Illustrated Parts Manual

Models
800S
860SJ
3121140
August 22, 2008

REVISION LOG
October 15, 2001 - Original Issue Of Manual (Edited to B/M 0010575 Revision 3)
December 15, 2001 - Revised Manual (Edited to B/M 0010575 Revision 7)
April 25, 2002 - Revised Manual (Edited to B/M 0010575 Revision 14)
November 19, 2002 - Revised Manual (Edited to B/M 0010575 Revision 22)
April 9, 2003 - Revised Manual (Edited to B/M 0010575 Revision 23)
September 5, 2003 - Revised Manual (Edited to B/M 0010575 Revision 36)
December 18, 2003 - Revised Manual (Edited to B/M 0010575 Revision 37)
March 5, 2004 - Revised Manual (Edited to B/M 0010575 Revision 37)
August 2, 2004 - Revised Manual (Edited to B/M 0010575 Revision 42)
November 1, 2004 - Revised Manual (Edited to B/M 0010575 Revision 42)
March 15, 2005 - Revised Manual (Edited to B/M 0010575 Revision 50)
September 16, 2005 - Revised Manual (Edited to B/M 0010575 Revision 61)
March 10, 2006 - Revised Manual (Edited to B/M 0010575 Revision 67)
June 5, 2006 - Revised Manual (Edited to B/M 0010575 Revision 67)
October 5, 2006 - Revised Manual (Edited to B/M 0010575 Revision 70)
March 1, 2007 - Revised Manual (Edited to B/M 0010575 Revision 73)
June 14, 2007 - Revised Manual (Edited to B/M 0010575 Revision 79)
October 5, 2007 - Revised Manual (Edited to B/M 0010575 Revision 81)
March 1, 2008 - Revised Manual (Edited to B/M 0010575 Revision 81)
August 22, 2008 - Revised Manual (Edited to B/M 0010575 Revision 96)

3121140

800S 860SJ

REVISION LOG

800S 860SJ

3121140

TABLE OF CONTENTS
FIGURE NO.

TITLE

PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12

AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE . . . . . . . . . . . . . .

AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . . .
TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE HUB ASSEMBLY (2WD PRIOR TO S/N 83331) . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO S/N 83331) . . . . . . . . . . . . . . . . . .
DRIVE HUB/BRAKE ASSEMBLY (S/N 83331 TO PRESENT) . . . . . . . . . . . . . . . . . . . .
DRIVE MOTOR ASSEMBLY (2WD PRIOR TO S/N 83331) . . . . . . . . . . . . . . . . . . . . . .
DRIVE MOTOR ASSEMBLY (2WD S/N 83331 TO S/N 98641 &
ALL 4WD MACHINES) (4 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME VALVES & SHIELDS INSTALLATIONS (PRIOR TO S/N 83331) . . . . . . . . . . .
FRAME VALVES & SHIELDS INSTALLATIONS (S/N 83331 TO PRESENT). . . . . . . . .
TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2
1-6
1-10
1-14
1-18
1-22
1-26
1-28
1-32
1-36
1-38
1-40

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-24
2-25
2-26
2-27
2-28
2-29
2-30
2-31
2-32

3121140

CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWING HUB ASSEMBLY (PRIOR TO S/N 66417) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWING MOTOR ASSEMBLY (PRIOR TO S/N 66417). . . . . . . . . . . . . . . . . . . . . . . . . .
SWING MOTOR/HUB ASSEMBLY (S/N 66417 TO S/N 0300134352) . . . . . . . . . . . . .
SWING MOTOR/HUB ASSEMBLY (S/N 0300134352 TO PRESENT) . . . . . . . . . . . . .
CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEUTZ ENGINE INSTALLATION (PRIOR TO S/N 77586) . . . . . . . . . . . . . . . . . . . . . .
DEUTZ ENGINE INSTALLATION (S/N 77586 TO PRESENT). . . . . . . . . . . . . . . . . . . .
FORD ENGINE INSTALLATION (PRIOR TO S/N 79612) . . . . . . . . . . . . . . . . . . . . . . .
FORD ENGINE INSTALLATION (S/N 79612 TO PRESENT) . . . . . . . . . . . . . . . . . . . .
DUAL FUEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTARY COUPLING INSTALLATION (PRIOR TO S/N 83331) . . . . . . . . . . . . . . . . . . .
ROTARY COUPLING INSTALLATION (S/N 83331 TO PRESENT) . . . . . . . . . . . . . . . .
GROUND CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . .
HOODS INSTALLATION (PRIOR TO S/N 89982) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOODS INSTALLATION (S/N 89982 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL). . . .
2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL). . . . . . . . . .
2500W GENERATOR INSTALLATION - FORD MACHINES (PRIOR TO S/N 79612)
(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500W GENERATOR INSTALLATION - FORD MACHINES
(S/N 79612 TO PRESENT) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL). . . . . . . . . . . . .
7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR &
DEUTZ ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES . . . . . . . . . . . .
7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES . . . . . . . . . . . . . .

800S 860SJ

2-2
2-6
2-8
2-12
2-14
2-16
2-22
2-26
2-34
2-38
2-48
2-54
2-60
2-64
2-72
2-76
2-80
2-84
2-86
2-90
2-96
2-100
2-106
2-112
2-114
2-118
2-124
2-128
2-132
2-136
2-142
2-146

TABLE OF CONTENTS
FIGURE NO.

TITLE

PAGE NO.

