JLG Boom Lift 1250AJP Parts Catalog 31223037

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JLG Boom Lift 1250AJP Parts Catalog 31223037
Size: 67.87 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 1250AJP Boom Lift
Part Number: 31223037
Publication Date: 2025
Number of Pages: 942 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - FIXED​

FIGURE 1-2. AXLE INSTALLATION - OSCILLATING​

FIGURE 1-3. AXLE STOP BLOCKS INSTALLATION​

FIGURE 1-4. STEER INSTALLATION​

FIGURE 1-5. WHEEL DRIVE INSTALLATION - REGGIANA RIDUTTORI​

FIGURE 1-6. DRIVE HUB AND MOTOR ASSEMBLY - REGGIANA RIDUTTORI​

FIGURE 1-7. DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI​

FIGURE 1-8. DRIVE MOTOR ASSEMBLY​

FIGURE 1-9. DRIVE HUB AND MOTOR ASSEMBLY - PMP PUMP​

FIGURE 1-10. DRIVE HUB AND MOTOR ASSEMBLY - PMP PUMP​

FIGURE 1-11. DRIVE MOTOR ASSEMBLY - PMP PUMPS​

FIGURE 1-12. TIRE AND WHEEL INSTALLATION - FOAM FILLED​

FIGURE 1-13. TIRE AND WHEEL INSTALLATION - SOLID​

FIGURE 1-14. FRAME VALVES INSTALLATION​

FIGURE 1-15. STEER VALVE ASSEMBLY​

FIGURE 1-16. TRACTION VALVE ASSEMBLY​

FIGURE 1-17. FRAME COVERS INSTALLATION​

SECTION 2 - TURNTABLE

FIGURE 2-1. TURNTABLE VALVES INSTALLATION​

FIGURE 2-2. MAIN VALVE ASSEMBLY​

FIGURE 2-3. BATTERY AND AUXILIARY PUMP INSTALLATION - WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 2-4. BATTERY AND AUXILIARY PUMP INSTALLATION - WITH COLD WEATHER PLUS PACKAGE​

FIGURE 2-5. AUXILIARY PUMP ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 2-6. AUXILIARY PUMP ASSEMBLY (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 2-7. SWING DRIVE INSTALLATION​

FIGURE 2-8. TURNTABLE BEARING AND LUBE INSTALLATION​

FIGURE 2-9. TURNTABLE LOCK INSTALLATION​

FIGURE 2-10. PINION SHIELD INSTALLATION​

FIGURE 2-11. SWING MOTOR/HUB ASSEMBLY​

FIGURE 2-12. ROTARY COUPLING AND COLLECTOR RING INSTALLATION​

FIGURE 2-13. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY​

FIGURE 2-14. TANK INSTALLATION​

FIGURE 2-15. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2011 ENGINES WITH REXROTH PUMP (OPTIONAL)​

FIGURE 2-16. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2011 ENGINES WITH SAUER PUMP (OPTIONAL)​

FIGURE 2-17. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES REXROTH PUMP (OPTIONAL)​

FIGURE 2-18. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES PMP PUMP (OPTIONAL)​

FIGURE 2-19. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2011 ENGINES WITH PMP PUMP (OPTIONAL)​

FIGURE 2-20. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES WITH SAUER PUMP (OPTIONAL)​

FIGURE 2-21. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH REXROTH PUMP (WITHOUT TOWER STOW) (ANSI EXPORT & AUSTRALIAN SPECS)​

FIGURE 2-22. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH REXROTH PUMP (WITH TOWER STOW) (ANSI EXPORT & AUSTRALIAN SPECS)​

FIGURE 2-23. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH SAUER PUMP (WITHOUT TOWER STOW) (ANSI EXPORT & AUSTRALIAN SPECS)​

FIGURE 2-24. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH SAUER PUMP (WITH TOWER STOW) (CE & UK CA SPECS) (LRC)​

FIGURE 2-25. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH REXROTH PUMPS (WITHOUT TOWER STOW) (CE & UK CA SPECS) (LRC)​

FIGURE 2-26. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH REXROTH PUMP (WITH TOWER STOW) (ANSI EXPORT & AUSTRALIAN SPECS)​

FIGURE 2-27. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH SAUER PUMPS (WITHOUT TOWER STOW) (CE & UK CA SPECS) (LRC)​

