JLG Boom Lift 600AJ HC3 Parts Catalog 31220618

Hyundai · Jun 21, 2026

JLG Boom Lift 600AJ HC3 Parts Catalog 31220618
Size: 66.23 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 600AJ HC3 Boom Lift
Part Number: 31220618
Publication Date: 2025
Number of Pages: 942 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION (WITHOUT TOW PACKAGE)

FIGURE 1-2. AXLE INSTALLATION (WITH TOW PACKAGE)

FIGURE 1-3. STEERING INSTALLATION (WITHOUT TOW PACKAGE)

FIGURE 1-4. STEERING INSTALLATION (WITH TOW PACKAGE)

FIGURE 1-5. WHEEL DRIVE INSTALLATION

FIGURE 1-6. DRIVE MOTOR ASSEMBLY

FIGURE 1-7. DRIVE HUB ASSEMBLY

FIGURE 1-8. FLOW DIVIDER ASSEMBLY

FIGURE 1-9. TIRE AND WHEEL INSTALLATION - FOAM FILLED

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - FOAM FILLED NON-MARKING

FIGURE 1-11. TIRE AND WHEEL INSTALLATION - FOAM FILLED (TURF)

FIGURE 1-12. FRAME SHIELDS INSTALLATION – 2WS (8FT/2.4M WIDE MACHINES)

FIGURE 1-13. TOW PACKAGE INSTALLATION (ANSI SPECS) (OPTIONAL)

FIGURE 1-14. TOW PACKAGE INSTALLATION (CSA SPECS) (OPTIONAL)

FIGURE 1-15. TOW PACKAGE INSTALLATION (CE, RUSSIAN & UK CA SPECS) (OPTIONAL)

FIGURE 1-16. TOW BAR ASSEMBLY

FIGURE 1-17. LP TANKS INSTALLATION

SECTION 2 - TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 2-2. CONTROL VALVES INSTALLATION - DEUTZ DT2.9L4, DEUTZ TD2.2L3 STAGE V & FORD ENGINES

FIGURE 2-3. MAIN VALVE BLOCK ASSEMBLY – 2WS

FIGURE 2-4. AUXILIARY PUMP INSTALLATION

FIGURE 2-5. AUXILIARY PUMP INSTALLATION WITH BATTERY DISCONNECT

FIGURE 2-6. AUXILIARY PUMP ASSEMBLY

FIGURE 2-7. SWING DRIVE INSTALLATION

FIGURE 2-8. SWING MOTOR/HUB ASSEMBLY

FIGURE 2-9. TURNTABLE BEARING INSTALLATION

FIGURE 2-10. TURNTABLE LOCK INSTALLATION (DEUTZ D2011 & FORD ENGINE MACHINES)

FIGURE 2-11. TURNTABLE LOCK INSTALLATION (DEUTZ TD2.9L4 & DEUTZ TD2.2L3 STAGE V ENGINE MACHINES)

FIGURE 2-12. ROTARY COUPLING INSTALLATION

FIGURE 2-13. TANK INSTALLATION – DEUTZ D2011 ENGINE (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-14. TANK INSTALLATION – DEUTZ D2011 ENGINE (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-15. TANK INSTALLATION – DEUTZ TD2.9L4 & TD2.2L3 STAGE V ENGINES (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-16. TANK INSTALLATION – DEUTZ TD2.9L4 & TD2.2L3 STAGE V ENGINES (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-17. TANK INSTALLATION – FORD ENGINE (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-18. TANK INSTALLATION – FORD ENGINE (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-19. HYDRAULIC OIL TANK ASSEMBLY

FIGURE 2-20. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ D2011 ENGINES (OPTIONAL)

FIGURE 2-21. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2.2L3 STAGE V ENGINES (OPTIONAL)

FIGURE 2-22. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2.9L4 ENGINES (OPTIONAL)

FIGURE 2-23. HYDRAULIC OIL COOLER INSTALLATION – FORD ENGINES (OPTIONAL)

FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) - WITH DIGITAL DISPLAY (ALL SPECS EXCEPT CE & UK CA SPECS)

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) - WITH MECHANICAL HOUR METER (ALL SPECS EXCEPT CE & UK CA SPECS) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) - WITH MECHANICAL HOUR METER (ALL SPECS EXCEPT CE & UK CA SPECS) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (CE & UK CA SPECS) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (CE & UK CA SPECS) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) - WITH DIGITAL DISPLAY