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1
3-2
3-3
3-4
3-5
3-6
3-7

TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . 3-2

MAIN BOOM INSTALLATION - 800S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
MAIN BOOM INSTALLATION - 860SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
ROTATOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . 3-22
BOOM CABLE CLAMPS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9

PLATFORM ASSEMBLIES (FRONT ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . 4-2

PLATFORM ASSEMBLIES - SIDE ENTRY (S/N 67916 TO PRESENT) . . . . . . . . . . . . . 4-6
PLATFORM COMPONENTS INSTALLATION (FALL ARRREST PLATFORM) . . . . . . . . 4-10
PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CONTROLLER ASSEMBLY (LIFT AND SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL) . . . . . . . . . 4-22
SOFT TOUCH SYSTEM INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) . . . 4-26
PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL) . . . . 4-28

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1
5-2
5-3
5-4
5-5
5-6

AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
LEVEL CYLINDER ASSEMBLY - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8

AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

DRIVE HYDRAULIC DIAGRAM - 2WD (PRIOR TO S/N 83331) . . . . . . . . . . . . . . . . . . . 6-4
DRIVE HYDRAULIC DIAGRAM - 2WD (S/N 83331 TO PRESENT) . . . . . . . . . . . . . . . . 6-8
DRIVE HYDRAULIC DIAGRAM - 4WD (PRIOR TO S/N 83331) . . . . . . . . . . . . . . . . . . . 6-12
DRIVE HYDRAULIC DIAGRAM - 4WD (S/N 83331 TO PRESENT) . . . . . . . . . . . . . . . . 6-16
MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . 6-20
STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
HYDRAULIC DIAGRAM LIST
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1
7-2
7-3
7-4
7-5
7-6

ii

ELECTRICAL DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

ELECTRICAL SCHEMATIC (CATERPILLAR/FORD/DEUTZ) (PRIOR TO S/N 99882) . . 7-4
ELECTRICAL SCHEMATIC (DEUTZ EMR2 & GM) (S/N 85332 TO S/N 99882) . . . . . . 7-8
ELECTRICAL SCHEMATIC (CATERPILLAR, DEUTZ EMR2 & GM)
(S/N 99882 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
HARNESS COMPONENTS INSTALLATION (PRIOR TO S/N 85332) . . . . . . . . . . . . . . 7-20
HARNESS COMPONENTS INSTALLATION (S/N 85332 TO PRESENT) . . . . . . . . . . . 7-32

800S 860SJ

3121140

TABLE OF CONTENTS
FIGURE NO.

TITLE

PAGE NO.

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8-1
8-2
8-3
8-4

DECAL INSTALLATION (ANSI SPEC) (PRIOR TO S/N 88933). . . . . . . . . . . . . . . . . . .

DECAL INSTALLATION (ANSI SPEC)(S/N 88933 TO PRESENT) . . . . . . . . . . . . . . . .
DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO S/N 88933) . . . . . . . . . . . . . .
DECAL INSTALLATION (COUNTRY SPEC) (S/N 88933 TO PRESENT) . . . . . . . . . . .

8-2
8-6
8-10
8-16

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10-1
10-2

SPECIAL OPTIONS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

SKY WELDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3121140

800S 860SJ

iii

TABLE OF CONTENTS
FIGURE NO.

iv

TITLE

800S 860SJ

PAGE NO.

3121140

SECTION 1
FRAME

3121140

800S 860SJ

1-1

SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

501

101
103

106
6
118
17

110
7

1
5
104
201

113

111

106
6

11
114

113

107

201
203
212
209

101
103

109

205
202

107

209
218

213
9
14
15

10

112 117
105
115 116
8 16
12
101
219 13
2
216
1

207

205

218

201
201 204
203

206
212
201
203
212
210

201
203
212

1
4

211

208
19
119

307

401
206
217

407
404
403

215
214
207
215

211
201
204

316

402
405
406
410
411
412
409

302
304
408
309

1-2

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE
ITEM #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

PART NUMBER

QTY.

0258286

Ref.

0100011
0681608
Not Used
0641820
0642212
0962102
3422703
3538047
3539877
3539878
3841287
4070878
4070879
4070944
4070945
4711600
4740472
Not Used
4845658

A/R
4

Loctite #242
Bolt 3/8-16NC x 1 (Grade 8)

2
1
2
1
2
2
2
1
A/R
A/R
A/R
A/R
4
1

Bolt 1/2-13NC x 2 1/2

Bolt 3/4-10NC x 1 1/2
Bushing, Garmax
Pin, Axle Pivot
Shim, Wear
Plate, Stop
Plate, Stop
Keeper, Pin
Shim 1/16
Shim 1/8
Shim 1/16
Shim 1/4
Flatwasher 3/8 Narrow
Washer, Special

0271135
0274571
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119

3121140

0100011
0100019
0641608
0642212
0681608
0962102
1683078
Not Used
3422702
3422703
3422755
3538047
3841143
3841287
4070878
4070879
4711600
4740472
4845658

1
Ref.
Ref.
Ref.
A/R
A/R
4
1
4
2
2
2
1
2
2
4
1
2
2
4
1
1

DESCRIPTION
FIXED AXLE INSTALLATION

REV.
C

Axle Weldment
OSCILLATING AXLE INSTALLATION
Prior to S/N 83331
S/N 83331 to Present

B
A

Loctite #242
Loctite #271
Bolt 3/8-16NC x1
Bolt 3/4-10NC x 1 1/2
Bolt 3/8-16NC x1 (Grade 8)
Bushing, Garmax
Lockout Cylinder Assembly (See Section 5 for Breakdown)
Pin
Pin, Main Pivot
Pin
Shim, Axle Wear
Shaft, Keeper 3/8 Dia x 3
Shaft, Keeper 3/8 Dia x 6
Shim, Axle Wear
Shim, Axle Wear
Flatwasher 3/8 Narrow
Washer, Special
Axle Weldment

800S 860SJ

1-3

SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)
ITEM #

201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219

301
302
303
304
305 to 306
307
308
309
310 to 315
316

401
402
403
404
405
406
407
408
409
410
411
412

1-4

PART NUMBER

QTY.