FIGURE 2-28. GROUND CONTROL BOX INSTALLATION - DEUTZ TD2011 ENGINES WITH SAUER PUMP (WITH TOWER STOW) (CE & UK CA SPECS) (LRC)​

FIGURE 2-29. GROUND CONTROL BOX INSTALLATION - DEUTZ TCD2.9L4 ENGINES (WITHOUT TOWER STOW) (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 2-30. GROUND CONTROL BOX INSTALLATION - DEUTZ TCD2.9L4 ENGINES (WITH TOWER STOW) (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS).​

FIGURE 2-31. GROUND CONTROL BOX INSTALLATION - CHINA IV (STAGE V) (CHINESE SPEC)​

FIGURE 2-32. GROUND CONTROL BOX INSTALLATION - DEUTZ TCD2.9L4 (STAGE V) ENGINES (WITHOUT TOWER STOW)(CE & UK CA SPECS)​

FIGURE 2-33. GROUND CONTROL BOX INSTALLATION - DEUTZ TCD2.9L4 (STAGE V) ENGINES (WITH TOWER STOW)(CE & UK CA SPECS)​

FIGURE 2-34. GROUND CONTROL BOX INSTALLATION (UN R96 WITH MSSO) (LRC) (SN 0300315597 to Present)​

FIGURE 2-35. GROUND CONTROL BOX INSTALLATION (UN R96 WITH MSSO) (WITH TOWER STOW) (LRC) (SN 0300315597 to Present)​

FIGURE 2-36. GROUND CONTROL ASSEMBLY - WITH DEUTZ TD2011 AND DEUTZ TCD2.9L4 ENGINES - WITH MECHANICAL HOUR METER (WITHOUT TOWER STOW) (ALL SPECS EXCEPT CE & UK CA SPECS)​

FIGURE 2-37. GROUND CONTROL BOX INSTALLATION - CHINA IV (CHINESE SPEC)​

FIGURE 2-38. GROUND CONTROL BOX INSTALLATION - CHINA IV (STAGE V) (CHINESE SPEC)​

FIGURE 2-39. GROUND CONTROL ASSEMBLY - WITH DEUTZ TD2011 AND DEUTZ TCD2.9L4 ENGINES - WITH MECHANICAL HOUR METER (WITH TOWER STOW) (ALL SPECS EXCEPT CE & UK CA SPECS)​

FIGURE 2-40. GROUND CONTROL ASSEMBLY - DEUTZ TD2011 ENGINES (WITHOUT TOWER STOW) (CE & UK CA SPECS)​

FIGURE 2-41. GROUND CONTROL ASSEMBLY - DEUTZ TD2011 ENGINES (WITH TOWER STOW) (CE & UK CA SPECS)​

FIGURE 2-42. GROUND CONTROL ASSEMBLY - DEUTZ TCD2.9L4 (STAGE V) (WITHOUT TOWER STOW) (CE & UK CA SPECS)​

FIGURE 2-43. GROUND CONTROL ASSEMBLY - DEUTZ TCD2.9L4 (STAGE V) (WITH TOWER STOW) (CE & UK CA SPECS)​

FIGURE 2-44. GROUND CONTROL ASSEMBLY - CHINA IV (CHINESE SPEC)​

FIGURE 2-45. GROUND CONTROL ASSEMBLY - CHINA IV (WITH TOWER STOW) (CHINESE SPEC)​

FIGURE 2-46. KEYSWITCH INSTALLATION​

FIGURE 2-47. LIGHT PANEL INSTALLATION​

FIGURE 2-48. ALARMS INSTALLATION​

FIGURE 2-49. BACKUP ALARM (WHITE NOISE) INSTALLATION​

FIGURE 2-50. BACKUP ALARM AMBIENT (WHITE NOISE) INSTALLATION​

FIGURE 2-51. ENGINE TRAY JACK INSTALLATION - DEUTZ TD2011 ENGINES​

FIGURE 2-52. ENGINE TRAY JACK INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 2-53. HOODS INSTALLATION - DEUTZ TD2011 ENGINES​