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) - WITH MECHANICAL HOUR METER (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-31. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) - WITH MECHANICAL HOUR METER (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-32. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) - WITH DIGITAL DISPLAY

FIGURE 2-33. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) - WITH MECHANICAL HOUR METER (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-34. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) - WITH MECHANICAL HOUR METER (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-35. GROUND CONTROL BOX ASSEMBLY (DEUTZ TD2.2L3 ENGINE)

FIGURE 2-36. GROUND CONTROL BOX ASSEMBLY (DEUTZ TD2.2L3 ENGINE) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-37. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) - WITH DIGITAL DISPLAY (ANSI EXPORT (LRC), AUSTRAILIAN & CHINEASE SPECS) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-38. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC), AUSTRAILIAN & CHINEASE SPECS) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 030028...

FIGURE 2-39. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC), AUSTRAILIAN & CHINEASE SPECS) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-40. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) (CE & UK CA SPECS) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-41. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) (CE & UK CA SPECS) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-42. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) (TOWER STOW) - WITH DIGITAL DISPLAY

FIGURE 2-43. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-44. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-45. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) (TOWER STOW) - WITH DIGITAL DISPLAY

FIGURE 2-46. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-47. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-48. GROUND CONTROL BOX ASSEMBLY (DEUTZ TD2.2L3 ENGINE) (TOWER STOW) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-49. GROUND CONTROL BOX ASSEMBLY (DEUTZ TD2.2L3 ENGINE) (TOWER STOW) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-50. LIGHT PANEL INSTALLATION - GROUND CONTROL

FIGURE 2-51. CRIBBING ENABLE SWITCH INSTALLATION

FIGURE 2-52. ALARM INSTALLATION

FIGURE 2-53. ALARM (WHITE NOISE AMBIENT) INSTALLATION

FIGURE 2-54. ALARM (WHITE NOISE) INSTALLATION

FIGURE 2-55. STROBE LIGHT INSTALLATION (AMBER) (WITHOUT CLEARSKY BEACON) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 2-56. STROBE LIGHT INSTALLATION (AMBER) (WITHOUT CLEARSKY BEACON) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 2-57. STROBE LIGHT INSTALLATION (BLUE) (WITHOUT CLEARSKY BEACON)

FIGURE 2-58. STROBE LIGHT INSTALLATION (RED) (WITHOUT CLEARSKY BEACON)

FIGURE 2-59. HOODS INSTALLATION – DEUTZ D2011 ENGINES WITHOUT NOISE REDUCTION (ABS)

FIGURE 2-60. HOODS INSTALLATION – DEUTZ D2011 ENGINES WITH NOISE REDUCTION (ABS)

FIGURE 2-61. HOODS INSTALLATION – DEUTZ TD2.2L3 STAGE V ENGINES (ABS)

FIGURE 2-62. HOODS INSTALLATION – DEUTZ TD2.9L4 AND FORD DF 2.5L ENGINES (ABS)

FIGURE 2-63. NOISE REDUCTION INSTALLATION - DEUTZ D2011 & DEUTZ TD2.9L4 ENGINES

FIGURE 2-64. NOISE REDUCTION INSTALLATION - DEUTZ TD2.2L3 ENGINES

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ D2011 ENGINE INSTALLATION – WITHOUT ARCTIC PACKAGE

FIGURE 3-2. DEUTZ D2011 ENGINE INSTALLATION – WITH ARCTIC PACKAGE

FIGURE 3-3. DEUTZ D2011 ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE

FIGURE 3-4. DEUTZ D2011 ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE

FIGURE 3-5. DEUTZ D2011 ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE

FIGURE 3-6. DEUTZ D2011 ENGINE ASSEMBLY – WITH ARCTIC PACKAGE

FIGURE 3-7. DEUTZ D2011 ENGINE COMPONENTS

FIGURE 3-8. DEUTZ TD2.2L3 (STAGE V) ENGINE INSTALLATION

FIGURE 3-9. DEUTZ TD2.2L3 (STAGE V) ENGINE/PUMP SUB-ASSEMBLY

FIGURE 3-10. DEUTZ TD2.2L3 (STAGE V) ENGINE ASSEMBLY

FIGURE 3-11. DEUTZ TD2.2L3 (STAGE V) ENGINE COMPONENTS

FIGURE 3-12. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.2L3 ENGINE)

