Spec1001122511 Latin American Spec34 1 Decal

3121270 800S 860SJ 8-11SECTION 8 DECALS43 0641408 1 Bolt 1/4in-20NC x 1in (USA Built Machines SN 0300140000 to SN 0300179244 Only & China Built Ma

8-12 800S 860SJ 3121270SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPEC) 5041937954847464543512547522323334735232439732

3121270 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 3121270SECTION 8 DECALS42 3251242 1 Decal - 240V-50Hz 43 0641408 1 Bolt 1/4in-20NC x 1in (USA Built Machines SN 0300140000 to SN 03001

3121270 800S 860SJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 800S/860SJThe following list will service one machine (built to current production

3121270 800S 860SJ 1-21SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

9-2 800S 860SJ 3121270SECTION 9 RECOMMENDED SERVICE PARTS STOCK4360336 Switch, Toggle (Machines with Generator Option) (Figures 2-19, 2-20, 2-21, 2-22

3121270 800S 860SJ 10-1SECTION 10SPECIAL OPTIONS

10-2 800S 860SJ 3121270SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applic

3121270 800S 860SJ 10-3SECTION 10 SPECIAL OPTIONSRef ClearSky (Telematics) Kit (Dealer Installed) 1001119939 Ref ANSI Spec1001139151 Ref Australian Sp

10-4 800S 860SJ 3121270SECTION 10 SPECIAL OPTIONS1001151082 Ref Decal - Titan Rentals (ANSI & CSA Specs)0271815 Ref Decal - United Rentals (ANSI &

3121270 800S 860SJ 10-5SECTION 10 SPECIAL OPTIONSRef Footswitch Shield Installation4060959 1 Shield, Footswitch (USA Built Machines SN 0300140000 toSN

10-6 800S 860SJ 3121270SECTION 10 SPECIAL OPTIONSRef Platform Mesh To Mid Rail Installation (Side Entry Platform)1001140318 Ref 800S/860SJ - 2.5ftx4ft

3121270 800S 860SJ 10-7SECTION 10 SPECIAL OPTIONSContinued Ref Sky Accessory:1001115388 Ref SkyPower - 7500W 60Hz (Deutz Engine) (ANSI & CSA Specs

10-8 800S 860SJ 3121270SECTION 10 SPECIAL OPTIONSRef Weld Leads at Platform Installations0271487 Ref 800S0271488 Ref 860SJNote: This list is to accomm

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-1SECTION 11 PARTS NUMBER INDEX0060048 ...3-11, 3-1900

1-22 800S 860SJ 3121270SECTION 1 FRAMEORVALVE ROTATED FOR CLARITYVALVE ROTATED FOR CLARITY12C12B1211121021311212A12C12D1311211110111C111A111B111C111D1

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX0641414 ... 4-11, 4-250

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-3SECTION 11 PARTS NUMBER INDEX7-221001094798 ...

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX1001116344 ... 2-751

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-5SECTION 11 PARTS NUMBER INDEX1060626 ...2-19, 2-2510

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX1706062 ... 2-25, 8-111

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-7SECTION 11 PARTS NUMBER INDEX2754240 ...

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX3520030 ... 2-

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-9SECTION 11 PARTS NUMBER INDEX4420051 ...1-25, 8-1344

PagePart Number PagePart Number PagePart NumberPagePart Number11-10 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX4711600 .1-3, 1-7, 2-4, 2-17, 2-1

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-11SECTION 11 PARTS NUMBER INDEX7000213 ... 1

3121270 800S 860SJ 1-23SECTION 1 FRAMEFIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.0273378 Ref DRIVE V

PagePart Number PagePart Number PagePart NumberPagePart Number11-12 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX7007633 ... 2

PagePart Number PagePart Number PagePart NumberPagePart Number3121270 800S 860SJ 11-13SECTION 11 PARTS NUMBER INDEX7023948 ... 2

PagePart Number PagePart Number PagePart NumberPagePart Number11-14 800S 860SJ 3121270SECTION 11 PARTS NUMBER INDEX