FIGURE 2-54. HOODS INSTALLATION - DEUTZ TCD2.9L4 ENGINES​

FIGURE 2-55. HOODS INSTALLATION - DEUTZ TCD2.9L4 (STAGE V) ENGINES​

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ TD2011 ENGINE INSTALLATION - WITH REXROTH PUMP (WITHOUT GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-2. DEUTZ TD2011 ENGINE ASSEMBLY - WITH REXROTH PUMP (WITHOUT GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-3. DEUTZ TD2011 ENGINE INSTALLATION - WITH REXROTH PUMP (WITH GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-4. DEUTZ TD2011 ENGINE ASSEMBLY - WITH REXROTH PUMP (WITH GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-5. DEUTZ TD2011 ENGINE INSTALLATION - WITH REXROTH PUMP (WITH GENERATOR AND WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-6. DEUTZ TD2011 ENGINE ASSEMBLY - WITH REXROTH PUMP (WITH GENERATOR AND WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-7. DEUTZ TD2011 ENGINE INSTALLATION - WITH SAUER PUMP (WITHOUT GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-8. DEUTZ TD2011 ENGINE ASSEMBLY - WITH SAUER PUMP (WITHOUT GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-9. DEUTZ TD2011 ENGINE INSTALLATION - WITH SAUER PUMP (WITH GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-10. DEUTZ TD2011 ENGINE ASSEMBLY - WITH SAUER PUMP (WITH GENERATOR AND WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-11. DEUTZ TD2011 ENGINE INSTALLATION - WITH SAUER PUMP (WITH GENERATOR AND WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-12. DEUTZ TD2011 ENGINE ASSEMBLY - WITH SAUER PUMP (WITH GENERATOR AND WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-13. DEUTZ TD2011 ENGINE COMPONENTS​

FIGURE 3-14. DEUTZ TCD2.9L4 EMR4 ENGINE INSTALLATION - WITH REXROTH PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-15. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH REXROTH PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-16. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITH REXROTH PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-17. DEUTZ TCD2.9L4 EMR4 ENGINE INSTALLATION - WITH REXROTH PUMP (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-18. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH REXROTH PUMP (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-19. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITH REXROTH PUMP (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-20. DEUTZ TCD2.9L4 EMR4 ENGINE INSTALLATION - WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-21. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH SAUER PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-22. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITH SAUER PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-23. DEUTZ TCD2.9L4 EMR4 ENGINE INSTALLATION - WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-24. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-25. DEUTZ D2.9L4 (EMR4) ENGINE SUB-ASSEMBLY WITH PMP PUMP AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-26. DEUTZ D2.9L4 (EMR4) ENGINE SUB-ASSEMBLY WITH PMP PUMP AND STEEL HOODS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-27. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-28. DEUTZ TCD2.9L4 EMR4 ENGINE COMPONENTS​

FIGURE 3-29. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH REXROTH PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-30. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH REXROTH PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-31. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH PMP PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-32. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH PMP PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-33. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-34. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-35. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH PMP PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-36. DEUTZ D2.9L4 - EMR5 ENGINE INSTALLATION WITH PMP PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-37. DEUTZ D2.9L4 - (STAGE V) ENGINE INSTALLATION WITH PMP PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-38. DEUTZ D2.9L4 - EMR5 ENGINE SUB-ASSEMBLY WITH REXROTH PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-39. DEUTZ D2.9L4 - EMR5 ENGINE SUB-ASSEMBLY WITH REXROTH PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-40. DEUTZ D2.9L4 - EMR5 ENGINE SUB-ASSEMBLY WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-41. DEUTZ D2.9L4 - EMR5 ENGINE SUB-ASSEMBLY WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-42. DEUTZ D2.9L4 - EMR5 ENGINE SUB-ASSEMBLY WITH PMP PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-43. DEUTZ D2.9L4 - EMR5 ENGINE SUB-ASSEMBLY WITH PMP PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-44. DEUTZ D2.9L4 - EMR5 ENGINE ASSEMBLY (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-45. DEUTZ D2.9L4 - EMR5 ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-46. ENGINE COMPONENTS - DEUTZ TCD2.9L4 EMR5 ENGINE​

FIGURE 3-47. PUMP ASSEMBLY - HYDRAULIC TANDEM​

FIGURE 3-48. PUMP ASSEMBLY - HYDRAULIC PISTON​

FIGURE 3-49. DEUTZ TCD2.9L4 (STAGE V) ENGINE INSTALLATION - WITH REXROTH PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-50. DEUTZ TCD2.9L4 (STAGE V) ENGINE SUB-ASSEMBLY - WITH REXROTH PUMP AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-51. DEUTZ D2.9L4 (STAGE V) ENGINE SUB-ASSEMBLY WITH PMP PUMP AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-52. DEUTZ TCD2.9L4 (STAGE V) ENGINE COMPONENTS​