FIGURE 3-13. DEUTZ TD2.9L4 - 49HP ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE (Prior to SN 0300295997, Except SN 0300285469 through 0300285471, Except SN 0300285757 through 0300285762, Except SN 0300286715 through 0300296723)

FIGURE 3-14. DEUTZ TD2.9L4 - 49HP ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE (SN 0300295997 to Present, SN 0300285469 through 0300285471, SN 0300285757 through 0300285762, SN 0300286715 through 0300296723)

FIGURE 3-15. DEUTZ TD2.9L4 - 49HP ENGINE INSTALLATION - WITH ARCTIC PACKAGE (Prior to SN 0300295997, Except SN 0300285469 through 0300285471, Except SN 0300285757 through 0300285762, Except SN 0300286715 through 0300296723)

FIGURE 3-16. DEUTZ TD2.9L4 - 49HP ENGINE INSTALLATION - WITH ARCTIC PACKAGE (SN 0300295997 to Present, SN 0300285469 through 0300285471, SN 0300285757 through 0300285762, SN 0300286715 through 0300296723)

FIGURE 3-17. DEUTZ TD2.9L4 - 49HP ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE (Prior to SN 0300295997, Except SN 0300285469 through 0300285471, Except SN 0300285757 through 0300285762, Except SN 0300286715 through 0300296723)

FIGURE 3-18. DEUTZ TD2.9L4 - 49HP ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE (SN 0300295997 to Present, SN 0300285469 through 0300285471, SN 0300285757 through 0300285762, SN 0300286715 through 0300296723)

FIGURE 3-19. DEUTZ TD2.9L4 - 49HP ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE (Prior to SN 0300295997, Except SN 0300285469 through 0300285471, Except SN 0300285757 through 0300285762, Except SN 0300286715 through 0300296723)

FIGURE 3-20. DEUTZ TD2.9L4 - 49HP ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE (SN 0300295997 to Present, SN 0300285469 through 0300285471, SN 0300285757 through 0300285762, SN 0300286715 through 0300296723)

FIGURE 3-21. DEUTZ TD2.9L4 - 49HP ENGINE ASSEMBLY – WITH ARCTIC PACKAGE

FIGURE 3-22. DEUTZ TD2.9L4 - 49HP ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE

FIGURE 3-23. DEUTZ TD2.9L4 - 49HP ENGINE COMPONENTS

FIGURE 3-24. DEUTZ TD2.9L4 - 63HP ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE

FIGURE 3-25. DEUTZ TD2.9L4 - 63HP ENGINE INSTALLATION - WITH ARCTIC PACKAGE

FIGURE 3-26. DEUTZ TD2.9L4 - 63HP ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE

FIGURE 3-27. DEUTZ TD2.9L4 - 63HP ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE

FIGURE 3-28. DEUTZ TD2.9L4 - 63HP ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE

FIGURE 3-29. DEUTZ TD2.9L4 - 63HP ENGINE ASSEMBLY – WITH ARCTIC PACKAGE

FIGURE 3-30. DEUTZ TD2.9L4 - 63HP ENGINE COMPONENTS

FIGURE 3-31. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)

FIGURE 3-32. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES WITH ARCTIC PACKAGE

FIGURE 3-33. QUICKFIT OIL DRAIN (DEUTZ TD 2.9L)

FIGURE 3-34. QUICKFIT OIL DRAIN (DEUTZ D ENGINES)

FIGURE 3-35. FORD ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE

FIGURE 3-36. FORD ENGINE INSTALLATION - WITH ARCTIC PACKAGE

FIGURE 3-37. FORD ENGINE/PUMP SUB-ASSEMBLY - WITHOUT ARCTIC PACKAGE

FIGURE 3-38. FORD ENGINE/PUMP SUB-ASSEMBLY - WITH ARCTIC PACKAGE

FIGURE 3-39. FORD ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE

FIGURE 3-40. FORD ENGINE ASSEMBLY - WITH ARCTIC PACKAGE

FIGURE 3-41. PUMP COUPLING AND FUEL SYSTEM ASSEMBLY (FORD ENGINES)