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

3121270 800S 860SJ AREVISION LOGNOTES:NOTE: USA Built Machines with SNs 0300174290, 0300180894 & 0300181347 are also built to the same specs asUSA

1-24 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-7. TOW PACKAGE INSTALLATION 10212111311311411411711211211511512010310510510410911010610610610610

3121270 800S 860SJ 1-25SECTION 1 FRAMEFIGURE 1-7. TOW PACKAGE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TOW BAR INSTALLATION0271354 Ref

1-26 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-7. TOW PACKAGE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121270 800S 860SJ 2-1SECTION 2TURNTABLE

2-2 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-1. CONTROL VALVES INSTALLATIONS 8191913719191151616156181022222122520122022322421722720921321

3121270 800S 860SJ 2-3SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref VALVES INSTAL

2-4 800S 860SJ 3121270SECTION 2 TURNTABLE18 AR Flatwasher Options:4711400 3 Flatwasher 1/4in Thin4711600 4 Flatwasher 3/8in Thin19 4751600 10 Flatwash

3121270 800S 860SJ 2-5SECTION 2 TURNTABLE214 Not Used215 4641263 1 Valve, Metering216 4751400 2 Flatwasher 1/4in Regular217 4751500 4 Flatwasher 5/16i

2-6 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY 18936825471613151115121410141718517A

3121270 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 3121270REVISION LOG

2-8 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION 201202203204FRAME REF.27865301302303103105305105104

3121270 800S 860SJ 2-9SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TURNTABLE WELD

2-10 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-4. SWING MOTOR/HUB ASSEMBLY11G1A1B1E1H1I1C233A4481111545A612201J24253B3B3E3G3C3C3F3D13

3121270 800S 860SJ 2-11SECTION 2 TURNTABLE 318K8J30352122233212011911711811611411511311211010910810710610510310410410410410410210128292829200A2

2-12 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-4. SWING MOTOR/HUB ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001101060 Ref SWING MOTOR/HUB

3121270 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 3121270SECTION 2 TURNTABLEFIGURE 2-5. CATERPILLAR ENGINE INSTALLATION70357064395638557476322321327606074029426251621348A69693370707732

3121270 800S 860SJ 2-15SECTION 2 TURNTABLE SUPPLYTANK REF.10711540472737161215A215B215B215C215D614426214426210612135827242453531171191041011110

2-16 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-5. CATERPILLAR ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001109065 Ref CATERPILL

3121270 800S 860SJ 2-17SECTION 2 TURNTABLE42 3311605 AR Locknut 3/8in-16NC43 3311801 1 Nut 1/2in-13NC44 3311805 4 Locknut 1/2in-13NC45 3574206 1 Plate

3121270 800S 860SJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18 800S 860SJ 3121270SECTION 2 TURNTABLERef CATERPILLAR TIER IVi ENGINE INSTALLATIONS1001110212 Ref Machines Without Arctic Package D1001110213 Ref

3121270 800S 860SJ 2-19SECTION 2 TURNTABLE207 3600410 1 Piston Pump Assembly (See PUMP ASSEMBLY (SAUER-DANFOSS) PUMP) for Breakdown)208 3600411 1 Load

2-20 800S 860SJ 3121270SECTION 2 TURNTABLE317 4811900 5 Flatwasher M8318 4812000 2 Flatwasher M10319 4812100 2 Flatwasher M12320 4811600 1 Flatwasher

3121270 800S 860SJ 2-21SECTION 2 TURNTABLE409 7026802 1 Flywheel7026803 1 Gear, Flywheel7026804 1 Gasket (Not Shown - Between Flywheel Housing & E

2-22 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-6. DEUTZ ENGINE INSTALLATION20820925625624024710924322325623722622622722722522321525926220920925625

3121270 800S 860SJ 2-23SECTION 2 TURNTABLE VENTRETURNFUEL PUMPSUPPLIEDWITHENGINE325620923725620923772525721624652182419217217248248161412159916

2-24 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-6. DEUTZ ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DEUTZ ENGINE INSTALLATIONR