FIGURE 3-53. DEUTZ TCD2.9L4 (STAGE V) ENGINE INSTALLATION - WITH SAUER PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-54. DEUTZ DIESEL TCD2.9L CHINA IV ENGINE INSTALLATION (CHINESE SPEC)​

FIGURE 3-55. DEUTZ TCD2.9L (CHINA IV) ENGINE SUB-ASSEMBLY​

FIGURE 3-56. DEUTZ TCD2.9L4 (STAGE V) ENGINE SUB-ASSEMBLY - WITH SAUER PUMP AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-57. DEUTZ TCD2.9L4 (STAGE V) ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-58. DEUTZ TCD2.9L4 (CHINA IV) ENGINE ASSEMBLY​

FIGURE 3-59. DEUTZ TCD2.9L4 (CHINA IV) ENGINE COMPONENTS​

FIGURE 3-60. PUMP ASSEMBLY (REXROTH) (DEUTZ TD2011 ENGINES)​

FIGURE 3-61. PUMP ASSEMBLY (REXROTH) (DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES)​

FIGURE 3-62. PUMP ASSEMBLY (SAUER TANDEM)​

FIGURE 3-63. PUMP ASSEMBLY (SAUER PISTON)​

FIGURE 3-64. PUMP ASSEMBLY (SAUER GEAR)​

FIGURE 3-65. PUMP COUPLING KIT​

FIGURE 3-66. BREATHER HEATER INST (DEUTZ TD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES)​

FIGURE 3-67. FUEL PUMP/FILTER BRACKET ASSEMBLY - DEUTZ TCD2.9L4 ENGINE AND DEUTZ TCD2.9L4 (STAGE V) ENGINE​

FIGURE 3-68. QUICKFIT OIL VALVE​

FIGURE 3-69. WATER/FUEL SEPARATOR INSTALLATION - DEUTZ TD2011 ENGINE​

FIGURE 3-70. FUEL FILTER INSTALLATION (CHINESE SPEC)​

FIGURE 3-71. SPARK ARRESTING CATALYTIC MUFFLER - DEUTZ TD2011 ENGINES (OPTIONAL)​

FIGURE 3-72. 2500W GENERATOR INSTALLATION - DEUTZ TD2011 ENGINES (OPTIONAL)​

FIGURE 3-73. 4000W GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TD2011 ENGINES)​

FIGURE 3-74. 4000W GENERATOR INSTALLATION - 50HZ SPEC (DEUTZ TD2011 ENGINES)​

FIGURE 3-75. 4000W GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TCD2.9L4 ENGINES)​

FIGURE 3-76. 4000W GENERATOR INSTALLATION - 50HZ SPEC (DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES)​

FIGURE 3-77. 7500W SKYPOWER GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TD2011 ENGINES) (OPTIONAL)​

FIGURE 3-78. 7500W SKYPOWER GENERATOR INSTALLATION - 50HZ SPEC (DEUTZ TD2011 ENGINES) (OPTIONAL)​

FIGURE 3-79. 7500W SKYPOWER GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TCD2.9L4 ENGINES) (OPTIONAL)​

FIGURE 3-80. 7500W SKYPOWER GENERATOR INSTALLATION - 50HZ SPEC (DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES) (OPTIONAL)​

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDER INSTALLATION - WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 4-2. BOOM AND CYLINDER INSTALLATION - WITH COLD WEATHER PLUS PACKAGE​

FIGURE 4-3. TOWER BOOM ASSEMBLY​

FIGURE 4-4. MAIN BOOM ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 4-5. MAIN BOOM ASSEMBLY - WITH COLD WEATHER PLUS PACKAGE​

FIGURE 4-6. PLATFORM ROTATE ASSEMBLY​

FIGURE 4-7. JIB ROTATE ASSEMBLY​

FIGURE 4-8. POWER TRACK AND BOOM CLAMPS INSTALLATION (TOWER BOOM)​

FIGURE 4-9. POWER TRACK AND BOOM CLAMPS INSTALLATION (MAIN BOOM AND JIB)​

FIGURE 4-10. BOOM SENSORS AND SWITCHES INSTALLATION​

FIGURE 4-11. PLATFORM SUPPORT INSTALLATION​

FIGURE 4-12. CONTROL VALVE INSTALLATION - PLATFORM​

FIGURE 4-13. PLATFORM VALVE ASSEMBLY​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH SWING GATE​

FIGURE 5-2. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH SWING GATE​

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - WITH DROP BAR​

FIGURE 5-4. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH DROP BAR​

FIGURE 5-5. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH DROP BAR​

FIGURE 5-6. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (ANSI AND ANSI EXPORT SPECS)​

