JLG Boom Lift 1500SJ Parts Catalog 31222389

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JLG Boom Lift 1500SJ Parts Catalog 31222389
Size: 61.89 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 1500SJ Boom Lift
Part Number: 31222389
Publication Date: 2025
Number of Pages: 852 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - FIXED​

FIGURE 1-2. AXLE INSTALLATION - OSCILLATING​

FIGURE 1-3. STEER INSTALLATION​

FIGURE 1-4. WHEEL DRIVE INSTALLATION - REGGIANA RIDUTTORI​

FIGURE 1-5. DRIVE HUB AND MOTOR ASSEMBLY - REGGIANA RIDUTTORI​

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

FIGURE 1-7. DRIVE MOTOR ASSEMBLY​

FIGURE 1-8. TIRE AND WHEEL INSTALLATION - FOAM FILLED​

FIGURE 1-9. TIRE AND WHEEL INSTALLATION - SOLID​

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - SOLID NON MARKIMG​

FIGURE 1-11. VALVES AND MODULES INSTALLATION - FRAME MOUNTED​

FIGURE 1-12. STEER VALVE ASSEMBLY​

FIGURE 1-13. TRACTION VALVE ASSEMBLY​

FIGURE 1-14. FRAME COVERS INSTALLATION - PLASTIC​

FIGURE 1-15. FRAME COVERS INSTALLATION - STEEL​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVE, MODULE AND FILTER INSTALLATION - TURNTABLE MOUNTED​

FIGURE 2-2. BATTERY, HORN AND AUXILIARY PUMP INSTALLATION​

FIGURE 2-3. MAIN VALVE ASSEMBLY​

FIGURE 2-4. AUXILIARY PUMP ASSEMBLY​

FIGURE 2-5. SWING DRIVE INSTALLATION​

FIGURE 2-6. TURNTABLE BEARING AND LUBE INSTALLATION​

FIGURE 2-7. TURNTABLE LOCK INSTALLATION​

FIGURE 2-8. SWING MOTOR/HUB ASSEMBLY​

FIGURE 2-9. ROTARY COUPLING AND COLLECTOR RING INSTALLATION​

FIGURE 2-10. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY​

FIGURE 2-11. TANK INSTALLATION - WITH 31 GAL/117.31 L FUEL TANK​

FIGURE 2-12. TANK INSTALLATION - WITH 58.2 GAL/200 L FUEL TANK​

FIGURE 2-13. HYDRAULIC OIL TANK ASSEMBLY​

FIGURE 2-14. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2011 ENGINES WITH REXROTH PUMPS (OPTIONAL)​

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

FIGURE 2-16. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES WITH REXROTH PUMPS (OPTIONAL)​

FIGURE 2-17. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES WITH REXROTH PUMPS (OPTIONAL) (CHINA SPEC ONLY)​

FIGURE 2-18. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) (CHINA IV) ENGINES WITH SAUER PUMPS (OPTIONAL)​

FIGURE 2-19. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES WITH SAUER PUMPS (OPTIONAL) (CHINA SPEC ONLY)​

FIGURE 2-20. GROUND CONTROL BOX INSTALLATION - TD2011 ENGINES WITH REXROTH PUMPS (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS)​

FIGURE 2-21. GROUND CONTROL BOX INSTALLATION - TD2011 ENGINES WITH REXROTH PUMPS (CE & UK CA (LRC) SPECS)​

FIGURE 2-22. GROUND CONTROL BOX INSTALLATION - TD2011 ENGINES WITH SAUER PUMPS (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS)​

FIGURE 2-23. GROUND CONTROL BOX INSTALLATION - TD2011 ENGINES WITH SAUER PUMPS (CE & UK CA (LRC) SPECS)​

FIGURE 2-24. GROUND CONTROL BOX INSTALLATION - TCD2.9L4 ENGINES WITH REXROTH PUMPS (ANSI, ANSI EXPORT (HRC), CHINA, CSA AND JAPANESE SPECS)​

FIGURE 2-25. GROUND CONTROL BOX INSTALLATION - DEUTZ TCD2.9L4 (STAGE V) ENGINES (CE & UK CA SPECS)​

FIGURE 2-26. GROUND CONTROL BOX INSTALLATION - DEUTZ TCD2.9L4 ENGINE (CHINA IV)​

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY - DEUTZ TD2011 ENGINES AND DEUTZ TCD2.9L4 ENGINES (ALL SPECS EXCEPT CE & UK CA SPECS)​