3121270 800S 860SJ 2-25SECTION 2 TURNTABLE29 1001093382 2 Bolt, Battery Hold-down30 Not Used31 1320176 1 Clamp32 1001101948 1 Tube, Exhaust33 1 Decal

2-26 800S 860SJ 3121270SECTION 2 TURNTABLE101 0100011 AR Compound, Locking102 0641407 1 Bolt 1/4in-20NC x 7/8in103 0641812 2 Bolt 1/2in-13NC x 1-1/2in

3121270 800S 860SJ 2-27SECTION 2 TURNTABLERef ENGINE AND PUMP ASSEMBLIES Ref Tier III/Tier IVi Engines1001098508 Ref Without Arctic Package (USA Built

ii 800S 860SJ 3121270FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS4-7 PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . .4

2-28 800S 860SJ 3121270SECTION 2 TURNTABLE230 AR Hose, Oil Drain Options:1001091892 6in/15cm USA Built Machines SN 0300140000 to SN 0300141456 Only275

3121270 800S 860SJ 2-29SECTION 2 TURNTABLE257 1001094321 1 Tray, Engine258 4791400 6 Starwasher 1/4in259 4812200 10 Flatwasher M14260 4845395 1 Adapte

2-30 800S 860SJ 3121270SECTION 2 TURNTABLE401 7026631 1 Dipstick7020487 1 O-Ring, Dipstick402 7020465 1 Cap, Filler403 70001850 1 Pump, Oil Lube702046

3121270 800S 860SJ 2-31SECTION 2 TURNTABLE421 7020459 1 Thermostat422 Not Used423 70001870 1 Flywheel424 7024579 1 Rim, Gear425 to 426 Not Used427 700

2-32 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-7. GM ENGINE INSTALLATION 219228204216226256244216113113114216215215 (NOT SHOWN)2152212272372172252

3121270 800S 860SJ 2-33SECTION 2 TURNTABLE 2934203B123472424635114025RETURN ON FUEL TANKTO ENGINE106FRONT ENGINEMTG BOLTAUX RELAYMTG BOLTBATTER

2-34 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-7. GM ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001114634 Ref GM 3.0L TIER III/i

3121270 800S 860SJ 2-35SECTION 2 TURNTABLE408.5ft/2.6mHose, Fuel Line Options:1001091587 SN 0300140000 to SN 03001818501001156819 SN 0300181850 to SN

2-36 800S 860SJ 3121270SECTION 2 TURNTABLE201 0080201 1 Adapter, Elbow202 0100011 AR Compound, Locking203 1001114595 1 Engine, GM 3.0L (See GM Engine

3121270 800S 860SJ 2-37SECTION 2 TURNTABLE241 4060805 3ft/0.9m Flex-Trim242 4341239 1 Tray, Engine243 4341241 1 Mount, Engine (Front)244 1001116545 1

3121270 800S 860SJ 1-1SECTION 1 FRAME

2-38 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS) 150215101509150815111503155604120412031201A1201122030411041

3121270 800S 860SJ 2-39SECTION 2 TURNTABLEFIGURE 2-8. PUMP ASSEMBLY (SAUER-DANFOSS)ITEM # PART NUMBER QTY. DESCRIPTION REV.3600295 Ref PUMP ASSEMBLIE

2-40 800S 860SJ 3121270SECTION 2 TURNTABLE159 7007454 1 Cover, Front160 to 162 Not Used163 7021207 6 Screw164 Not Used165 7021208 2 Spring (Part of It

3121270 800S 860SJ 2-41SECTION 2 TURNTABLE1004to1102Not Used1103 7010122 1 SCR Kit (Includes items 166, 106 & 165)1104 7010122 1 SCR Kit (Includes

2-42 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-9. PUMP ASSEMBLY (EATON)

3121270 800S 860SJ 2-43SECTION 2 TURNTABLEFIGURE 2-9. PUMP ASSEMBLY (EATON)ITEM # PART NUMBER QTY. DESCRIPTION REV.1001142522 Ref PUMP ASSEMBLY B1Not