FIGURE 5-7. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (ANSI AND CSA SPECS)​

FIGURE 5-8. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH SWING GATE​

FIGURE 5-9. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH DROP BAR​

FIGURE 5-10. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH DROPBAR​

FIGURE 5-11. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH DROPGATE​

FIGURE 5-12. TRAY INSTALLATION​

FIGURE 5-13. PLATFORM CONTROLS INSTALLATION (WITHOUT TOWER STOW)​

FIGURE 5-14. PLATFORM CONTROLS INSTALLATION (WITH TOWER STOW)​

FIGURE 5-15. PLATFORM CONSOLE ASSEMBLY (WITHOUT TOWER STOW)​

FIGURE 5-16. PLATFORM CONSOLE ASSEMBLY (WITH TOWER STOW)​

FIGURE 5-17. LIGHT PANEL INSTALLATION​

FIGURE 5-18. TOWER LIFT SWITCH INSTALLATION​

FIGURE 5-19. FOOTSWITCH ASSEMBLY​

FIGURE 5-20. SKYEYE INSTALLATION​

FIGURE 5-21. SKYGUARD BAR INSTALLATION​

FIGURE 5-22. SKYLINE INSTALLATION​

FIGURE 5-23. USB CHARGER INSTALLATION​

FIGURE 5-24. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M PLATFORMS (OPTIONAL)​

FIGURE 5-25. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM​

FIGURE 5-26. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.4M PLATFORMS (OPTIONAL)​

FIGURE 5-27. SKYGLAZIER INSTALLATION (ANSI, AUSTRALIAN AND CSA SPECS)​

FIGURE 5-28. SKYGLAZIER INSTALLATION (BRAZIL SPECS)​

FIGURE 5-29. SKYGLAZIER INSTALLATION (DANISH SPECS)​

FIGURE 5-30. SKYGLAZIER INSTALLATION (FRENCH SPECS)​

FIGURE 5-31. SKYGLAZIER INSTALLATION (GERMAN SPECS)​

FIGURE 5-32. SKYGLAZIER INSTALLATION (ITALIAN SPECS)​

FIGURE 5-33. SKYGLAZIER INSTALLATION (LATIN AMERICAN SPECS)​

FIGURE 5-34. SKYGLAZIER INSTALLATION (PORTUGUESE SPECS)​

FIGURE 5-35. SKYGLAZIER INSTALLATION (SPANISH SPECS)​

FIGURE 5-36. SKYGLAZIER INSTALLATION (SWEDISH SPECS)​

FIGURE 5-37. SKYGLAZIER INSTALLATION (UK SPECS)​

FIGURE 5-38. SKYCUTTER INSTALLATION​

FIGURE 5-39. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)​

FIGURE 5-40. PLASMA CUTTER ASSEMBLY​

FIGURE 5-41. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-42. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-43. SKYWELDER PREP PACKAGE (60HZ)​

FIGURE 5-44. WELDER ASSEMBLY​

FIGURE 5-45. FALL ARREST INSTALLATION (BOLT - ON EXTERNAL) 6FT/1.82M PLATFORM​

FIGURE 5-46. FALL ARREST INSTALLATION (BOLT - ON EXTERNAL) 6FT/1.82M PLATFORM​

FIGURE 5-47. FALL ARREST INSTALLATION (BOLT - ON EXTERNAL) 8FT/2.4M PLATFORM​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE EXTENSION CYLINDER ASSEMBLY​

FIGURE 6-2. AXLE LOCKOUT CYLINDER ASSMBLY​

FIGURE 6-3. PLATFORM LEVEL CYLINDER ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - TOWER BOOM​

FIGURE 6-6. JIB CYLINDER ASSEMBLY​

FIGURE 6-7. STEER CYLINDER ASSEMBLY​

FIGURE 6-8. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM​

FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM - BOOM (WITH REXROTH PUMPS)​