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY - DEUTZ TD2011 ENGINES (CE & UK CA SPECS)​

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY - DEUTZ TCD2.9L4 (STAGE V) ENGINES (CE & UK CA SPECS)​

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY - DEUTZ TCD2.9L4 ENGINES (CHINA IV)​

FIGURE 2-31. KEYSWITCH INSTALLATION​

FIGURE 2-32. LIGHT PANEL INSTALLATION​

FIGURE 2-33. ALARMS INSTALLATION​

FIGURE 2-34. BACKUP ALARM (WHITE NOISE) INSTALLATION​

FIGURE 2-35. BACKUP ALARM AMBIENT (WHITE NOISE) INSTALLATION​

FIGURE 2-36. STROBE LIGHT INSTALLATION (AMBER) (WITHOUT CLEARSKY BEACON)​

FIGURE 2-37. STROBE LIGHT INSTALLATION (BLUE) (WITHOUT CLEARSKY BEACON)​

FIGURE 2-38. STROBE LIGHT INSTALLATION (RED) (WITHOUT CLEARSKY BEACON)​

FIGURE 2-39. PINION SHIELD INSTALLATION​

FIGURE 2-40. ENGINE TRAY JACK INSTALLATION - DEUTZ TD2011 ENGINES​

FIGURE 2-41. ENGINE TRAY JACK INSTALLATION - DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 2-42. HOOD INSTALLATION - DEUTZ TD2011 ENGINES​

FIGURE 2-43. HOOD INSTALLATION - DEUTZ TCD2.9L4 ENGINES​

FIGURE 2-44. HOOD INSTALLATION - DEUTZ TCD2.9L4 (STAGE V / CHINA IV) ENGINES​

SECTION 3 - ENGINE

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

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

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

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

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

FIGURE 3-6. DEUTZ TD2011 ENGINE ASSEMBLY - WITH REXROTH PUMPS (WTH SKYPOWER AND WITH COLD WEATHER PLUS PACKAGE)​

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

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

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

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

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

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

FIGURE 3-13. DEUTZ TD2011 ENGINE COMPONENTS​

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

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

FIGURE 3-16. DEUTZ TCD2.9L4 EMR4 ENGINE INSTALLATION - WITH REXROTH PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE) (CHINA SPEC ONLY)​

FIGURE 3-17. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH REXROTH PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE) (CHINA SPEC ONLY)​

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

FIGURE 3-19. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH REXROTH PUMPS (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 PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-22. DEUTZ TCD2.9L4 EMR4 ENGINE INSTALLATION - WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE) (CHINA SPEC ONLY)​

FIGURE 3-23. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE) (CHINA SPEC ONLY)​

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

FIGURE 3-25. DEUTZ TCD2.9L4 EMR4 ENGINE SUB-ASSEMBLY - WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-26. DEUTZ D2.9L4 EMR4 ENGINE INSTALLATION WITH PMP PUMP AND STEEL HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-27. DEUTZ D2.9L4 EMR4 ENGINE SUB-ASSEMBLY WITH PMP PUMP AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-28. DEUTZ D2.9L4 EMR4 ENGINE SUB ASSEMBLY WITH PMP PUMPS AND STEEL HOODS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-29. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 3-30. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 3-31. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE (CHINA SPEC ONLY)​

FIGURE 3-32. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE (CHINA SPEC ONLY) (PVC 2007)​

FIGURE 3-33. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITH COLD WEATHER PLUS PACKAGE​

FIGURE 3-34. DEUTZ TCD2.9L4 EMR4 ENGINE ASSEMBLY - WITH COLD WEATHER PLUS PACKAGE​

FIGURE 3-35. DEUTZ TCD2.9L4 (EMR4) ENGINE COMPONENTS​

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

FIGURE 3-37. DEUTZ D2.9L4 EMR5 ENGINE INSTALLATION WITH PMP PUMP AND STEEL HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-38. DEUTZ D2.9L4 EMR5 ENGINE INSTALLATION WITH REXROTH PUMPS AND STEEL HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-39. DEUTZ D2.9L4 EMR5 ENGINE INSTALLATION WITH SAUER PUMPS AND STEEL HOODS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-40. DEUTZ D2.9L4 EMR5 ENGINE INSTALLATION WITH SAUER PUMPS AND STEEL HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-41. DEUTZ D2.9L4 EMR5 ENGINE SUB-ASSEMBLY WITH PMP PUMPS (WITH 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 REXROTH PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-44. DEUTZ D2.9L4 EMR5 ENGINE SUB-ASSEMBLY WITH REXROTH PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-45. DEUTZ D2.9L4 EMR5 ENGINE SUB-ASSEMBLY WITH SAUER PUMPS (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-46. DEUTZ D2.9L4 EMR5 ENGINE SUB-ASSEMBLY WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-47. DEUTZ D2.9L4 EMR ENGINE ASSEMBLY (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-48. DEUTZ D2.9L4 EMR ENGINE ASSEMBLY (WITH COLD WEATHER PLUS PACKAGE)​