2-44 800S 860SJ 3121270SECTION 2 TURNTABLE53 70004346 1 Orifice54 Not Used55 70004347 1 Coupler56 Not Used57 See Note 2 Plug (Note: Not Available for

3121270 800S 860SJ 2-45SECTION 2 TURNTABLEFIGURE 2-9. PUMP ASSEMBLY (EATON) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-46 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-10. LOAD SENSING PUMP ASSEMBLY

3121270 800S 860SJ 2-47SECTION 2 TURNTABLEFIGURE 2-10. LOAD SENSING PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600324 Ref LOAD SENSING PUM

1-2 800S 860SJ 3121270SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE 8121310111711211611521649141519119107210215

2-48 800S 860SJ 3121270SECTION 2 TURNTABLE404 7022318 1 Plug404A Use 7023967 1 O-Ring405 7023961 1 Pin— — — — — — — — — — 501 7023962 1 Ring, Retainin

3121270 800S 860SJ 2-49SECTION 2 TURNTABLEFIGURE 2-10. LOAD SENSING PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-50 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-11. TANK INSTALLATIONS 21139201101248106107A112131110710410510810910310210176STANDARDMACHINE

3121270 800S 860SJ 2-51SECTION 2 TURNTABLEFIGURE 2-11. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TANKS INSTALLATION 0270881 Ref D

2-52 800S 860SJ 3121270SECTION 2 TURNTABLE109 7024440 1 GasketRef FUEL TANK CAP INSTALLATION201 1 Cap Options:7016314 Standard Non-Locking (Part of It

3121270 800S 860SJ 2-53SECTION 2 TURNTABLEFIGURE 2-11. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-54 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-12. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) 2116111129208675414221013121718151933333

3121270 800S 860SJ 2-55SECTION 2 TURNTABLEFIGURE 2-12. LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.0255524

2-56 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-13. ROTARY COUPLING INSTALLATION 112117126126 1271251231241241181161191211201131141041011010

3121270 800S 860SJ 2-57SECTION 2 TURNTABLEFIGURE 2-13. ROTARY COUPLING INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001107531 Ref ROTARY COUP

3121270 800S 860SJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.0258286 Re

2-58 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-14. GROUND CONTROL BOX ASSEMBLY 143231414030303019242328101822313711895526272925151317161233

3121270 800S 860SJ 2-59SECTION 2 TURNTABLEFIGURE 2-14. GROUND CONTROL BOX ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GROUND CONTROL BOX ASSE

2-60 800S 860SJ 3121270SECTION 2 TURNTABLE10 2420172 1 Gauge, Hourmeter11 2760105 1 Housing, Display Light12 3300205 4 Nut, Retainer13 3300408 AR Lock

3121270 800S 860SJ 2-61SECTION 2 TURNTABLE37 1 Ground Control Box Wiring Diagram (Not Shown - See ELECTRICAL SECTION for Breakdown)1001110344 Caterpil

2-62 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS 800SAB36621210411588999F256257258259260

3121270 800S 860SJ 2-63SECTION 2 TURNTABLEFIGURE 2-15. LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref EL

2-64 800S 860SJ 3121270SECTION 2 TURNTABLE204 4711400 4 Flatwasher 1/4in Thin205 to 210 Not Used0270805 Ref STROBE LIGHT INSTALLATION (AMBER) (OPTIONA

3121270 800S 860SJ 2-65SECTION 2 TURNTABLE252 0902206 2 Bracket, Mounting253 0642612 1 Bolt 1in-8NC x 1-1/2in254 4220162 2 Spacer255 0100011 AR Compou

2-66 800S 860SJ 3121270SECTION 2 TURNTABLEFIGURE 2-16. HOODS INSTALLATION (ABS) 374834647474747472663030481544433441304741304791348483120314548

3121270 800S 860SJ 2-67SECTION 2 TURNTABLE482031483112323846295394816402845732124850474929483248748324832144334442473048377748114832481147664730474730