0272003

Ref.

0100011
0362726
0641608
0641810
0962152
0962224
1683740
3422701
3422702
3422754
3422849
3841143
4130389
4130390
4740111
4740256
4740463
4740473
1001103810

A/R
1
6
16
4
2
2
2
2
2
4
6
1
1
4
A/R
2
2
2

0271341

Ref.

Not Used
0100019
Not Used
0682016
Not Used
2780229
Not Used
3300007
Not Used
4892000

DESCRIPTION
STEERING INSTALLATIONS (2WS)

REV.
B

Loctite #242
Tie-Rod
Bolt 3/8-16NC x 1
Bolt 1/2-13NC x 1 1/4
Bearing
Bearing
Steer Cylinder Assembly (See Section 5 for Breakdown)
Pin, Steer, Spindle Attach
Pin, Tie-Rod
Pin, Attach
Kingpin
Shaft, Keeper 3/8 x 3
Spindle Weldment (RH)
Spindle Weldment (LH)
Washer, Special
Washer, Thrust
Washer, Special
Washer, Thrust
Washer, Thrust (S/N 0300134352 to Present)
HUB INSTALLATION (2WD ONLY)

A/R

Loctite #271

16

Bolt 5/8-16NC x 2 (Grade 8)

Hub Assembly (See Items 401-412 for Breakdown)

20

Lugnut

16

Flatwasher, Hardened 5/8

2780229

Ref.

HUB ASSEMBLY (2WD ONLY)

7017052
7017053
7010404
7010405
7017056
7017055
7010406
7000265
7017054
7017051
7017057
7017058

2
2
2
2
2
2
2
20
2
2
2
2

Spindle (1 per Assembly)

Housing (1 per Assembly)
Cup, Bearing - Inner (1 per Assembly)
Cone, Bearing - Inner (1 per Assembly)
Cup, Bearing - Outer (1 per Assembly)
Cone, Bearing - Outer (1 per Assembly)
Seal, Lip (1 per Assembly)
Stud (10 per Assembly)
Dust Cap (1 per Assembly)
Washer, Special (1 per Assembly)
Washer, Tanged (1 per Assembly)
Nut, Bearing (1 per Assembly)

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)
ITEM #

PART NUMBER

501

QTY.
Ref.
1

2360568
2360687
2360555
2360688
1
2360566
2360689
2360568
2360687

3121140

DESCRIPTION

REV.

FRAME WELDMENT OPTIONS

800S Options:
2WD Prior to S/N 83331
2WD S/N 83331 to Present
4WD Prior to S/N 83331
4WD S/N 83331 to Present
860SJ Options:
2WD Prior to S/N 83331
2WD S/N 83331 to Present
4WD Prior to S/N 83331
4WD S/N 83331 to Present

800S 860SJ

1-5

SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

501

101
103
113

111
106
110
106
118
114
102
104

113

107

201
204
218
212

101
103

109

205
201 220
204
211
218

202

107

212

225

209
223

221

222

206

218
216

204
218

222
208

230
229

226

101
116 112 117 105
115

205

225

207

201
203
217
201
204
207
218 215

201
204
218

201
227
213

210
119
201
228
201
204
218
214

407
404
403

224

209

307

401
206

219
213
201
227

402
405
406
410
411
412
409

301
304
408

221
309
221

1-6

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE
ITEM #

101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119

201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223

3121140

PART NUMBER

QTY.

0271353
0274572

Ref.
Ref.
Ref.

0100011
0100019
0641608
0642212
0681608
0962102
1683078
Not Used
3422702
3422703
3422755
3538047
3841143
3841287
4070878
4070879
4711600
4740472
4846413

A/R
A/R
4
1
4
2
2

0271352

Ref.

0100011
0362726
0641508
0641608
0962152
0962448
0962292
0962348
1683740
3422567
3422701
3422702
3422972
3422754
3422813
3422848
2573001
3841143
4130390
4130388
4740111
4740155
4740256

A/R
1
1
7
2
4
2
1
2
1
1
2
4
2
1
1
1
8
1
1
6
2
4

2
1
2
2
4
1
2
2
4
1
1

DESCRIPTION
OSCILLATING AXLE INSTALLATION
Prior to S/N 83331
S/N 83331 to Present

REV.
A
A

Loctite #242
Loctite #271
Bolt 3/8-16NC x1
Bolt 3/4-10NC x 1 1/2
Bolt 3/8-16NC x1 (Grade 8)
Bushing, Garmax
Lockout Cylinder Assembly (See Section 5 for Breakdown)
Pin
Pin, Main Pivot
Pin
Shim, Axle Wear
Shaft, Keeper 3/8 Dia x 3
Shaft, Keeper 3/8 Dia x 6
Shim, Axle Wear
Shim, Axle Wear
Flatwasher 3/8 Narrow
Washer, Special
Axle Weldment
STEERING INSTALLATION

Loctite #242
Tie-Rod
Bolt 5/16- 18NC x 1
Bolt 3/8-16NC x 1
Bearing, Garmax
Bearing, Garmax
Bearing, Garmax
Bearing, Garmax
Steer Cylinder Assembly (See Section 5 for Breakdown)
Pin, Steer Spindle Attach (RH)
Pin, Steer Spindle Attach (LH)
Pin, Tie-Rod
Kingpin
Pin, Attach
Pin
Pin, Hitch
Link, Connecting
Shaft, Keeper 3/8 x 3
Spindle Weldment (LH)
Spindle Weldment (RH)
Washer, Special
Washer, Thrust
Washer, Thrust

800S 860SJ

1-7

SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)
ITEM #

PART NUMBER

QTY.