FIGURE 7-2. HYDRAULIC DIAGRAM - BOOM (WITH SAUER PUMPS)​

FIGURE 7-3. HYDRAULIC DIAGRAM - DRIVE (WITH REXROTH PUMPS)​

FIGURE 7-4. HYDRAULIC DIAGRAM - DRIVE (WITH SAUER PUMPS)​

FIGURE 7-5. HYDRAULIC DIAGRAM - OSCILLATING AXLE (WITH REXROTH PUMPS)​

FIGURE 7-6. HYDRAULIC DIAGRAM - OSCILLATING AXLE (WITH SAUER PUMPS)​

FIGURE 7-7. HYDRAULIC DIAGRAM - STEER (WITH REXROTH PUMPS)​

FIGURE 7-8. HYDRAULIC DIAGRAM - STEER (WITH SAUER PUMPS)​

FIGURE 7-9. HYDRAULIC DIAGRAM - TURNTABLE (DEUTZ TD2011 ENGINES WITH REXROTH PUMPS)​

FIGURE 7-10. HYDRAULIC DIAGRAM - TURNTABLE (DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES WITH REXROTH PUMPS)​

FIGURE 7-11. HYDRAULIC DIAGRAM - TURNTABLE (WITH SAUER PUMPS) (Prior to SN 0300311787)​

FIGURE 7-12. HYDRAULIC DIAGRAM - TURNTABLE (WITH SAUER PUMPS) (SN 0300311787 to Present)​

FIGURE 7-13. HYDRAULIC DIAGRAM - TURNTABLE (WITH PMP PUMPS) (SN 0300311787 to Present)​

FIGURE 7-14. HYDRAULIC DIAGRAM - AUXILIARY POWER MOTOR​

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM - 110V GFI RECEPTACLE (ANSI SPECS)​

FIGURE 8-2. AC BOX AT PLATFORM - 220V GFI RECEPTACLE (ANSI SPECS)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - BOX WITH COVER (2X4 BOX) WITH 4000W GENERATOR (ANSI EXPORT, AUSTRALIAN, JAPANESE, CE & UK CA SPECS)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-18. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-19. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN & CE & UK CA SPECS)​

FIGURE 8-20. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 8-21. AC LEAD INSTALLATION (ANSI EXPORT, AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 8-22. AC 10 AMP BREAKER BOX INSTALLATION (CE & UK CA SPECS)​

FIGURE 8-23. AC 16 AMP BREAKER BOX INSTALLATION (CE & UK CA SPECS)​

FIGURE 8-24. ANALYZER CALBE HARNESS​

FIGURE 8-25. AXLE POWER TRACK HARNESS ASSEMBLY​

FIGURE 8-26. BATTERY DISCONNECT INSTALLATION​

FIGURE 8-27. B.L.A.M. HARNESS​

FIGURE 8-28. BOOM CABLE INSTALLATION (ANSI, ANSI EXPORT AND JAPANESE SPECS)​

FIGURE 8-29. BOOM CABLE INSTALLATION (AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 8-30. BOOM CABLE INSTALLATION - 4000W 60HZ GENERATOR​

FIGURE 8-31. BOOM CABLE INSTALLATION - 4000W 50HZ GENERATOR​

FIGURE 8-32. BOOM CABLE INSTALLATION - 7500W GENERATOR​

FIGURE 8-33. BREAKER BOX KIT - 10 AMP (2500W GENERATOR)​

FIGURE 8-34. BREAKER BOX KIT - 16 AMP (2500W GENERATOR)​

FIGURE 8-35. BREAKER BOX KIT - 16 AMP (4000W GENERATOR)​

FIGURE 8-36. BREAKER BOX KIT - 30MA/16 AMP (WITHOUT GENERATOR)​

FIGURE 8-37. CHASSIS POWER DISTRIBUTION HARNESS​

FIGURE 8-38. CHASSIS HARNESS ASSEMBLY​

FIGURE 8-39. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-40. CLEARSKY READY HARNESS (DEUTZ TD2011, DEUTZ TCD2.9L4 & DEUTZ TCD2.9L4 (STAGE V PRE-BUY) ENGINES)​

FIGURE 8-41. CLEARSKY READY HARNESS (DEUTZ TCD2.9L4 (STAGE V) ENGINES )​

FIGURE 8-42. DIAGNOSTIC HARNESS​

FIGURE 8-43. DUAL CAPACITY JIB POSITION SWITCH HARNESS​

FIGURE 8-44. ENGINE HARNESS - DEUTZ TD2011 ENGINES​

FIGURE 8-45. ENGINE HARNESS - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V PRE-BUY) ENGINES​