FIGURE 3-49. DEUTZ D2.9L4 EMR ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-50. DEUTZ D2.9L4 EMR ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-51. DEUTZ TCD2.9L4 (EMR5) ENGINE COMPONENTS​

FIGURE 3-52. DEUTZ TCD2.9L4 ENGINE COMPONENTS (CHINA SPEC ONLY)​

FIGURE 3-53. DEUTZ TCD2.9L4 (CHINA IV) ENGINE INSTALLATON​

FIGURE 3-54. DEUTZ TCD2.9L4 (CHINA IV) ENGINE INSTALLATION WITH PMP PUMPS​

FIGURE 3-55. DEUTZ TCD2.9L4 (CHINA IV) ENGINE AND PUMP SUB - ASSEMBLY​

FIGURE 3-56. DEUTZ TCD2.9L4 (CHINA IV) ENGINE AND PUMP SUB-ASSEMBLY (WITH PMP PUMPS)​

FIGURE 3-57. DEUTZ TCD2.9L4 (CHINA IV) ENGINE ASSEMBLY​

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

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

FIGURE 3-60. DEUTZ TCD2.9L4 (STAGE V) DIESEL ENGINE INSTALLATION - WITH SAUER PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-61. DEUTZ TCD2.9L4 (STAGE V) DIESEL ENGINE INSTALLATION - WITH REXROTH PUMPS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-62. DEUTZ TCD2.9L4 (STAGE V) ENGINE INSTALLATION WITH PMP PUMPS​

FIGURE 3-63. DEUTZ TCD2.9L4 (STAGE V) ENGINE SUB-ASSEMBLY - WITH SAUER PUMP (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-64. DEUTZ D2.9L4 (STAGE V) ENGINE SUB ASSEMBLY WITH PMP PUMPS AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-65. DEUTZ TCD2.9L4 (STAGE V) ENGINE SUB-ASSEMBLY - WITH REXROTH PUMP AND ABS HOODS (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-66. DEUTZ TCD2.9L4 (STAGE V) ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-67. DEUTZ TCD2.9L4 (STAGE V) ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-68. DEUTZ TCD2.9L4 (STAGE V) ENGINE ASSEMBLY (WITHOUT COLD WEATHER PLUS PACKAGE)​

FIGURE 3-69. DEUTZ TCD2.9L4 (STAGE V) ENGINE COMPONENTS​

FIGURE 3-70. PUMP ASSEMBLY (REXROTH) (DEUTZ TD2011 ENGINES)​

FIGURE 3-71. PUMP ASSEMBLY (REXROTH) (DEUTZ TCD2.9L4 ENGINES​

FIGURE 3-72. PUMP ASSEMBLY (SAUER TANDEM)​

FIGURE 3-73. PUMP ASSEMBLY (SAUER PISTON)​

FIGURE 3-74. PUMP ASSEMBLY (SAUER GEAR)​

FIGURE 3-75. PUMP ASSEMBLY (PMP TANDEM)​

FIGURE 3-76. PUMP ASSEMBLY (PMP PISTON)​

FIGURE 3-77. PUMP COUPLING KIT​

FIGURE 3-78. BREATHER HEATER INSTALLATION - DEUTZ TCD2.9L4 ENGINES, DEUTZ TCD2.9L4 (STAGE V PRE-BUY) ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES WITH ARCTIC PACKAGE​

FIGURE 3-79. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ TD2011 (OPTIONAL)​

FIGURE 3-80. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TCD2.9L4 ENGINE AND DEUTZ TCD2.9L4 (STAGE V PRE-BUY) ENGINE)​