224
225
226

4740463
4740473

2
2
1

227
228

229
230

301
302 to 303
304
305 to 306
307
308
309
310 to 315
316

401
402
403
404
405
406
407
408
409
410
411
412

4846414
4846935
0641810

16
4

2
4

0271341

Ref.

0100011
Not Used
0682016
Not Used
2780229
Not Used
3300007
Not Used
4892000

A/R

Loctite #242

16

Bolt 5/8-16NC x 2 (Grade 8)

Hub Assembly (See Items 401-412 for Breakdown)

20

Lugnut

16

Flatwasher, Hardened 5/8

2780229

Ref.

HUB ASSEMBLY (2WD ONLY)

7017052
7017053
7010404
7010405
7017056
7017055
7010406
7000265
7017054
7017051
7017057
7017058

2
2
2
2
2
2
2
20
2
2
2
2
Ref.
1

2360568
2360687
2360555
2360688
1
2360566
2360689
2360568

REV.

Washer, Thrust
Washer, Special
Bar, Pivot Options:
Prior to S/N 74135
S/N 74135 to Present
Bolt 1/2-13NC x 1 1/4
Screw Options:
Screw 3/8-16NC x 3/4 (S/N 70782 to S/N 74135)
Screw 3/8-16NC x 1 1/4 (S/N 74135 to Present)
Pad, Stop (S/N 70782 to Present)
Shim (S/N 70782 to Present)

0741607
0741609
3340966
4071059

501

1-8

DESCRIPTION

HUB INSTALLATION (2WD ONLY)

Spindle (1 per Assembly)

Housing (1 per Assembly)
Cup, Bearing - Inner (1 per Assembly)
Cone, Bearing - Inner (1 per Assembly)
Cup, Bearing - Outer (1 per Assembly)
Cone, Bearing - Outer (1 per Assembly)
Seal, Lip (1 per Assembly)
Stud (10 per Assembly)
Dust Cap (1 per Assembly)
Washer, Special (1 per Assembly)
Washer, Tanged (1 per Assembly)
Nut, Bearing (1 per Assembly)
FRAME WELDMENT OPTIONS
800S Options:
2WD Prior to S/N 83331
2WD S/N 83331 to Present
4WD Prior to S/N 83331
4WD S/N 83331 to Present
860SJ Options:
2WD Prior to S/N 83331
2WD S/N 83331 to Present
4WD Prior to S/N 83331

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)
ITEM #

PART NUMBER

501 (contd)

2360687

3121140

QTY.

DESCRIPTION

REV.

4WD S/N 83331 to Present

800S 860SJ

1-9

SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

8
1 16
4

11
11
10
1
12

101
104
112

101 113
105

9
6

108

2WD
PRIOR TO
S/N 83331

107
302
114

4WD
PRIOR TO
S/N 83331

206

201
204
214

106

208

213

201
203

304

305

301
209

303
306
307

1-10

2WD & 4WD

S/N 83331 TO
PRESENT

DETAIL OF
VALVE STEM
800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
ITEM #

1
2 to 3
4
5

6
7
8
9
10
11
12
13 to 15
16

101
102 to 103
104
105
106
107
108
109 to 111
112
113
114

PART NUMBER

QTY.

0271341

Ref.
Ref.
A/R

Loctite #242

16
2
1
2
2

Bolt 5/8-11NC x 2 (Grade 8)

Drive Brake Assembly (was p/n 0920117)
Kit, Repair
Gasket (Between Components)
Drive Hub Assembly (See Figure 1-4 for Breakdown)

2
20
4
4
4

Drive Motor Assembly (See Figure 1-7 for Breakdown)

Nut, Wheel
Nut 1/2 - 13 NC
O-Ring
Stud

16

Flatwasher 5/8

0271349

Ref.

0100011
Not Used
0681810
0682016
2780259
3160266
3790045
Not Used
4891800
4892000
3300007

A/R

Loctite #242

8
32
4
4
4

Bolt 1/2-13NC x 1 1/4 (Grade 8)

Bolt 5/8-11NC x 2 (Grade 8)
Drive Hub/Brake Assembly (See Figure 1-5 for Breakdown)
Drive Motor Assembly (See Figure 1-8 for Breakdown)
O-Ring

4
32
40

Flatwasher 1/2
Flatwasher 5/8
Nut, Wheel

0100011
Not Used
3311801
0682016
2300016
2780272
3020008
Use 3160347

3121140

WHEEL DRIVE INSTALLATION (PRIOR TO S/N 83331)

2WD (PRIOR TO S/N 83331)

0100011
Not Used
0682016
Use 0920119
70001800
7000731
2780227
Not Used
3160268
3300007
3311801
3790045
4300097
Not Used
4892000

0273378
0273704

201
202
203
204
205
206
207
208

DESCRIPTION

Ref.
Ref.
Ref.

4WD (PRIOR TO S/N 83331)

WHEEL DRIVE INSTALLATION (S/N 83331 TO PRESENT)

2WD
4WD
Note: 2WD Qty Shown. For 4WD, Double Qty Shown.

A/R

Loctite #242

4
16
A/R
2
A/R
2
2

Nut 1/2-13 NC
Bolt 5/8-11NC x 2 (Grade 8)
Fluid, Hydraulic (Not Shown)
Drive Hub Assembly (See Figure 1-6 for Breakdown)
Lubricant (Not Shown)
Drive Motor Assembly Options:
2WD Rear (Prior to S/N 98924 p/n was 3160308 - See Figure
1-8 for Breakdown) (S/N 98924 to Present p/n 3160347 - See
Figure 1-9 for Breakdown)

800S 860SJ

REV.
E

D
D

1-11

SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
ITEM #

PART NUMBER

QTY.

