JLG Boom Lift 450AJ HC3 Parts Catalog 3122322800

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JLG Boom Lift 450AJ HC3 Parts Catalog 3122322800
Size: 66.29 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 450AJ HC3 Boom Lift
Part Number: 3122322800
Publication Date: 2025
Number of Pages: 818 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-2. AXLE INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-3. STEER INSTALLATION WITHOUT TOW PACKAGE​

FIGURE 1-4. STEER INSTALLATION WITH TOW PACKAGE​

FIGURE 1-5. WHEEL DRIVE INSTALLATION (4WD)​

FIGURE 1-6. DRIVE HUB AND BRAKE ASSEMBLY - REAR​

FIGURE 1-7. DRIVE HUB ASSEMBLY - FRONT​

FIGURE 1-8. DRIVE MOTOR ASSEMBLY (4WD)​

FIGURE 1-9. FRAME SHIELD INSTALLATION​

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED (AVAILABLE ON ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)​

FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED NON MARKING (AVAILABLE ON ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)​

FIGURE 1-12. TIRE AND WHEEL INSTALLATION - 14 X17.5 FOAM FILLED​

FIGURE 1-13. TIRE AND WHEEL INSTALLATION - 14 X17.5 FOAM FILLED NON-MARKING​

FIGURE 1-14. TIRE AND WHEEL INSTALLATION - 33 X 12-20 FOAM-FILLED (AVAILABLE ON ALL SPECS)​

FIGURE 1-15. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING (AVAILABLE ON ANSI EXPORT, AUSTRALIAN, CE, CIS/EAC & UK CA SPECS)​

FIGURE 1-16. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM-FILLED (AVAILABLE ON ALL SPECS)​

FIGURE 1-17. TIRE AND WHEEL INSTALLATION - 33 X 16L500 TURF AND SAND FOAM-FILLED (AVAILABLE ON ANSI, ANSI EXPORT & CSA SPECS)​

FIGURE 1-18. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED (AVAILABLE ON ANSI EXPORT, AUSTRALIAN, CE, CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 1-19. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING (AVAILABLE ON ANSI EXPORT, AUSTRALIAN, CE, CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 1-20. VALVES INSTALLATION - FRAME MOUNTED (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-21. VALVES INSTALLATION - FRAME MOUNTED (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-22. TRACTION VALVE ASSEMBLY - 4WD​

FIGURE 1-23. TOW PACKAGE INSTALLATION (OPTIONAL)​

FIGURE 1-24. TOW BAR ASSEMBLY​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVES INSTALLATION - TURNTABLE (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-2. VALVES INSTALLATION - TURNTABLE (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-3. MAIN VALVE ASSEMBLY​

FIGURE 2-4. AUXILIARY PUMP ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-5. AUXILIARY PUMP ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-6. SWING DRIVE AND TURNTABLE BEARING INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-7. SWING DRIVE AND TURNTABLE BEARING INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-8. SWING MOTOR ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-9. SWING MOTOR ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-10. TURNTABLE BEARING ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-11. TURNTABLE BEARING ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 2-12. TURNTABLE COVERS INSTALLATION​

FIGURE 2-13. TURNTABLE LOCK INSTALLATION​

FIGURE 2-14. TANKS INSTALLATION - DIESEL MACHINES (HYDRAULIC TANK WITH 4 INCH BREATHER)​

FIGURE 2-15. TANKS INSTALLATION - DIESEL MACHINES (HYDRAULIC TANK WITH 6 INCH BREATHER)​

FIGURE 2-16. TANKS INSTALLATION - GAS MACHINES​

FIGURE 2-17. HYDRAULIC TANK ASSEMBLY - WITH 4 INCH BREATHER (DIESEL MACHINES)​

FIGURE 2-18. DRIVE ORIENTATION INSTALLATION​

FIGURE 2-19. GROUND CONTROL ASSEMBLY (ALL SPECS EXCEPT CE, CIS/EAC & UK CA SPECS)​

FIGURE 2-20. GROUND CONTROL ASSEMBLY (CE, CIS/EAC & UK CA SPECS)​

FIGURE 2-21. GROUND CONTROL ASSEMBLY (STAGE V ONLY) (CE & UK CA SPECS)​

FIGURE 2-22. LIGHT PANEL INSTALLATION – GROUND CONTROL​

FIGURE 2-23. ELECTRICAL SYSTEM INSTALLATION​

FIGURE 2-24. BEACON LIGHT INSTALLATION - AMBER (WITHOUT CLEARSKY BEACON)​

FIGURE 2-25. BEACON LIGHT INSTALLATION - ORANGE (WITHOUT CLEARSKY BEACON)​

FIGURE 2-26. BATTERY AND CABLE INSTALLATION​

FIGURE 2-27. HOODS INSTALLATION (ABS) - DEUTZ ENGINES (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-28. HOODS INSTALLATION (ABS) - DEUTZ ENGINES (MACHINES WITH SN STARTING WITH B3 FOR ANSI EXPORT, CHINA, RUSSIA & JAPANESE SPECS)​

FIGURE 2-29. HOODS INSTALLATION (ABS) - DEUTZ ENGINES (MACHINES WITH SN STARTING WITH B3 FOR AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 2-30. HOODS INSTALLATION (ABS) - KUBOTA ENGINE​

FIGURE 2-31. HOODS INSTALLATION (STEEL)​

FIGURE 2-32. HOOD ASSEMBLY (ABS) - ENGINE SIDE (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-33. HOOD ASSEMBLY (ABS) - ENGINE SIDE (MACHINES WITH SN STARTING WITH B3 FOR ANSI EXPORT, CHINA, RUSSIA & JAPANESE SPECS)​

FIGURE 2-34. HOOD ASSEMBLY (ABS) - ENGINE SIDE (MACHINES WITH SN STARTING WITH B3 FOR AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 2-35. HOOD ASSEMBLY (ABS) - TANK SIDE (MACHINES WITH SN STARTING WITH 03)​

FIGURE 2-36. HOOD ASSEMBLY (ABS) - TANK SIDE (MACHINES WITH SN STARTING WITH B3 FOR ANSI EXPORT, CHINA, CIS/EAC & JAPANESE SPECS)​

FIGURE 2-37. HOOD ASSEMBLY (ABS) - TANK SIDE (MACHINES WITH SN STARTING WITH B3 FOR AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 2-38. HOOD ASSEMBLY (STEEL) - ENGINE SIDE​

FIGURE 2-39. HOOD ASSEMBLY (STEEL) - TANK SIDE​

FIGURE 2-40. WHITE NOISE ALARM INSTALLATION​

FIGURE 2-41. WHITE NOISE ALARM AMBIENT INSTALLATION​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA CIS/EAC & UK CA SPECS)​

FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 3-4. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-5. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-6. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH 17GAL HYDRAULIC TANK & ARCTIC PACKAGE) (ANSI EXPORT, CHINA & RUSSIA SPECS)​

FIGURE 3-7. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH 36GAL HYDRAULIC TANK & ARCTIC PACKAGE) (ANSI EXPORT & RUSSIA SPECS)​

FIGURE 3-8. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITH ARCTIC PACKAGE) (ANSI EXPORT, CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 3-9. ENGINE ASSEMBLY - DEUTZ TD2.9L4 EMR4 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-10. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-11. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-12. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 3-13. ENGINE COMPONENTS - DEUTZ D2011​

FIGURE 3-14. ENGINE INSTALLATION - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)​

FIGURE 3-15. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE(WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)​

FIGURE 3-16. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-17. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-18. ENGINE ASSEMBLY - DEUTZ TD2.9L4 EMR4 ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-19. DEUTZ D2.9L4 - EMR4 (49HP) ENGINE COMPONENTS​

FIGURE 3-20. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (Prior to SN 0300321460, Prior to SN B300027499)​

FIGURE 3-21. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (SN 0300321461 to Present, SN B300027500 to Present, Including B300027340)​

FIGURE 3-22. ENGINE INSTALLATION - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)​

FIGURE 3-23. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-24. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)​

FIGURE 3-25. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE(WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS​

FIGURE 3-26. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS) (Prior to SN 0300321460, Prior to SN B300027499)​

FIGURE 3-27. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS) (SN 0300321461 to Present, SN B300027500 to Present, Including B300027340)​

FIGURE 3-28. ENGINE COMPONENTS - DEUTZ D2.9L4 ERM5 ENGINE (ANSI, ANSI EXPORT AND CSA SPECS)​

FIGURE 3-29. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-30. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-31. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (WITH PMP PUMP)​

FIGURE 3-32. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V)​

FIGURE 3-33. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS) (Prior to SN 0300321460, Prior to SN B300027499)​

FIGURE 3-34. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS) (SN 0300321461 to Present, SN B300027500 to Present, Including B300027340)​

FIGURE 3-35. ENGINE COMPONENTS - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-36. MOTOR MOUNT INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) WITHOUT GENERATOR​

FIGURE 3-37. MOTOR MOUNT INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) WITH GENERATOR​

FIGURE 3-38. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)​

FIGURE 3-39. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V)​

FIGURE 3-40. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINE WITH ARCTIC PACKAGE​

FIGURE 3-41. PUMP COUPLING KIT – DEUTZ ENGINES​

FIGURE 3-42. ENGINE INSTALLATION - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-43. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-44. ENGINE ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-45. ENGINE INSTALLATION - KUBOTA ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-46. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-47. ENGINE ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-48. ENGINE COMPONENTS - KUBOTA​

FIGURE 3-49. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (CHINA IV) (WITH PMP PUMP)​

FIGURE 3-50. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-51. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 CHINA IV ENGINE)​

FIGURE 3-52. ENGINE ASSEMBLY - DEUTZ D2.9L4 (CHINA IV)​

FIGURE 3-53. DEUTZ D2.9L4 ENGINE COMPONENTS (CHINA IV)​

FIGURE 3-54. FUEL/WATER SEPARATOR ASSEMBLY​

FIGURE 3-55. PUMP COUPLING KIT - KUBOTA ENGINE​

FIGURE 3-56. PISTON PUMP ASSEMBLY​

FIGURE 3-57. CLOSED PUMP LOOP ASSEMEBLY​

FIGURE 3-58. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE​

FIGURE 3-59. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES​

FIGURE 3-60. ENGINE BAFFLE INSTALLATION – WITH KUBOTA ENGINE​

FIGURE 3-61. GENERATOR INSTALLATION - 2500W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-62. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-63. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2.9L4 ENGINE)​

FIGURE 3-64. GENERATOR INSTALLATION - 2500W/60HZ (KUBOTA ENGINE)​

FIGURE 3-65. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-66. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-67. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2.9L4 ENGINE)​

FIGURE 3-68. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ ENGINE) (STAGE V)​

FIGURE 3-69. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-70. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-71. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2.9L4 ENGINE)​

FIGURE 3-72. GENERATOR INSTALLATION - 7500W/60HZ (KUBOTA ENGINE)​

FIGURE 3-73. QUICKFIT OIL DRAIN INSTALLATION (DEUTZ ENGINES)​

FIGURE 3-74. QUICKFIT OIL DRAIN INSTALLATION (KUBOTA ENGINES)​

SECTION 4 - BOOM

FIGURE 4-1. BOOM INSTALLATION​

FIGURE 4-2. MAIN BOOM ASSEMBLY​

FIGURE 4-3. TOWER BOOM ASSEMBLY​

FIGURE 4-4. JIB INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-5. JIB INSTALLATION (MACHINES WITH SN STARTING WITH B3) (Prior to SN B300027499)​

FIGURE 4-6. JIB INSTALLATION (MACHINES WITH SN STARTING WITH B3) (SN B300027500 to Present, Including B300027340)​

FIGURE 4-7. ROTATOR ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-8. ROTATOR ASSEMBLY (MACHINES WITH SN STARTING WITH B3) (Prior to SN B300027499)​

FIGURE 4-9. ROTATOR ASSEMBLY (MACHINES WITH SN STARTING WITH B3) (SN B300027500 to Present, Including B300027340)​

FIGURE 4-10. PLATFORM SUPPORT INSTALLATION​

FIGURE 4-11. VALVES INSTALLATION - BOOM MOUNTED (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-12. VALVES INSTALLATION - BOOM MOUNTED (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-13. UPRIGHT VALVE ASSEMBLY​

FIGURE 4-14. BOOM VALVE ASSEMBLY​

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 - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR​

FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY​

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR​

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - FALL ARREST​

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY​

FIGURE 5-8. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR​

FIGURE 5-9. PLATFORM CONSOLE BOX INSTALLATION​

FIGURE 5-10. PLATFORM CONSOLE BOX ASSEMBLY​

FIGURE 5-11. LIGHT PANEL INSTALLATION - PLATFORM CONSOLE​

FIGURE 5-12. FOOTSWITCH ASSEMBLY​

FIGURE 5-13. TRAY ASSEMBLY​

FIGURE 5-14. USB CHARGER INSTALLATION​

FIGURE 5-15. SKYEYE INSTALLATION​

FIGURE 5-16. SKYGUARD BAR INSTALLATION​

FIGURE 5-17. SKYLINE INSTALLATION​

FIGURE 5-18. SKYGLAZIER INSTALLATION​

FIGURE 5-19. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-20. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-21. SKYWELDER PREP PACKAGE INSTALLATION​

FIGURE 5-22. WELDER ASSEMBLY​

FIGURE 5-23. SOFT TOUCH INSTALLATION (WITHOUT FALL ARREST)​

FIGURE 5-24. SOFT TOUCH INSTALLATION (WITH FALL ARREST)​

FIGURE 5-25. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)​

FIGURE 5-26. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-2. AXLE LOCKOUT CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MAIN LIFT​

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

FIGURE 6-7. MASTER CYLINDER ASSEMBLY​

FIGURE 6-8. STEER CYLINDER ASSEMBLY​

FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. 4WD HYDRAULIC SYSTEM INSTALLATION (WITH 17GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03) (Prior to SN 0300323005)​

FIGURE 7-2. 4WD HYDRAULIC SYSTEM INSTALLATION (WITH 17GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03) (SN 0300323006 to Present)​

FIGURE 7-3. 4WD HYDRAULIC SYSTEM INSTALLATION (WITH 36GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 7-4. 4WD HYDRAULIC SYSTEM INSTALLATION (MACHINES WITH SN STARTING WITH B3) (Prior to SN B300027559)​

FIGURE 7-5. 4WD HYDRAULIC SYSTEM INSTALLATION (MACHINES WITH SN STARTING WITH B3) (SN B300027560 to Present)​

FIGURE 7-6. 4WD HYDRAULIC SYSTEM INSTALLATION - 450AJ (WITH PMP PUMP)​

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V - ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS​

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN POST GROUND (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN SIDE GROUND (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (AUSTRALIAN, CE & UK CA SPECS)​

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)​

FIGURE 8-15. AC CABLE INSTALLATION - WITH TWO BREAKERS (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-16. AC CABLE INSTALLATION - WITH TWO BREAKERS (MACHINES WITH SN STARTING WITH B3)​

FIGURE 8-17. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-18. AC CABLE AND PLUG INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 8-19. BATTERY DISCONNECT SWITCH​

FIGURE 8-20. BEACON JUMPER HARNESS (AMBER LIGHT)​

FIGURE 8-21. BEACON JUMPER HARNESS (ORANGE LIGHT)​

FIGURE 8-22. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITHOUT GENERATOR & WITHOUT AC CABLES)​

FIGURE 8-23. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITHOUT GENERATOR & WITH AC CABLES)​

FIGURE 8-24. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITHOUT GENERATOR AND WITH ARCTIC PACKAGE)​

FIGURE 8-25. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITH 50HZ 4000W GENERATOR)​

FIGURE 8-26. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITH 60HZ 4000W GENERATOR)​

FIGURE 8-27. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITH 7500W GENERATOR)​

FIGURE 8-28. BOOM CABLES AND CLAMPS INSTALLATION (MACHINES WITH 7500W GENERATOR AND WITH ARCTIC PACKAGE)​

FIGURE 8-29. BOOM HARNESS (MAIN BOOM) (WITHOUT ARCTIC PACKAGE)​

FIGURE 8-30. BOOM HARNESS (MAIN BOOM) (WITH ARCTIC PACKAGE)​

FIGURE 8-31. BOOM HARNESS (MAIN BOOM AC CABLE) (WITHOUT GENERATOR AND WITHOUT ARCTIC PACKAGE)​

FIGURE 8-32. BOOM HARNESS (MAIN BOOM AC CABLE) (WITHOUT GENERATOR AND WITH ARCTIC PACKAGE)​

FIGURE 8-33. BOOM HARNESS - TOWER BOOM (WITHOUT ARCTIC PACKAGE)​

FIGURE 8-34. BOOM HARNESS - TOWER BOOM (WITH ARCTIC PACKAGE)​

FIGURE 8-35. BOOM HARNESS - TOWER BOOM AC CABLE (WITHOUT ARCTIC PACKAGE)​

FIGURE 8-36. BOOM HARNESS - TOWER BOOM AC CABLE (WITH ARCTIC PACKAGE)​

FIGURE 8-37. BOOM SENSORS INSTALLATION​

FIGURE 8-38. BOOM SENSOR HARNESS​

FIGURE 8-39. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-40. BREAKER BOX KIT WITH THREE BREAKERS (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-41. BREAKER BOX KIT - 30MA/16 AMP​

FIGURE 8-42. BREAKER BOX KIT​

FIGURE 8-43. CAPACITY HARNESS​

FIGURE 8-44. CHASSIS SOLENOID HARNESS​

FIGURE 8-45. CLEARSKY CS550 BEACON INSTALLATION - WITH METAL HOOD​

FIGURE 8-46. CLEARSKY CS550 BEACON INSTALLATION - WITH PLASTIC HOOD​

FIGURE 8-47. ENGINE HARNESS - DEUTZ D2011​

FIGURE 8-48. ENGINE HARNESS - DEUTZ D2.9L4​

FIGURE 8-49. ENGINE HARNESS​

FIGURE 8-50. ENGINE HARNESS - KUBOTA​

FIGURE 8-51. ENGINE HARNESS - DEUTZ D2.9L4 (CHINA IV)​

FIGURE 8-52. FUEL HARNESS - DEUTZ D2.9L4 ENGINE​

FIGURE 8-53. GENERATOR HARNESS - 2500W GENERATOR (60HZ)​

FIGURE 8-54. GENERATOR HARNESS - 2500W GENERATOR (50HZ)​

FIGURE 8-55. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-56. GROUND CONTROL PANEL HARNESS​

FIGURE 8-57. HOUR METER JUMPER HARNESS​

FIGURE 8-58. KUBOTA D/F POWER HARNESS​

FIGURE 8-59. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-60. PLATFORM INTERFACE HARNESS​

FIGURE 8-61. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-62. RECEPTACLE BOX KIT - 220V IEC BLUE (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-63. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-64. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-65. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-66. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-67. SKYEYE RECEIVER HARNESS​

FIGURE 8-68. SKYEYE EMITTER HARNESS​

FIGURE 8-69. SKYLINE HARNESS​

FIGURE 8-70. TRANSPORT HARNESS​

FIGURE 8-71. TURNTABLE HARNESS​

FIGURE 8-72. VALVE HARNESS - BOOM​

FIGURE 8-73. VALVE HARNESS - MAIN VALVE​

FIGURE 8-74. VALVE HARNESS - PLATFORM VALVE​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI, ANSI EXPORT AND CSA SPECS WITH DEUTZ ENGINES (ENGLISH LANGUAGE)​

FIGURE 9-2. DECAL INSTALLATION - ANSI AND ANSI EXPORT SPECS WITH KUBOTA ENGINES (ENGLISH LANGUAGE)​

FIGURE 9-3. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH LANGUAGE)​

FIGURE 9-4. DECAL INSTALLATION - BRAZIL SPEC (PORTUGUESE/SPANISH LANGUAGES)​

FIGURE 9-5. DECAL INSTALLATION - CE & UK CA SPEC (ENGLISH LANGUAGE)​

FIGURE 9-6. DECAL INSTALLATION - CSA SPEC WITH DEUTZ ENGINES (FRENCH/ENGLISH LANGUAGES)​

FIGURE 9-7. DECAL INSTALLATION - CSA SPEC WITH KUBOTA ENGINES (FRENCH/ENGLISH LANGUAGES)​

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

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

FIGURE 9-10. DECAL INSTALLATION - KOREAN SPEC (KOREAN/ENGLISH LANGUAGES)​

FIGURE 9-11. DECAL INSTALLATION - LATIN AMERICA SPEC (SPANISH/ENGLISH LANGUAGES)​

FIGURE 9-12. DECAL INSTALLATION - OPTIONS​

FIGURE 9-13. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI, ANSI EXPORT, CE, CHINA, CIS/EAC, JAPANESE & UK CA SPECS)​

FIGURE 9-14. TOW BAR DECAL INSTALLATION - ENGLISH/SPANISH LANGUAGE (ANSI EXPORT SPECS)​

FIGURE 9-15. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (ANSI EXPORT, CE, CIS/EAC & UK CA SPECS)​

FIGURE 9-16. SKYWELDER DECAL INSTALLATION – 50HZ (ANSI EXPORT SPECS)​

FIGURE 9-17. SKYWELDER DECAL INSTALLATION - 60HZ (ANSI EXPORT SPECS)​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

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

PART NUMBER INDEX