FIGURE 3-42. FORD ENGINE COMPONENTS

FIGURE 3-43. DRIVE BELT INSTALLATION - FORD ENGINES MACHINES WITHOUT GENERATORS

FIGURE 3-44. PUMP COUPLING KIT - DEUTZ ENGINES

FIGURE 3-45. PISTON PUMP ASSEMBLY - DEUTZ ENGINES - DANFOSS

FIGURE 3-46. PISTON PUMP ASSEMBLY WITH FITTINGS - DEUTZ ENGINES - HENGLI

FIGURE 3-47. PISTON PUMP ASSEMBLY - FORD ENGINES

FIGURE 3-48. GEAR PUMP ASSEMBLY

FIGURE 3-49. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-50. EXHAUST PIPE INSTALLATION - FORD ENGINES

FIGURE 3-51. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ D2011 ENGINES (OPTIONAL)

FIGURE 3-52. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITHOUT GENERATORS)

FIGURE 3-53. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)

FIGURE 3-54. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.2L3 ENGINES MACHINES WITHOUT GENERATORS)

FIGURE 3-55. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.2L3 ENGINES MACHINES WITH GENERATORS)

FIGURE 3-56. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.9L4 ENGINES MACHINES WITHOUT GENERATORS)

FIGURE 3-57. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.9L4 ENGINES MACHINES WITH GENERATORS)

FIGURE 3-58. ENGINE TRAY JACK INSTALLATION - DEUTZ D2011 ENIGNES

FIGURE 3-59. ENGINE TRAY JACK INSTALLATION - DEUTZ TD2.9L4 & TD2.2L3 STAGE V ENGINES

FIGURE 3-60. ENGINE TRAY JACK INSTALLATION - FORD ENIGNES

FIGURE 3-61. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-62. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-63. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-64. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (ANSI EXPORT AND CHINA SPECS)

FIGURE 3-65. 2500W GENERATOR INSTALLATION - FORD ENGINES

FIGURE 3-66. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-67. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-68. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.2L3 ENGINES

FIGURE 3-69. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-70. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-71. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-72. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES

FIGURE 3-73. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.2L3 STAGE V ENGINES

FIGURE 3-74. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES

FIGURE 3-75. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD ENGINES

SECTION 4 - BOOM

FIGURE 4-1. BOOMS AND CYLINDERS INSTALLATION

FIGURE 4-2. TOWER BOOM ASSEMBLY

FIGURE 4-3. MAIN BOOM ASSEMBLY

FIGURE 4-4. JIB BOOM ASSEMBLY

FIGURE 4-5. ROTATOR ASSEMBLY

FIGURE 4-6. PLATFORM SUPPORT INSTALLATION

FIGURE 4-7. POWER TRACK INSTALLATION - MAIN BOOM

FIGURE 4-8. POWER TRACK INSTALLATION - TOWER BOOM

FIGURE 4-9. CONTROL VALVES INSTALLATION - DEUTZ D2011 AND STAGE V ENGINES

FIGURE 4-10. CONTROL VALVES INSTALLATION - DEUTZ TD2.9L4 & FORD ENGINES

FIGURE 4-11. BOOM VALVE ASSEMBLY

FIGURE 4-12. BOOM VALVES AND LIMIT SWITCHES INSTALLATION

FIGURE 4-13. BOOM SENSOR INSTALLATION (TOWER STOW)

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76.2CM X 1.22M) WITH SWING GATE

FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - 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 8FT (91.5CM X 2.44M) WITH SWING GATE

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

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 4FT (76.2CM X 1.22M) WITH DROP BAR

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - DROP BAR ENTRY

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

FIGURE 5-9. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH DROP BAR

FIGURE 5-10. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST

FIGURE 5-11. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST

FIGURE 5-12. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH SWING GATE

FIGURE 5-13. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH SWING GATE

FIGURE 5-14. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH DROPBAR

FIGURE 5-15. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH DROPBAR

FIGURE 5-16. TRAY ASSEMBLY

FIGURE 5-17. CONSOLE AND FOOTSWITCH INSTALLATION

FIGURE 5-18. CONSOLE AND FOOTSWITCH INSTALLATION (TOWER STOW)

FIGURE 5-19. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH

FIGURE 5-20. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (TOWER STOW)

FIGURE 5-21. FOOTSWITCH ASSEMBLY

FIGURE 5-22. CONTROLLER ASSEMBLY- DRIVE/STEER

FIGURE 5-23. CONTROLLER ASSEMBLY - LIFT/SWING

FIGURE 5-24. CRAB STEER SWITCH INSTALLATION - 4WS (WITHOUT TOW PACKAGE)

FIGURE 5-25. CRAB STEER SWITCH INSTALLATION - 4WS (WITH TOW PACKAGE)

FIGURE 5-26. LIGHT PANEL INSTALLATION

FIGURE 5-27. STEER SWITCH INSTALLATION – 4WS

FIGURE 5-28. SKYEYE INSTALLATION

FIGURE 5-29. SKYGUARD BAR INSTALLATION

FIGURE 5-30. SKYLINE INSTALLATION (Prior to SN 0300279212)

FIGURE 5-31. SKYLINE INSTALLATION (SN 0300279212 to Present)

FIGURE 5-32. SKYGLAZIER INSTALLATION (ALL SPECS EXCEPT CHINA, JAPANESE, CE & UK CA SPECS) (OPTIONAL)

FIGURE 5-33. SKYCUTTER INSTALLATION (OPTIONAL)

FIGURE 5-34. PLASMA CUTTER ASSEMBLY

FIGURE 5-35. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ) (OPTIONAL)

FIGURE 5-36. SKYWELDER INSTALLATION (50HZ) (OPTIONAL)

FIGURE 5-37. SKYWELDER INSTALLATION (60HZ) (OPTIONAL)

FIGURE 5-38. WELDER ASSEMBLY

FIGURE 5-39. SKYWELDER PREP PACKAGE (60HZ) (OPTIONAL)

FIGURE 5-40. SKYWELDER LOCKING BRACKET INSTALLATION (OPTIONAL)

FIGURE 5-41. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M PLATFORMS (OPTIONAL)

FIGURE 5-42. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M FALL ARREST PLATFORMS (OPTIONAL)

FIGURE 5-43. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM (OPTIONAL)

FIGURE 5-44. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM (OPTIONAL)

FIGURE 5-45. PLATFORM PADDING INSTALLATION (30IN/76CM DEPTH PLATFORMS) (ANSI, ANSI EXPORT, CSA AND CHINA SPECS) (OPTIONAL)

FIGURE 5-46. FALL ARREST (BOLT-ON) INSTALLATION - 30IN X 4FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)

FIGURE 5-47. FALL ARREST (BOLT-ON) INSTALLATION - 30IN X 5FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)

FIGURE 5-48. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 6FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)

FIGURE 5-49. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 6FT TRI-ENTRY PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)

FIGURE 5-50. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 8FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)

FIGURE 5-51. USB CHARGER INSTALLATION

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY

FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY

FIGURE 6-3. LEVEL (UPRIGHT) CYLINDER ASSEMBLY

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - JIB

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - MAIN BOOM

FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MAIN BOOM

FIGURE 6-9. MASTER CYLINDER ASSEMBLY

FIGURE 6-10. STEER CYLINDER ASSEMBLY

FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM

FIGURE 6-12. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM

SECTION 7 - HYDRAULIC

FIGURE 7-1. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS WITHOUT ARCTIC PACKAGE

FIGURE 7-2. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS WITH ARCTIC PACKAGE

FIGURE 7-3. FLUSHING LOOP HYDRAULIC INSTALLATION - 4WD

FIGURE 7-4. HYDRAULIC DIAGRAM - STANDARD (DEUTZ D2011 ENGINE)

FIGURE 7-5. HYDRAULIC DIAGRAM - STANDARD (DEUTZ TD2.9L4 & DEUTZ TD2.2L3 STAGE V ENGINES)

FIGURE 7-6. HYDRAULIC DIAGRAM - STANDARD (FORD ENGINES)

FIGURE 7-7. HYDRAULIC DIAGRAM - OSCILLATING AXLE

FIGURE 7-8. HYDRAULIC DIAGRAM - TOW BAR

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC CABLE CONNECTOR INSTALLATION - 110V/220V (MACHINES NO GENERATOR) (ANSI EXPORT, AUSTRALIAN, CHINA, CE & UK CA SPECS)

FIGURE 8-2. AC CABLE CONNECTOR INSTALLATION – SKYPOWER (MACHINES NO GENERATOR) (ALL SPECS)

FIGURE 8-3. AC CABLE CONNECTOR INSTALLATION – 4000W GENERATOR (MACHINES NO GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN, CE & UK CA SPECS)

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V GFI RECEPTACLE (MACHINES WITH 2500W GENERATOR/NO GENERATOR OPTIONS) (ALL SPECS EXCEPT AUSTRALIAN, CE& UK CA SPECS)

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V RECEPTACLE (MACHINES WITH 2500W GENERATOR/NO GENERATOR OPTIONS) (ANSI, CSA AND JAPANESE SPECS)

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - BOX WITH COVER (2X4 BOX) (ANSI EXPORT SPECS) (4000W GENERATOR)

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION – DUAL AC 110V GFI (MACHINES WITH 2500W GENERATOR) (ANSI EXPORT AND CHINA SPECS)

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE & UK CA SPECS)

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW (CE & UK CA SPECS) (4000W GENERATOR)

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE& UK CA SPECS)

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPECS) (2500W GENERATOR)

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE (CE & UK CA SPECS) (4000W GENERATOR)

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE & UK CA SPECS)

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

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

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE & UK CA SPECS)

FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE & UK CA SPECS) (2500W GENERATOR)

FIGURE 8-18. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) (CE & UK CA SPECS) (4000W GENERATOR)

FIGURE 8-19. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE & UK CA SPECS)

FIGURE 8-20. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE & UK CA SPECS) (2500W GENERATOR)

FIGURE 8-21. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) (CE & UK CA SPECS) (4000W GENERATOR)

FIGURE 8-22. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS WITH 4000W SKYPOWER GENERATOR)

FIGURE 8-23. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI AND CSA SPECS WITH 7500W SKYPOWER GENERATOR)

FIGURE 8-24. BATTERY DISCONNECT SWITCH INSTALLATION – DEUTZ D2011 ENGINES

FIGURE 8-25. BATTERY DISCONNECT SWITCH INSTALLATION (DEUTZ TD2.9L4, DEUTZ D2.9L4, DEUTZ TD2.2L3 STAGE V AND FORD DF2.5L ENGINES)

FIGURE 8-26. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)

FIGURE 8-27. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR OR NO GENERATOR

FIGURE 8-28. BOOM CABLE INSTALLATION - WITH 4000W/50HZ GENERATOR

FIGURE 8-29. BOOM CABLES INSTALLATION - WITH 4000W/60HZ GENERATOR

FIGURE 8-30. BOOM CABLE INSTALLATION - WITH 7500W GENERATOR

FIGURE 8-31. BOOM CABLE - MAIN BOOM

FIGURE 8-32. BOOM CABLE - TOWER BOOM (WITHOUT ARCTIC PACKAGE)

FIGURE 8-33. BREAKER BOX KIT - SINGLE DOUBLE POLE BREAKER (WITH 4000W/50HZ GENERATOR)

FIGURE 8-34. BREAKER BOX KIT - 30MA/16 AMP (WITH GENERATOR)

FIGURE 8-35. CLEARSKY 3-WIRE TELEMATICS INSTALLATION (ALL SPECS EXCEPT CHINA SPEC)

FIGURE 8-36. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (ANSI EXPORT, CE, EAC & UK CA SPECS)

FIGURE 8-37. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (AUSTRALIAN SPEC

FIGURE 8-38. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (ALL SPECS EXCEPT CHINA & EAC SPECS)

FIGURE 8-39. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (CHINA SPEC)

FIGURE 8-40. CLEARSKY CS550 BEACON INSTALLATION

FIGURE 8-41. CLEARSKY HARNESS - 3-WIRE TELEMATICS

FIGURE 8-42. CLEARSKY HARNESS - CANBUS TELEMATICS

FIGURE 8-43. CSB HARNESS

FIGURE 8-44. ENGINE HARNESS ASSEMBLY (DEUTZ D2011 ENGINES) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 8-45. ENGINE HARNESS ASSEMBLY (DEUTZ D2011 ENGINES) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 8-46. ENGINE HARNESS ASSEMBLY (DEUTZ TD2.9L4 & DEUTZ DT2.2L3 STAGE V ENGINES) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 8-47. ENGINE HARNESS ASSEMBLY (DEUTZ TD2.9L4 & DEUTZ DT2.2L3 STAGE V ENGINES) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 8-48. ENGINE HARNESS - DEUTZ TD2.2L3 ENGINES (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 8-49. ENGINE HARNESS - DEUTZ TD2.2L3 ENGINES (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 8-50. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-51. ENGINE HARNESS ASSEMBLY (FORD DF2.5L ENGINES) (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 8-52. ENGINE HARNESS ASSEMBLY (FORD DF2.5L ENGINES) (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 8-53. ECU POWER JUMPER HARNESS

FIGURE 8-54. FUEL HARNESS - DEUTZ TD2.2L3 (STAGE V) ENGINE

FIGURE 8-55. FUEL HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-56. FULL EXTENSION PROXIMITY HARNESS

FIGURE 8-57. GENERATOR TO CONTROL BOX HARNESS - 4000W

FIGURE 8-58. GENERATOR TO CONTROL BOX HARNESS - 7500W GENERATOR

FIGURE 8-59. GENERATOR HARNESS - 7500W GENERATOR (FORD ENGINES)

FIGURE 8-60. GENERATOR HARNESS - 7500W GENERATOR (DEUTZ TD2.9L4 ENGINES)

FIGURE 8-61. GENERATOR TO ENGINE HARNESS - 2500W

FIGURE 8-62. GENERATOR TO ENGINE HARNESS - 4000W

FIGURE 8-63. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ONLY)

FIGURE 8-64. GENERATOR TO REAR OF BOOM HARNESS - 110V

FIGURE 8-65. GENERATOR TO REAR OF BOOM HARNESS - 220V

FIGURE 8-66. GROUND CONTROL BOX HARNESS (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 8-67. GROUND CONTROL BOX HARNESS (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 8-68. MID PROXIMITY HARNESS

FIGURE 8-69. PLATFORM CONSOLE BOX HARNESS

FIGURE 8-70. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPEC)

FIGURE 8-71. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPEC)

FIGURE 8-72. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPECS) (2500W GENERATOR)

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

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

FIGURE 8-75. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE & UK CA SPEC)

FIGURE 8-76. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)

FIGURE 8-77. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE & UK CA SPEC)

FIGURE 8-78. RECEPTACLE BOX KIT - 220V AFSINT 107 KEYED GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)

FIGURE 8-79. SKYEYE INTERMEDIATE HARNESS

FIGURE 8-80. SKYEYE EMITTER HARNESS

FIGURE 8-81. SKYEYE RECEIVER HARNESS

FIGURE 8-82. SKYLINE HARNESS

FIGURE 8-83. SKYGUARD INTERFACE HARNESS

FIGURE 8-84. STROBE JUMPER HARNESS

FIGURE 8-85. VALVE HARNESS - BOOM VALVE

FIGURE 8-86. VALVE HARNESS - MAIN CONTROL VALVE (Prior to SN 0300298302, Except SN 0300286716 through 0300286723, Excluding 0300285470 and 0300285471)

FIGURE 8-87. VALVE HARNESS - MAIN CONTROL VALVE (SN 0300298302 to Present, SN 0300286716 through 0300286723, Including 0300285470 and 0300285471)

FIGURE 8-88. WHITE NOISE ALARM HARNESS

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI SPECS

FIGURE 9-2. DECAL INSTALLATION - AUSTRALIAN SPECS

FIGURE 9-3. DECAL INSTALLATION - BRAZIL SPECS

FIGURE 9-4. DECAL INSTALLATION - CE, RUSSIAN & UK CA SPECS

FIGURE 9-5. DECAL INSTALLATION - CHINESE SPECS (SIMPLIFIED)

FIGURE 9-6. DECAL INSTALLATION - CHINESE SPECS (TRADITIONAL)

FIGURE 9-7. DECAL INSTALLATION - CSA SPECS

FIGURE 9-8. DECAL INSTALLATION - JAPANESE SPECS

FIGURE 9-9. DECAL INSTALLATION - KOREAN SPECS

FIGURE 9-10. DECAL INSTALLATION - LATIN AMERICAN SPECS

FIGURE 9-11. DECAL INSTALLATION - OPTIONS

FIGURE 9-12. SKYCUTTER DECAL INSTALLATION (ALL SPECS EXCEPT AUSTRALIAN, CE & JAPANESE SPECS)

FIGURE 9-13. SKYCUTTER DECAL INSTALLATION (JAPANESE SPECS)

FIGURE 9-14. SKYWELDER DECAL INSTALLATION - 50HZ

FIGURE 9-15. SKYWELDER DECAL INSTALLATION - 60HZ

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PART STOCK

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS

PART NUMBER INDEX

JLG Boom Lift 600AJ HC3 Parts Catalog 31220618

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