DESCRIPTION

208 (contd)

Use 3160348

209
210 to 212
213
214

3300007
Not Used
4891800
4892000

20

4WD Front & Rear (Prior to S/N 98641 p/n was 3160266 See Figure 1-8 for Breakdown) (S/N 98641 to Present p/n
3160348 - See Figure 1-9 for Breakdown)
Nut, Wheel

4
16

Flatwasher, 1/2 Hardened

Flatwasher 5/8 Hardened

0270885
0272322
0270886
0270888
0271419

Ref.
Ref.
Ref.
Ref.
Ref.
Ref.

0271083
0271084
0272334
0272333
0271085
0271086
0271090
0271091
0271419

2
2
2
2
2
2
2
2
4

301

1
1702701

302

303
304

305
306
307

1-12

1
4520252
4520253
4520256
4640113
4860224
4860225
4860230
1705364
1300019
1120552

1
1

A/R
A/R
A/R

REV.

TIRE AND WHEEL INSTALLATIONS

15-625 NHS Pneumatic
15-625 NHS Pneumatic W/Sealant
15-625 NHS Foam-Filled
18-625 NHS Foam-Filled
41/18LLx22.5 Sand & Turf Foam-Filled

A
1
A
A
B

15-625 NHS Pneumatic Left Side

15-625 NHS Pneumatic Right Side
15-625 NHS Pneumatic W/Sealant Left Side
15-625 NHS Pneumatic W/Sealant Right Side
15-625 NHS Foam-Filled Left Side
15-625 NHS Foam-Filled Right Side
18-625 NHS Foam-Filled Left Side
18-625 NHS Foam-Filled Right Side
41/18LLx22.5 Sand & Turf Foam-Filled
Note: Assemblies may require ballast/foam filling to
manufacturers specifications prior to installing on a
machine. Refer to Operation & Safety or Service &
Maintenance Manuals. Purchase individual tire and/or rim
only if able to foam fill tire & wheel assembly, otherwise,
purchase complete assembly.
Decal Options (Pneumatic Only):
95 PSI/6.5 Bar (15-625 Tires)
Tire Options:
15-625 Tire
18-625 Tire
41/18LLx22.5 Sand & Turf Tire
Valve, Air
Rim, Wheel Options:
13 x 24.5 Rim (Use with 15-625 Tires)
15 x 24.5 Rim (Use with 18-625 Tires)
22.5 x 14 (41/18LLx22.5 Sand & Turf Tires)
Decal - Tire Sealant (W/Sealant Only)
Chemical, Tire Sealant (Green) (W/Sealant Only)
Cap, Valve Stem (Green) (W/Sealant Only)

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
ITEM #

3121140

PART NUMBER

QTY.

DESCRIPTION

800S 860SJ

REV.

1-13

SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO S/N 83331)
6C
6D
6E

100

9
21
10

17

6F
6H

6B

6G
6A

20

11

20
2

5
1
4

1H
1E

5
15

1F

16
15

1G

3G

1J
3E

3A

1
1J

3B
3C
13
12

1N
3

1D

3D
3C

1C
3F
1B

3B

1A

15
16
15

19

1-14

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO S/N 83331)
ITEM #

1
1A
1B
1C
1D
1E
1F
1G
1H
1I
1J
1K
1L
1M
1N
2
3
3A
3B
3C
3D
3E
3F
3G
4
5
6
6A
6B
6C
6D
6E
6F
6G
6H
7
8
9
10
11
12
13
14
15
16
17
18

3121140

PART NUMBER

QTY.

DESCRIPTION

2780227

Ref.

DRIVE HUB ASSEMBLY (2WD)

Not Available
7010464
7000236
7000273
7000272
7000275
7000274
7017033
7000239
7000240
7001928
Not Used
Not Used
Not Used
7000265
7017034
Not Available
7017036
7001901
7001902
7001903
7017040
7017037
7001906
7017035
7000224
Not Available
7024155
7017042
7000220
7000231
7000235
7000213
7000238
7017048
7000282
7000283
7000284
7017027
7017039
7017041
7017038
Not Used
7000287
7000288
7000289
Not Used

1
1
1
1
1
1
1
1
1
1
1

Spindle/Housing Assembly
Spindle
Seal
Cone, Bearing
Cup, Bearing
Cone, Bearing
Cup, Bearing
Housing
Washer, Thrust
Ring, Retaining
Plug, Pipe

10
1
1
1
6
96
3
3
3
3
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
1
1
1

Stud, Wheel
Gear, Ring
Carrier Assembly
Carrier
Thrustwasher, Tanged
Bearing, Needle
Spacer, Thrust
Shaft, Planet
Gear, Cluster
Rollpin
Gear, Internal
O-Ring
Cover Assembly
Cover
Cap
Bolt 1/4-20NC x 3/4
Cap, Disengage
Rod, Disengage
O-Ring
O-Ring
Plug, Pipe
Thrustwasher
O-Ring
Ring, Retaining
Ring, Retaining
Shaft, Input
Spacer, Input
Gear, Sun

4
2
12

Thrustwasher
Thrustwasher
Bolt 3/8-16NC x 2 1/2 (Grade 8)

800S 860SJ

REV.
A

1-15

SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO S/N 83331) (CONTINUED)
ITEM #

PART NUMBER

QTY.

19
20
21

7000290
7017047
7017050

1
2
A/R
Ref.

100

1-16

7017068

DESCRIPTION

REV.

Coupling
Pin, Dowel
Thrustwasher
KIT OPTIONS:
Seal Kit

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (2WD PRIOR TO S/N 83331) (CONTINUED)
ITEM #

3121140

PART NUMBER

QTY.

DESCRIPTION

800S 860SJ

REV.

1-17

SECTION 1 FRAME
FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO S/N 83331)

1
101F
105

200

104
103 1C
1D

15 16 2 3B 3C

3F

3E

3D

17

3G

6A
6
18
21
6C
101A

6B

7
19

6D

102

6E
6F

106

6G
6H
101B
101C

13
11

101D
101E

12
3

1B

3A

107
1A

1J 5

22

20

4
10

1H 1I
1N

1G

201A
201B
201C
201D

14

8
23

GENUINE PARTS

1-18

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO S/N 83331)
ITEM #

1
1A
1B
1C
1D
1E to 1F
1G
1H
1I
1J
1K
1L
1M
1N
2
3
3A
3B
3C
3D
3E
3F
3G
4
5
6
6A
6B
6C
6D
6E
6F
6G
6H
7
8
9
10
11
12
13
14
15
16
17
18
19

3121140

PART NUMBER

QTY.

2780259

Ref.

DRIVE HUB ASSEMBLY (2WD)

Not Available
7024139
7024140
7024144
7024143
Not Used
7024142
7024137
7024141
7001928
Not Used
Not Used
Not Used
7000265
7024150
7024145
7024147
7001901
7001902
7001903
7024146
7024148
7001906
7024151
7000224
Not Available
7024155
7024156
7000220
7000231
7000235
7000213
7000238
7017048
7024106
7000283
7000284
7017027
7024152
7024154
7024149
7017050
7000287
7000288
7000289
7024108
7024153

1
1
1
2
2

Spindle/Housing Assembly
Spindle
Seal
Cone, Bearing
Cup, Bearing

1
1
1
1

10
1
1
1
6
84
3
3
3
3
1
2
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
12
1
1

DESCRIPTION

REV.
A

Housing
Washer, Thrust
Ring, Retaining
Plug, Pipe

Stud, Wheel
Gear, Internal
Carrier Assembly
Carrier
Thrustwasher, Tanged
Bearing, Needle
Spacer, Thrust
Shaft, Planet
Gear, Cluster
Rollpin
Gear, Ring
O-Ring
Cover Assembly
Cover
Cap
Bolt 1/4-20NC x 3/4
Cap, Disengage
Rod, Disengage
O-Ring
O-Ring
Plug, Pipe
Brake Assembly (See Items 101A - 108)
Spring
Ring, Retaining
Ring, Retaining
Shaft, Input
Spacer, Input
Gear, Sun
Washer, Thrust
Thrustwasher
Thrustwasher
Bolt 3/8-16NC x 2 1/2 (Grade 8)
Plug, Pressure
Coupling

800S 860SJ

1-19

SECTION 1 FRAME
FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO S/N 83331) (CONTINUED)
ITEM #

PART NUMBER

QTY.

20
21
22
23

7017047
7017082
7024138
7000282

2
1
1
1

7024106

Ref.

Use Item 201A

Use Item 201C
Use Item 201C
Use Item 201C
Use Item 201C
Use Item 201A
Use Item 201A
Not Serviced
Use Item 201B
Use Item 201A
Not Serviced
Use Item 201B
Use Item 201D

1
1
1
1
1
1
1
1
8
1
6
7
10

101A
101B
101C
101D
101E
101F
102
103
104
105
106
107
108

Ref.
200
201
201A
201B
201C
201D

1-20

7024720
7024719
7024710
7024709
7024711

1
A/R
1
1
1
1

DESCRIPTION

REV.

Pin, Dowel
Plug, O-Ring
Coupling
Thrustwasher
BRAKE ASSEMBLY
Internal Circlip
O-Ring
Back-Up Ring
O-Ring
Back-Up Ring
Internal Circlip
Plate. End
Piston
Plate, Outer
Spacer
Screw
Plate, Inner
Spring, Compression
KIT OPTIONS:
Seal Kit - Hub (Includes Items 1B, 1I & 5)
Repair Kit Options:
Hardware
Lining
O-Ring
Spring

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD PRIOR TO S/N 83331) (CONTINUED)
ITEM #

3121140

PART NUMBER

QTY.

DESCRIPTION

800S 860SJ

REV.

1-21

SECTION 1 FRAME
FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (S/N 83331 TO PRESENT)

9
21
10

6C
6D

17

6E

111
110

112

6F
6H

6
6B

121

102

11

6G
6A

122
123
2

20

119

20
104

1
1H

103

4
1E
106
5

1F

103

15

106

1G

16

26

1J

15

101

3G
1J
3
3A

1N

3E

3C

12

3D
3C

115

1D

3B
13

116

109
1C
118
117

1B
3F

15

1A

16

120

3B

107

15
108
114
113

19
201A
201B
201C
201D

105

27
200A
200B

31

28
29

GENUINE PARTS

1-22

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (S/N 83331 TO PRESENT)
ITEM #

1
1A
1B
1C
1D
1E
1F
1G
1H
1I
1J
1K
1L
1M
1N
2
3
3A
3B
3C
3D
3E
3F
3G
4
5
6
6A
6B
6C
6D
6E
6F
6G
6H
7
8
9
10
11
12
13
14
15
16
17

3121140

PART NUMBER

QTY.

DESCRIPTION

2780272

Ref.

DRIVE HUB/BRAKE ASSEMBLY

2780227
Not Available
7010464
7000236
7000273
7000272
7000275
7000274
7017033
7000239
7000240
7001928
Not Used
Not Used
Not Used
7000265
7024782
Not Available
7024147
7001901
7001902
7001903
7024146
7024148
7001906
7024151
7000224
Not Available
7024155
7024783
7000220
7000231
7000235
7000213
7000238
7017048
7000282
7000283
7000284
7000285
7024781
7024154
7024149
Not Used
7000287
7000288
7000289

Ref.
1
1
1
1
1
1
1
1
1
1
1

Hub Assembly
Spindle/Housing Assembly
Spindle
Seal
Cone, Bearing
Cup, Bearing
Cone, Bearing
Cup, Bearing
Housing
Washer, Thrust
Ring, Retaining
Plug, Pipe

10
1
1
1
6
96
3
3
3
3
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
1
1
1

Stud, Wheel
Gear, Ring
Carrier Assembly
Carrier
Thrustwasher, Tanged
Bearing, Needle
Spacer, Thrust
Shaft, Planet
Gear, Cluster
Rollpin
Gear, Internal
O-Ring
Cover Assembly
Cover
Cap
Bolt 1/4-20NC x 3/4
Cap, Disengage
Rod, Disengage
O-Ring
O-Ring
Plug, Pipe
Thrustwasher
O-Ring
Ring, Retaining
Ring, Retaining
Shaft, Input
Spacer, Input
Gear, Sun

4
2
12

Thrustwasher
Thrustwasher
Bolt 3/8-16NC x 2 1/2 (Grade 8)

800S 860SJ

REV.

1-23

SECTION 1 FRAME
FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (S/N 83331 TO PRESENT) (CONTINUED)
ITEM #

PART NUMBER

18
19
20
21
22 to 25
26
27
28
29
30
31

Not Used
7000290
7017047
7017050
Not Used
7024182
7024763
7024717
7024718
Not Used
7000731

101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123

QTY.
1
2
1

Brake Assembly (Includes Items 101-123)

O-Ring
Stud 1/2-13NC x 4 5/8
Nut 1/2-13NC

Gasket

7024182

Ref.

7024189
Not Available
Use Item 201C
Use Item 201C
7000731
Use Item 201C
See Note
7024191
7024192
Use Item 201D
Use Item 201D
Use Item 201D
Not Available
Not Available
Use Item 200B
Use Item 200B
Use Item 200B
Use Item 200B
7024190
Not Available
Not Available
Use Item 201A
Use Item 201B

1
1
2
1
1
2
1
1
1
1
1
1
6
6
1
1
1
1
2
1
2
10
2

201A
201B
201C

1-24

7024195

A/R
1
1
A/R
1

7024196

7017068
7024194

7024193

REV.

Coupling
Pin, Dowel
Thrustwasher

1
2
2
2

Ref.
200
200A
200B
201

DESCRIPTION

BRAKE ASSEMBLY
Shaft
Housing
Plate, Friction
Plate, Pressure
Gasket
Plate, Outer
Gasket (Note: Use Items 200B, 201C or 201D)
Cylinder
Piston
Bearing, Ball
Ring, Retaining
Seal, Shaft
Capscrew
Lockwasher
O-Ring
Ring, Back-up
O-Ring
Ring, Back-up
Pin, Dowel
Plug
Plug
Spring Kit (Natural)
Spring Kit (Blue)
KIT OPTIONS:
Seal Kit Options:
Seal Kit - Hub (Includes Items 1B,5,6F,6G & 8)
Seal Kit - 7024182 Brake (Includes Items 105, 107 & 215-218)
Repair Kit Options:
Spring Kit - 7024182 Brake (Includes 12 Natural Colored
Springs Item 122)
Spring Kit - 7024182 Brake (Includes 12 Blue Colored Springs
Item 123)
Friction Disc Kit - 7024182 Brake (Includes Items 103, 104, 106
& 107)

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (S/N 83331 TO PRESENT) (CONTINUED)
ITEM #

PART NUMBER

QTY.

201D

7024197

3121140

DESCRIPTION

REV.

Bearing Kit - 7024182 Brake (Includes Items 107 & 110-112)

800S 860SJ

1-25

SECTION 1 FRAME
FIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD PRIOR TO S/N 83331)

1-26

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD PRIOR TO S/N 83331)
ITEM #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

PART NUMBER

QTY.

3160268

Ref.

7023938
7023939
7023940
7007435
7021202
7007437
7007438
7007439
7021203
7007441
7007442
7023941
Use Item 100
7007446
7007425
7007419
Use Item 100
7021223
7021207
Use Item 100
7022371
Use Item 100
Use Item 100
7023942
7023943
7023944
7021219
7023945
7007470
7021219
Not Serviced
7010114
7010116
Use Item 100

1
1
2
1
1
1
2
2
2
1
1
1
1
1
1
2
1
10
6
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
Ref.

100

3121140

7023946

DESCRIPTION
DRIVE MOTOR ASSEMBLY

REV.
B

Plate, Motor Valve

Swashplate Assembly (Includes Item 10)
Bearing, Journal
Pin, Spring
Screw
Bearing, Ball
Ring
Ring
Pin, Spring
Pin
Bearing, Sleeve
Cover, Front
Gasket, Front Cover
Pin
Bearing, Needle
Plug (Includes O-Ring)
Gasket, Servo
Screw
Screw
Ring, Bearing
Washer, Support
Gasket, Servo
Seal, Lip
Shaft, 13 Tooth
Stop
Spring, Servo
Cover, Servo
Piston, Servo
Plug, (Includes O-Ring)
Cover, Servo
Housing
Plug (Includes O-Ring) (Not Shown)
Cylinder Block Kit
Piston Ring & O-Ring Kit
KIT OPTIONS:
Seal Kit (Includes Items 13, 17, 20, 22, 23, 34 & O-Rings on 16,
29 & 32)

800S 860SJ

1-27

SECTION 1 FRAME
FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD S/N 83331 TO S/N 98641 & ALL 4WD MACHINES)
(4 BOLT ASSEMBLY)

1-28

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD S/N 83331 TO S/N 98641 & ALL 4WD
MACHINES) (4 BOLT ASSEMBLY)
ITEM #

1
2
3
4
5
6

7
8

PART NUMBER

QTY.

3160308
3160266

Ref.
Ref.
Ref.

7022302
Use Item 100
Use Item 100
7007446
7007438
7024861
7022305
Use Item 100
7027435
Not Required

2
1
1
1
2
1

1
A/R
2
0
1

7027740
7023907
10

11
12

13
14

1
7024862
7023908
Use Item 9
Use Item 9
7021277
7021275

1
1

3
9

7024865
Use Item 9
15

16
17

1
Use Item 9
7022310
7022311

1
1

7024867
7022312
18

19
20
21
22

23
24

3121140

1
7022313
Use Item 9
7022314
7023910
7007439
Not Available
7022367
7022368
7021249

1
1
1
1

4
1

DESCRIPTION
DRIVE MOTOR ASSEMBLY
2WD
4WD

REV.
C
D

Bearing, Journal
O-Ring
O-Ring
Pin
Ring, Retaining
Swashplate Options:
2WD
4WD
O-Ring
Pin Options:
2WD
4WD
Cylinder Block Kit (Includes Items 11-19) Options:
2WD
4WD
Plate, Valve Options:
2WD
4WD
Block, Cylinder
Guide, Slipper Retainer Options:
2WD
4WD
Pin, Slipper Hold Down
Piston Assembly Options:
2WD
4WD
Retainer, Slipper Options:
2WD
4WD
Ring, Retaining
Spring Options:
2WD
4WD
Washer
2WD
4WD
Retainer, Spring
Shaft
Ring, Retaining
Cap, End - Axial Options:
2WD
4WD
Screw
Bearing, Needle

800S 860SJ

1-29

SECTION 1 FRAME
FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD S/N 83331 TO S/N 98641 & ALL 4WD
MACHINES) (4 BOLT ASSEMBLY) (CONTINUED)
ITEM #

PART NUMBER

QTY.

25
26
27
28
29
30
31

7022321
Use Item 100
7007420
Use Item 100
7007419
Use Item 100

1
1
1
1
2
2
1

7027741
7022372
32

33
34
35
36
37
38
39

40
41
42
43

1
7024870
7022370
7007419
Use Item 100
7022321
Use Item 100
Use Item 100
Use Item 100
7024871
7022323
7007437
7022326
Use Item 100
7022371

2
2
1
1
1
1
1

1
1
1
1
Ref.

100

1-30

7022328

DESCRIPTION

REV.

Plug (Includes Item 26)

O-Ring
Plug (Includes Item 28)
O-Ring
Plug (Includes Item 30)
O-Ring
Seat, Spring Options:
2WD
4WD
Housing Options:
2WD
4WD
Plug (Items Item 34)
O-Ring
Plug (Items Item 36)
O-Ring
O-Ring
Ring, Seal
Piston, Servo Options:
2WD (Includes Items 37 & 38)
4WD (Piston Only - Does not include items 37 & 38)
Bearing
Spring
Seal, Lip
Washer, Support
KIT OPTIONS:
Seal Kit (Includes Items 2,3,7,26,28,30,34,36,37,38 and 42)

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-8. DRIVE MOTOR ASSEMBLY (2WD S/N 83331 TO S/N 98641 & ALL 4WD
MACHINES) (4 BOLT ASSEMBLY) (CONTINUED)
ITEM #

3121140

PART NUMBER

QTY.

DESCRIPTION

800S 860SJ

REV.

1-31

SECTION 1 FRAME
FIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)
27

28
24

29

25

39

26

37
36

5
23

35

21
8
20

22

14
17
15
16
7A
13
10
9

12
11

31
32

31
1
32
33
34
30

18

38
19
3

100

40
41
3

1-32

800S 860SJ

3121140

SECTION 1 FRAME
FIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)
ITEM #

PART NUMBER

QTY.
Ref.

3160347
3160348
1
2
3
4

5
6
7

7A
8

7022302
7007446
7007438
70000794
7022305
Not Available
Use Item 100
7027740
7023907
Not Available

2
1
2
1

2
1
1

1
1

7024862
7023908
9

10
11
12

1
Not Available
7021277
7021275
Not Available

3
9
1

Not Available
7022310
13

14
15

1
Not Required
7021276
7022311

1
1

7024867
7022312
16

17
18
19
20

21
22
23
24
25
26

3121140

1
7022313
7024868
7022314
7023910
7007439
70000795
70000797
7022368
7021249
2220886
Use Item 100
2220883
Use Item 100

1
1
1
1

5
1
1
1
1
1

DESCRIPTION
DRIVE MOTOR ASSEMBLIES:
2WD
4WD

REV.
B
B

Bearing, Journal
Pin
Ring, Retaining
Swashplate Options:
2WD
4WD
Pin
Gasket
Cylinder Block Kit (Includes Items 7A & 9-17)
2WD
4WD
Block, Cylinder
Plate, Valve Options:
2WD
4WD
Guide, Slipper Retainer Options:
2WD
4WD
Pin, Slipper Hold Down
Piston Assembly
Retainer, Slipper Options:
2WD
4WD
Retainer, Hold Down Pin Options:
2WD
4WD
Ring, Retaining
Spring Options:
2WD
4WD
Washer Options:
2WD
4WD
Retainer, Spring
Shaft
Ring, Retaining
Cap, End - Axial Options:
2WD
4WD
Screw
Bearing, Needle
Plug (Includes Item 24)
O-Ring
Plug (Includes Item 26)
O-Ring

800S 860SJ

1-33