FIGURE 3-81. FUEL PUMP/FILTER BRACKET ASSEMBLY - DEUTZ TCD2.9L4 ENGINE​

FIGURE 3-82. FUEL FILTER/WATER SEPARATOR INSTALLATION - DEUTZ TCD2.9L4 ENGINE​

FIGURE 3-83. QUICKFIT OIL VALVE ASSEMBLY​

FIGURE 3-84. 4000W GENERATOR INSTALLATION - 60HZ SPECS (DEUTZ TD2011 ENGINES)​

FIGURE 3-85. 4000W GENERATOR INSTALLATION - 50HZ SPECS (DEUTZ TD2011 ENGINES)​

FIGURE 3-86. 4000W GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TCD2.9L4 ENGINES)​

FIGURE 3-87. 4000W GENERATOR INSTALLATION - 50HZ SPEC (DEUTZ TCD2.9L4 ENGINES AND DEUTZ TCD2.9L4 (STAGE V) ENGINES)​

FIGURE 3-88. 7500W SKYPOWER GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TD2011 ENGINES) (OPTIONAL)​

FIGURE 3-89. 7500W SKYPOWER GENERATOR INSTALLATION - 50HZ SPEC (DEUTZ TD2011 ENGINES) (OPTIONAL)​

FIGURE 3-90. 7500W SKYPOWER GENERATOR INSTALLATION - 60HZ SPEC (DEUTZ TCD2.9L4 ENGINES) (OPTIONAL)​

FIGURE 3-91. 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 INSTALLATION - WITHOUT COLD WEATHER PLUS PACKAGE​

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

FIGURE 4-3. BOOM ASSEMBLY - WITHOUT COLD WEATHER PLUS PACKAGE​

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

FIGURE 4-5. WIRE ROPE TOOLS INSTALLATION (OPTIONAL)​

FIGURE 4-6. JIB INSTALLATION​

FIGURE 4-7. JIB BOOM ASSEMBLY​

FIGURE 4-8. PLATFORM ROTATE ACTUATOR ASSEMBLY​

FIGURE 4-9. JIB ROTATE ACTUATOR ASSEMBLY​

FIGURE 4-10. POWER TRACK INSTALLATION​

FIGURE 4-11. BOOM SENSORS AND SWITCHES INSTALLATION​

FIGURE 4-12. VALVES INSTALLATION - BOOM MOUNTED​

FIGURE 4-13. PLATFORM VALVE ASSEMBLY​

FIGURE 4-14. JIB VALVE ASSEMBLY​

FIGURE 4-15. ENCLOSURE BOX ASSEMBLY​

FIGURE 4-16. PLATFORM SUPPORT INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY​

FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY​

FIGURE 5-3. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH SWING GATE​

FIGURE 5-4. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH SWING GATE​

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

FIGURE 5-6. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH TRI-ENTRY (1 GATE/2 DROP BARS)​

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) WITH DROP BAR​

FIGURE 5-8. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH DROP BAR​

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

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

FIGURE 5-11. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH TRI-ENTRY (3 DROP BARS)​

FIGURE 5-12. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (ANSI SPECS)​

FIGURE 5-13. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (AUSTRALIAN SPECS)​

FIGURE 5-14. PLATFORM CONSOLE BOX INSTALLATION​

FIGURE 5-15. PLATFORM CONSOLE ASSEMBLY​

FIGURE 5-16. FALL ARREST INSTALLATION (BOLT - ON EXTERNAL) 4FFT/1.22M PLATFORM)​

FIGURE 5-17. FALL ARREST INSTALLTION (BOLT-ON EXTERNAL) (6FT/1.82M PLATFORM)​

FIGURE 5-18. FALL ARREST INSTALLTION (BOLT-ON EXTERNAL) (6FT/1.82M TRI-ENTRY PLATFORM)​

FIGURE 5-19. FALL ARREST INSTALLTION (BOLT-ON EXTERNAL) (8FT/2.4M PLATFORM)​

FIGURE 5-20. FOOTSWITCH ASSEMBLY​

FIGURE 5-21. LCD DISPLAY INSTALLATION​

FIGURE 5-22. LIGHT PANEL INSTALLATION - PLATFORM CONSOLE​

FIGURE 5-23. PLASMA CUTTER ASSEMBLY​

FIGURE 5-24. SKYCUTTER INSTALLATION​

FIGURE 5-25. SKYEYE INSTALLATION​

FIGURE 5-26. SKYGLAZIER INSTALLATIONS (ANSI, AUSTRALIAN AND CSA SPECS)​

FIGURE 5-27. SKYGUARD BAR INSTALLATION​

FIGURE 5-28. SKYLINE INSTALLATION​

FIGURE 5-29. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-30. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-31. SKYWELDER PREP PACKAGE (60HZ)​

FIGURE 5-32. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)​

FIGURE 5-33. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)​

FIGURE 5-34. USB CHARGER INSTALLATION​

FIGURE 5-35. WELDER ASSEMBLY​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE EXTENSION CYLINDER ASSEMBLY​

FIGURE 6-2. AXLE LOCKOUT CYLINDER ASSEMBLY​

FIGURE 6-3. LEVEL (JIB) CYLINDER ASSEMBLY - WITH OR WITHOUT COLD WEATHER PLUS PACKAGE​

FIGURE 6-4. LEVEL (PLATFORM) CYLINDER ASSEMBLY​

FIGURE 6-5. LIFT (BOOM) CYLINDER ASSEMBLY​

FIGURE 6-6. LIFT (JIB) CYLINDER ASSEMBLY​

FIGURE 6-7. LOCK (JIB) CYLINDER ASSEMBLY​

FIGURE 6-8. STEER CYLINDER ASSEMBLY​

FIGURE 6-9. TELESCOPE (JIB) CYLINDER ASSEMBLY​

FIGURE 6-10. TELESCOPE (MAIN BOOM) CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM - BOOM​

FIGURE 7-2. HYDRAULIC DIAGRAM - DRIVE​

FIGURE 7-3. HYDRAULIC DIAGRAM - OSCILLATING AXLE​

FIGURE 7-4. HYDRAULIC DIAGRAM - STEER​

FIGURE 7-5. HYDRAULIC DIAGRAM - TURNTABLE (DEUTZ TD2011 ENGINE MACHINES WITH REXROTH PUMPS)​

FIGURE 7-6. HYDRAULIC DIAGRAM - TURNTABLE (DEUTZ TCD2.9L4 ENGINE MACHINES WITH REXROTH PUMPS)​

FIGURE 7-7. HYDRAULIC DIAGRAM - TURNTABLE (DEUTZ TD2011 AND DEUTZ TCD2.9L4 ENGINE MACHINES WITH SAUER PUMPS)​

FIGURE 7-8. HYDRAULIC DIAGRAM - TURNTABLE (WITH PMP PUMPS) (SN 0300311785 to Present)​

SECTION 8 - ELECTRICAL

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

FIGURE 8-2. AC BOX AT PLATFORM - 110V GFI RECEPTACLE (ANSI SPECS)​

FIGURE 8-3. AC BOX AT PLATFORM - 220V GFI RECEPTACLE (ANSI SPECS)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - BOX WITH COVER (2X4 BOX) WITH 4000W GENERATOR (ANSI EXPORT, AUSTRALIAN, CHINA AND JAPANESE SPECS)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 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 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

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

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITH 4000W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN, CHINA, CE & UK CA SPECS)​

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN, CHINA, CE & UK CA SPECS)​

FIGURE 8-17. AC 16 AMP BREAKER BOX INSTALLATION (CE & UK CA SPECS)​

FIGURE 8-18. BATTERY DISCONNECT INSTALLATION​

FIGURE 8-19. BEACON LIGHT HARNESS​

FIGURE 8-20. B.L.A.M. HARNESS​

FIGURE 8-21. B.L.A.M. TO BOOM LENGTH SENSOR HARNESS​

FIGURE 8-22. B.L.A.M. TO BOOM ANGLE SENSOR HARNESS (LEFT SIDE)​

FIGURE 8-23. B.L.A.M. TO BOOM ANGLE SENSOR HARNESS (RIGHT SIDE)​

FIGURE 8-24. BOOM CABLES INSTALLATION (ANSI, CSA AND JAPANESE SPECS)​

FIGURE 8-25. BOOM CABLES INSTALLATION - WITH 4000W 60HZ GENERATOR (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 8-26. BOOM CABLES INSTALLATION - WITH 4000W 50HZ GENERATOR (ANSI EXPORT, AUSTRALIAN, CHINA, CE & UK CA SPECS)​

FIGURE 8-27. BOOM CABLES INSTALLATION - WITH 7500W GENERATOR​

FIGURE 8-28. BOOM CYLINDER ANGLE HARNESS​

FIGURE 8-29. BREAKER BOX KIT - 16 AMP​

FIGURE 8-30. BREAKER BOX KIT - 16 AMP (4000W GENERATOR)​

FIGURE 8-31. BREAKER BOX KIT - 16 AMP/30MA​

FIGURE 8-32. CLEARSKY 3-WIRE TELEMATICS INSTALLATION (ALL SPECS EXCEPT CHINA SPECS)​

FIGURE 8-33. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (ANSI EXPORT, CE & UK CA SPECS)​

FIGURE 8-34. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (AUSTRALIAN SPECS)​

FIGURE 8-35. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (ALL SPECS EXCEPT CHINA SPECS)​

FIGURE 8-36. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (CHINA SPECS)​

FIGURE 8-37. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-38. CLEARSKY INSTALLATION - WITH DEUTZ TCD2.9L (CHINA IV) ENGINES (CHINA SPECS) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 8-39. CLEARSKY INSTALLATION - WITH DEUTZ TCD2.9L (CHINA IV) ENGINES (CHINA SPECS) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 8-40. CLEARSKY HARNESS - 3-WIRE TELEMATICS​

FIGURE 8-41. CLEARSKY HARNESS - CANBUS TELEMATICS​

FIGURE 8-42. CLEARSKY HARNESS - WITH DEUTZ TCD2.9L (CHINA IV) ENGINES​

FIGURE 8-43. CLEARSKY TELEMATICS JUMPER HARNESS - WITH DEUTZ TCD2.9L (CHINA IV) ENGINES​

FIGURE 8-44. TELEMATICS CONTROL MODULE ASSEMBLY - WITH DEUTZ TCD2.9L (CHINA IV) ENGINES​

FIGURE 8-45. CHASSIS HARNESS​

FIGURE 8-46. DIAGNOSTIC HARNESS​

FIGURE 8-47. ENGINE HARNESS - DEUTZ TD2011 ENGINES​

FIGURE 8-48. ENGINE HARNESS - DEUTZ TCD2.9L4 ENGINES​

FIGURE 8-49. ENGINE HARNESS - DEUTZ TCD2.9L4 (CHINA IV) ENGINES​

FIGURE 8-50. ENGINE HARNESS - DEUTZ TCD2.9L4 & DEUTZ TCD2.9L4 (STAGE V) ENGINES​

FIGURE 8-51. FUEL FILTER HARNESS - DEUTZ TCD2.9L4 ENGINES​

FIGURE 8-52. FUEL HARNESS - DEUTZ TCD2.9L4 & DEUTZ TCD2.9L4 (STAGE V PRE-BUY) ENGINES​

FIGURE 8-53. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-54. GENERATOR HARNESS - 7500W GENERATOR​

FIGURE 8-55. GROUND CONTROL BOX HARNESS​

FIGURE 8-56. INTERFACE HARNESS​

FIGURE 8-57. JIB BOOM CONTROL HARNESS​

FIGURE 8-58. JIB ENABLE HARNESS​

FIGURE 8-59. JIB VALVE HARNESS​

FIGURE 8-60. LCD DISPLAY HARNESS​

FIGURE 8-61. LOAD SENSING PIN HARNESS​

FIGURE 8-62. MAIN BOOM CONTROL HARNESS​

FIGURE 8-63. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-64. PLATFORM VALVE HARNESS​

FIGURE 8-65. PUMP HARNESS​

FIGURE 8-66. PUMP ADAPTER HARNESS - SAUER PUMP TO REXROTH PUMP​

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

FIGURE 8-68. RECEPTACLE BOX KIT - 220V IEC BLUE WITHOUT 2500W GENERATOR (CE & UK CA SPECS)​

FIGURE 8-69. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND WITHOUT 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-70. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND WITHOUT 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-71. RECEPTACLE BOX KIT - 220V AFSINT 107 KEYED GROUND WITHOUT 2500W GENERATOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-72. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-73. SKYEYE RECEIVER HARNESS​

FIGURE 8-74. SKYEYE EMITTER HARNESS​

FIGURE 8-75. SKYLINE HARNESS​

FIGURE 8-76. STROBE LIGHT HARNESS (AMBER)​

FIGURE 8-77. TURNTABLE 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 (PORTUGUESE/ENGLISH)​

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

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

FIGURE 9-6. DECAL INSTALLATION - CHINESE SPEC (ENGLISH)​

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. SKYCUTTER DECAL INSTALLATION (ANSI, ANSI EXPORT AND CSA SPECS)​

FIGURE 9-12. SKYCUTTER DECAL INSTALLATION (JAPANESE SPECS)​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS

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

PART NUMBER INDEX