FIGURE 8-46. ENGINE HARNESS - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 8-47. ENGINE HARNESS - DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 8-48. FUEL FILTER HARNESS - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 8-49. FUEL HARNESS - DEUTZ TCD2.9L4 ENGINES, DEUTZ TCD2.9L4 (STAGE V PRE-BUY) ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 8-50. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-51. GENERATOR CABLE HARNESS - 7500W GENERATOR​

FIGURE 8-52. GROUND CONTROL BOX HARNESS​

FIGURE 8-53. GROUND CONTROLS TO ENGINE HARNESS​

FIGURE 8-54. JIB STOW SWITCH HARNESS​

FIGURE 8-55. LOAD SENSING PIN HARNESS​

FIGURE 8-56. LOCKOUT VALVE HARNESS​

FIGURE 8-57. MAIN BOOM CONTROL CABLE HARNESS​

FIGURE 8-58. MAIN BOOM DUAL CAPACITY SWITCH HARNESS​

FIGURE 8-59. MAIN BOOM TRANSPORT SWITCH HARNESS​

FIGURE 8-60. MAIN VALVE HARNESS​

FIGURE 8-61. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-62. SKYGUARD INERFACE HARNESS​

FIGURE 8-63. PLATFORM VALVE HARNESS​

FIGURE 8-64. PRESSURE TRANSDUCER HARNESS​

FIGURE 8-65. PRESSURE TRANSDUCER HARNESS​

FIGURE 8-66. PUMP ADAPTER HARNESS - SAUER PUMPS​

FIGURE 8-67. RECEPTACLE BOX KIT - 110V IEC YELLOW WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-68. RECEPTACLE BOX KIT - 110V IEC YELLOW WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-69. RECEPTACLE BOX KIT - 220V IEC BLUE WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-70. RECEPTACLE BOX KIT - 220V IEC BLUE WITH 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-71. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND WITHOUT 2500W GENERSTOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-72. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND WITH 2500W GENERSTOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-73. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND WITHOUT 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-74. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND WITH 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-75. RECEPTACLE BOX KIT - 220V AFSINT 107 KEYED GROUND WITHOUT 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-76. RECEPTACLE BOX KIT - 220V AFSINT 107 KEYED GROUND WITH 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-77. RELAY HARNESS​

FIGURE 8-78. TILT SENSOR HARNESS (LEFT)​

FIGURE 8-79. TILT SENSOR HARNESS (RIGHT)​

FIGURE 8-80. TOWER BOOM ANGLE SENSOR HARNESS (LEFT)​

FIGURE 8-81. TOWER BOOM ANGLE SENSOR HARNESS (RIGHT)​

FIGURE 8-82. TOWER BOOM CONTROL CABLE HARNESS​

FIGURE 8-83. TOWER BOOM FLY TO GROUND CONTROL BOX HARNESS​

FIGURE 8-84. TOWER BOOM FLY TO MAIN BOOM BASE HARNESS​

FIGURE 8-85. TOWER BOOM LENGTH SENSORS HARNESS​

FIGURE 8-86. TOWER BOOM TRANSPORT LENGTH SWITCH HARNESS​

FIGURE 8-87. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-88. SKYEYE RECEIVER HARNESS​

FIGURE 8-89. SKYEYE EMITTER HARNESS​

FIGURE 8-90. SKYLINE HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI SPEC​

FIGURE 9-2. DECAL INSTALLATION - AUSTRALIAN SPEC​

FIGURE 9-3. DECAL INSTALLATION - BRAZIL SPEC (PORTGUESE/ENGLISH)​

FIGURE 9-4. DECAL INSTALLATION - CE & UK CA SPEC​

FIGURE 9-5. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH)​

FIGURE 9-6. DECAL INSTALLATION - CSA SPEC (ENGLISH/FRENCH)​

FIGURE 9-7. DECAL INSTALLATION - JAPANESE SPEC (JAPANESE/ENGLISH)​

FIGURE 9-8. DECAL INSTALLATION - KOREAN SPEC (KOREAN/ENGLISH)​

FIGURE 9-9. DECAL INSTALLATION - LATIN AMERICAN SPEC (SPANISH/ENGLISH)​

FIGURE 9-10. DECAL INSTALLATION - OPTIONS​

FIGURE 9-11. SKYWELDER DECAL INSTALLATION - 50HZ​

FIGURE 9-12. SKYWELDER DECAL INSTALLATION - 60HZ​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS​

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX