JLG Boom Lift 600AJ HC3 Parts Catalog 31222410

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JLG Boom Lift 600AJ HC3 Parts Catalog 31222410
Size: 65.99 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: 31222410
Publication Date: 2025
Number of Pages: 898 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 - 4WD/2WS​

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​

FIGURE 2-14. TANK INSTALLATION – DEUTZ TD2.9L4 & TD2.2L3 STAGE V ENGINES​

FIGURE 2-15. TANK INSTALLATION – FORD ENGINE​

FIGURE 2-16. HYDRAULIC OIL TANK ASSEMBLY​

FIGURE 2-17. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ D2011 ENGINES (OPTIONAL)​

FIGURE 2-18. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2.2L3 STAGE V ENGINES (OPTIONAL)​

FIGURE 2-19. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2.9L4 ENGINES (OPTIONAL)​

FIGURE 2-20. HYDRAULIC OIL COOLER INSTALLATION – FORD ENGINES (OPTIONAL)​

FIGURE 2-21. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) - WITH MECHANICAL HOUR METER (ALL SPECS EXCEPT CE & UK CA SPECS)​

FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (CE & UK CA SPECS)​

FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) - WITH MECHANICAL HOUR METER​

FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) - WITH MECHANICAL HOUR METER​

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY (DEUTZ TD2.2L3 ENGINE)​

FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER (ANSI EXPORT (LRC), AUSTRAILIAN & CHINESE SPECS)​

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY (DEUTZ D2011 ENGINE) (TOWER STOW) (CE & UK CA SPECS)​

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY (DEUTZ 2.9L4 ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER​

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY (FORD ENGINE) (TOWER STOW) - WITH MECHANICAL HOUR METER​

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY (DEUTZ TD2.2L3 ENGINE) (TOWER STOW)​

FIGURE 2-31. LIGHT PANEL INSTALLATION - GROUND CONTROL​

FIGURE 2-32. CRIBBING ENABLE SWITCH INSTALLATION​

FIGURE 2-33. ALARM INSTALLATION​

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

FIGURE 2-35. ALARM (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. HOODS INSTALLATION – DEUTZ D2011 ENGINES WITHOUT NOISE REDUCTION (ABS)​

FIGURE 2-40. HOODS INSTALLATION – DEUTZ D2011 ENGINES WITH NOISE REDUCTION (ABS)​

FIGURE 2-41. HOODS INSTALLATION – DEUTZ TD2.2L3 STAGE V ENGINES (ABS)​

FIGURE 2-42. HOODS INSTALLATION – DEUTZ TD2.9L4 AND FORD DF 2.5L ENGINES (ABS)​

FIGURE 2-43. NOISE REDUCTION INSTALLATION - DEUTZ D2011 & DEUTZ TD2.9L4 ENGINES​

FIGURE 2-44. NOISE REDUCTION INSTALLATION - DEUTZ TD2.2L3 ENGINES​

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ D2011 ENGINE INSTALLATION – WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-2. DEUTZ D2011 ENGINE INSTALLATION – WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-3. DEUTZ D2011 ENGINE INSTALLATION – WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-4. DEUTZ D2011 ENGINE INSTALLATION – WITH ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-5. DEUTZ D2011 ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-6. DEUTZ D2011 ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-7. DEUTZ D2011 ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-8. DEUTZ D2011 ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-9. DEUTZ D2011 ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE​

FIGURE 3-10. DEUTZ D2011 ENGINE ASSEMBLY – WITH ARCTIC PACKAGE​

FIGURE 3-11. DEUTZ D2011 ENGINE COMPONENTS​

FIGURE 3-12. DEUTZ TD2.2L3 (STAGE V) ENGINE INSTALLATION - (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-13. DEUTZ TD2.2L3(STAGE V) ENGINE/PUMP SUB ASSEMBLY - (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-14. DEUTZ TD2.2L3 (STAGE V) ENGINE ASSEMBLY​

FIGURE 3-15. DEUTZ TD2.2L3 (STAGE V) ENGINE COMPONENTS​

FIGURE 3-16. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.2L3 ENGINE)​

FIGURE 3-17. DEUTZ TD2.9L4 - 49HP EMR4 ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-18. DEUTZ TD2.9L4 - 49HP EMR5 ENGINE INSTALLATION - WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-19. DEUTZ TD2.9L4 - 49HP EMR4 ENGINE INSTALLATION - WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-20. DEUTZ D2.9L4 EMR5 ENGINE INSTALLATION (WITH ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-21. DEUTZ TD2.9L4 - 49HP EMR4 ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-22. DEUTZ TD2.9L4 - 49HP EMR4 ENGINE/PUMP SUB-ASSEMBLY – WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-23. DEUTZ TD2.9L4 - 49HP EMR4 ENGINE/PUMP SUB-ASSEMBLY – WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-24. DEUTZ D2.9L4 EMR5 ENGINE/PUMP SUB ASSEMBLY (WITH ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-25. DEUTZ D2.9L4 EMR4 (49HP) ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-26. DEUTZ D2.9L4 EMR4 (49HP) ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-27. DEUTZ D2.9L4 EMR5 (49HP) ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-28. DEUTZ D2.9L4 EMR5 (49HP) ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-29. DEUTZ D2.9L4 EMR4 (49HP) ENGINE ASSEMBLY - WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-30. DEUTZ D2.9L4 EMR4 (49HP) ENGINE ASSEMBLY - WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-31. ENGINE ASSEMBLY - DEUTZ D2.9L4 EMR5 ENGINE (WITH ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-32. DEUTZ D2.9L4 EMR4 (49HP) ENGINE COMPONENTS (Prior to SN 0300307127)​

FIGURE 3-33. ENGINE COMPONENTS - DEUTZ D2.9L4 ERM5 ENGINE (49HP) (SN 0300307363 to Present)​

FIGURE 3-34. DEUTZ TP2.9L4 (67HP) EMR4 ENGINE INSTALLATION - (WITHOUT ARCTIC PACKAGE) (Prior to SN 0300307127)​

FIGURE 3-35. DEUTZ TP2.9L4 (67HP) EMR5 ENGINE INSTALLATION - (WITHOUT ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-36. DEUTZ TP2.9L4 (67HP) EMR4 ENGINE INSTALLATION - (WITH ARCTIC PACKAGE) (Prior to SN 0300307127)​

FIGURE 3-37. DEUTZ TP2.9L4 (67HP) EMR5 ENGINE INSTALLATION - (WITH ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-38. DEUTZ TP2.9L4 (67HP) EMR4 ENGINE/PUMP SUB ASSEMBLY - (WITHOUT ARCTIC PACKAGE) (Prior to SN 0300307127)​

FIGURE 3-39. DEUTZ TP2.9L4 (67HP) EMR5 ENGINE/PUMP SUB ASSEMBLY - (WITHOUT ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-40. DEUTZ TP2.9L4 (67HP) EMR4 ENGINE/PUMP SUB ASSEMBLY - (WITH ARCTIC PACKAGE) (Prior to SN 0300307127)​

FIGURE 3-41. DEUTZ TP2.9L4 (67HP) EMR5 ENGINE/PUMP SUB ASSEMBLY - (WITH ARCTIC PACKAGE) (SN 0300307363 to Present)​

FIGURE 3-42. DEUTZ TD2.9L4 - 63HP EMR4 ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-43. DEUTZ TD2.9L4 - 63HP EMR5 ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-44. DEUTZ TD2.9L4 - 63HP EMR5 ENGINE ASSEMBLY – WITHOUT ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-45. DEUTZ TD2.9L4 - 63HP EMR4 ENGINE ASSEMBLY – WITH ARCTIC PACKAGE (Prior to SN 0300307127)​

FIGURE 3-46. DEUTZ TD2.9L4 - 63HP EMR5 ENGINE ASSEMBLY – WITH ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-47. DEUTZ TD2.9L4 - 63HP EMR5 ENGINE ASSEMBLY – WITH ARCTIC PACKAGE (SN 0300307363 to Present)​

FIGURE 3-48. DEUTZ TD2.9L4 - 63HP EMR4 ENGINE COMPONENTS (Prior to SN 0300307127)​

FIGURE 3-49. DEUTZ TD2.9L4 - 63HP EMR5 ENGINE COMPONENTS (SN 0300307363 to Present)​

FIGURE 3-50. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)​

FIGURE 3-51. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES WITH ARCTIC PACKAGE​

FIGURE 3-52. QUICKFIT OIL DRAIN (DEUTZ TD 2.9L)​

FIGURE 3-53. QUICKFIT OIL DRAIN (DEUTZ D ENGINES)​

FIGURE 3-54. FORD ENGINE INSTALLATION - (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-55. FORD ENGINE INSTALLATION - (WITH ARCTIC PACKAGE)​

FIGURE 3-56. FORD ENGINE/PUMP SUB ASSEMBLY – (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-57. FORD ENGINE/PUMP SUB ASSEMBLY - (WITH ARCTIC PACKAGE)​

FIGURE 3-58. FORD ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE​

FIGURE 3-59. FORD ENGINE ASSEMBLY - WITH ARCTIC PACKAGE​

FIGURE 3-60. PUMP COUPLING AND FUEL SYSTEM ASSEMBLY (FORD ENGINES)​

FIGURE 3-61. FORD ENGINE COMPONENTS​

FIGURE 3-62. DRIVE BELT INSTALLATION - FORD ENGINES MACHINES WITHOUT GENERATORS​

FIGURE 3-63. PUMP COUPLING KIT - DEUTZ ENGINES​

FIGURE 3-64. PISTON PUMP ASSEMBLY - DEUTZ ENGINES - DANFOSS​

FIGURE 3-65. PISTON PUMP AND FITTINGS SUB-ASSEMBLY - DEUTZ ENGINES - HENGLI​

FIGURE 3-66. PISTON PUMP AND FITTINGS SUB-ASSEMBLY - FORD ENGINES - HENGLI​

FIGURE 3-67. PISTON PUMP ASSEMBLY - HENGLI​

FIGURE 3-68. GEAR PUMP ASSEMBLY​

FIGURE 3-69. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-70. EXHAUST PIPE INSTALLATION - FORD ENGINES​

FIGURE 3-71. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ D2011 ENGINES (OPTIONAL)​

FIGURE 3-72. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITHOUT GENERATORS)​

FIGURE 3-73. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)​

FIGURE 3-74. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.2L3 ENGINES MACHINES WITHOUT GENERATORS)​

FIGURE 3-75. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.2L3 ENGINES MACHINES WITH GENERATORS)​

FIGURE 3-76. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.9L4 ENGINES MACHINES WITHOUT GENERATORS)​

FIGURE 3-77. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ TD2.9L4 ENGINES MACHINES WITH GENERATORS)​

FIGURE 3-78. ENGINE TRAY JACK INSTALLATION - DEUTZ D2011 ENIGNES​

FIGURE 3-79. ENGINE TRAY JACK INSTALLATION - DEUTZ TD2.9L4 & TD2.2L3 STAGE V ENGINES​

FIGURE 3-80. ENGINE TRAY JACK INSTALLATION - FORD ENIGNES​

FIGURE 3-81. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-82. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-83. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-84. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (ANSI EXPORT AND CHINA SPECS)​

FIGURE 3-85. 2500W GENERATOR INSTALLATION - FORD ENGINES​

FIGURE 3-86. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-87. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-88. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.2L3 ENGINES​

FIGURE 3-89. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-90. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-91. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-92. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-93. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.2L3 STAGE V ENGINES​

FIGURE 3-94. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-95. 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. CRAB STEER SWITCH INSTALLATION - 4WS (WITHOUT TOW PACKAGE)​

FIGURE 5-23. CRAB STEER SWITCH INSTALLATION - 4WS (WITH TOW PACKAGE)​

FIGURE 5-24. LIGHT PANEL INSTALLATION​

FIGURE 5-25. STEER SWITCH INSTALLATION – 4WS​

FIGURE 5-26. SKYEYE INSTALLATION​

FIGURE 5-27. SKYGUARD BAR INSTALLATION​

FIGURE 5-28. SKYLINE INSTALLATION​

FIGURE 5-29. SKYGLAZIER INSTALLATION (ALL SPECS EXCEPT CHINA, JAPANESE, CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-30. SKYCUTTER INSTALLATION (OPTIONAL)​

FIGURE 5-31. PLASMA CUTTER ASSEMBLY​

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

FIGURE 5-33. SKYWELDER INSTALLATION (50HZ) (OPTIONAL)​

FIGURE 5-34. SKYWELDER INSTALLATION (60HZ) (OPTIONAL)​

FIGURE 5-35. WELDER ASSEMBLY​

FIGURE 5-36. SKYWELDER PREP PACKAGE (60HZ) (OPTIONAL)​

FIGURE 5-37. SKYWELDER LOCKING BRACKET INSTALLATION (OPTIONAL)​

FIGURE 5-38. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M PLATFORMS (OPTIONAL)​

FIGURE 5-39. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M FALL ARREST PLATFORMS (OPTIONAL)​

FIGURE 5-40. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM (OPTIONAL)​

FIGURE 5-41. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM (OPTIONAL)​

FIGURE 5-42. PLATFORM PADDING INSTALLATION (30IN/76CM DEPTH PLATFORMS) (ANSI, ANSI EXPORT, CSA AND CHINA SPECS) (OPTIONAL)​

FIGURE 5-43. FALL ARREST (BOLT-ON) INSTALLATION - 30IN X 4FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-44. FALL ARREST (BOLT-ON) INSTALLATION - 30IN X 5FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-45. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 6FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-46. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 6FT TRI-ENTRY PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-47. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 8FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-48. 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)​

FIGURE 8-45. ENGINE HARNESS ASSEMBLY (DEUTZ TD2.9L4 & DEUTZ DT2.2L3 STAGE V ENGINES)​

FIGURE 8-46. ENGINE HARNESS - DEUTZ TD2.2L3 ENGINES​

FIGURE 8-47. ENGINE HARNESS ASSEMBLY (FORD DF2.5L ENGINES)​

FIGURE 8-48. ECU POWER JUMPER HARNESS​

FIGURE 8-49. FUEL HARNESS - DEUTZ TD2.2L3 (STAGE V) ENGINE​

FIGURE 8-50. FUEL HARNESS - DEUTZ TD2.9L4 ENGINES​

FIGURE 8-51. FULL EXTENSION PROXIMITY HARNESS​

FIGURE 8-52. GENERATOR TO CONTROL BOX HARNESS - 4000W​

FIGURE 8-53. GENERATOR TO CONTROL BOX HARNESS - 7500W GENERATOR​

FIGURE 8-54. GENERATOR HARNESS - 7500W GENERATOR (FORD ENGINES)​

FIGURE 8-55. GENERATOR HARNESS - 7500W GENERATOR (DEUTZ TD2.9L4 ENGINES)​

FIGURE 8-56. GENERATOR TO ENGINE HARNESS - 2500W​

FIGURE 8-57. GENERATOR TO ENGINE HARNESS - 4000W​

FIGURE 8-58. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ONLY)​

FIGURE 8-59. GENERATOR TO REAR OF BOOM HARNESS - 110V​

FIGURE 8-60. GENERATOR TO REAR OF BOOM HARNESS - 220V​

FIGURE 8-61. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES​

FIGURE 8-62. GROUND CONTROL BOX HARNESS​

FIGURE 8-63. MID PROXIMITY HARNESS​

FIGURE 8-64. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-65. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPEC)​

FIGURE 8-66. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPEC)​

FIGURE 8-67. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-68. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND WITHOUT 2500W GENERSTOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-69. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-70. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE & UK CA SPEC)​

FIGURE 8-71. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-72. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE & UK CA SPEC)​

FIGURE 8-73. RECEPTACLE BOX KIT - 220V AFSINT 107 KEYED GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-74. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-75. SKYEYE EMITTER HARNESS​

FIGURE 8-76. SKYEYE RECEIVER HARNESS​

FIGURE 8-77. SKYLINE HARNESS​

FIGURE 8-78. SKYGUARD INTERFACE HARNESS​

FIGURE 8-79. STROBE LIGHT JUMPER HARNESS​

FIGURE 8-80. TILT SENSOR HARNESS​

FIGURE 8-81. VALVE HARNESS - BOOM VALVE​

FIGURE 8-82. VALVE HARNESS - MAIN CONTROL VALVE​

FIGURE 8-83. 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