JLG Boom Lift 600AJ HC3 Parts Catalog 3122344000

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JLG Boom Lift 600AJ HC3 Parts Catalog 3122344000
Size: 69.85 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: 3122344000
Publication Date: 2025
Number of Pages: 956 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 D2011 ENGINES (SN 0300332867 to Present)​

FIGURE 2-3. CONTROL VALVES INSTALLATION - DEUTZ DT2.9L4, DEUTZ TD2.2L3 STAGE V & FORD ENGINES​

FIGURE 2-4. CONTROL VALVES INSTALLATION - DEUTZ DT2.9L4, DEUTZ TD2.2L3 STAGE V & FORD ENGINES (SN 0300332867 to Present)​

FIGURE 2-5. MAIN VALVE BLOCK ASSEMBLY - 2WS​

FIGURE 2-6. AUXILIARY PUMP INSTALLATION​

FIGURE 2-7. AUXILIARY PUMP INSTALLATION WITH BATTERY DISCONNECT​

FIGURE 2-8. AUXILIARY PUMP ASSEMBLY​

FIGURE 2-9. SWING DRIVE INSTALLATION​

FIGURE 2-10. SWING MOTOR/HUB ASSEMBLY​

FIGURE 2-11. TURNTABLE BEARING INSTALLATION​

FIGURE 2-12. TURNTABLE LOCK INSTALLATION (DEUTZ D2011 & FORD ENGINE MACHINES)​

FIGURE 2-13. TURNTABLE LOCK INSTALLATION (DEUTZ TD2.9L4 & DEUTZ TD2.2L3 STAGE V ENGINE MACHINES)​

FIGURE 2-14. ROTARY COUPLING INSTALLATION​

FIGURE 2-15. TANK INSTALLATION – DEUTZ D2011 ENGINE​

FIGURE 2-16. TANK INSTALLATION – DEUTZ TD2.9L4 & TD2.2L3 STAGE V ENGINES​

FIGURE 2-17. TANK INSTALLATION – FORD ENGINE​

FIGURE 2-18. HYDRAULIC OIL TANK ASSEMBLY​

FIGURE 2-19. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ D2011 ENGINES (OPTIONAL)​

FIGURE 2-20. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2.2L3 STAGE V ENGINES (OPTIONAL)​

FIGURE 2-21. HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TD2.9L4 ENGINES (OPTIONAL)​

FIGURE 2-22. HYDRAULIC OIL COOLER INSTALLATION - FORD ENGINES (OPTIONAL)​

FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY - DEUTZ 2011 ENGINE​

FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY - DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (CHINA IV) ENGINES​

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY - FORD DF 2.5​

FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY - DEUTZ TD2.2L3 ENGINE​

FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY - DEUTZ D2011 ENGINE AND TOWER STOW​

FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY - DEUTZ TD2.9L4 AND CHINA IV ENGINES AND TOWER STOW​

FIGURE 2-29. GROUND CONTROL BOX ASSEMBLY - FORD DF 2.5L AND TOWER STOW​

FIGURE 2-30. GROUND CONTROL BOX ASSEMBLY - DEUTZ TD2.2L3 (STAGE V) ENGINES AND 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)​

FIGURE 2-37. STROBE LIGHT INSTALLATION (BLUE)​

FIGURE 2-38. STROBE LIGHT INSTALLATION (RED)​

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​

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 - (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-9. DEUTZ TD2.2L3(STAGE V) ENGINE/PUMP SUB ASSEMBLY - (WITHOUT ARCTIC PACKAGE)​

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 D2.9L4 EMR5 ENGINE INSTALLATION (WITH ARCTIC PACKAGE)​

FIGURE 3-14. DEUTZ D2.9L4 EMR5 ENGINE/PUMP SUB ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-15. DEUTZ D2.9L4 EMR5 (49HP) ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-16. DEUTZ D2.9L4 EMR5 (49HP) ENGINE/PUMP SUB ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-17. DEUTZ D2.9L4 EMR5 (49HP) ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-18. ENGINE COMPONENTS - DEUTZ D2.9L4 ERM5 ENGINE (49HP)​

FIGURE 3-19. ENGINE ASSEMBLY - DEUTZ D2.9L4 EMR5 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-20. DEUTZ D2.9L4 EMR5 (67HP) ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-21. DEUTZ D2.9L4 EMR5 (67HP) ENGINE/PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-22. DEUTZ D2.9L4 EMR5 (67HP) ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-23. DEUTZ D2.9L4 EMR5 (67HP) ENGINE INSTALLATION (WITH ARCTIC PACKAGE)​

FIGURE 3-24. DEUTZ D2.9L4 EMR5 (67HP) ENGINE/PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-25. DEUTZ D2.9L4 EMR5 (67HP) ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)​

FIGURE 3-26. DEUTZ D2.9L4 EMR5 (67HP) ENGINE COMPONENTS​

FIGURE 3-27. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)​

FIGURE 3-28. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES WITH ARCTIC PACKAGE​

FIGURE 3-29. QUICKFIT OIL DRAIN (DEUTZ TD 2.9L)​

FIGURE 3-30. QUICKFIT OIL DRAIN (DEUTZ D ENGINES)​

FIGURE 3-31. FORD ENGINE INSTALLATION - (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-32. FORD ENGINE INSTALLATION - (WITH ARCTIC PACKAGE)​

FIGURE 3-33. FORD ENGINE/PUMP SUB ASSEMBLY – (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-34. FORD ENGINE/PUMP SUB ASSEMBLY - (WITH ARCTIC PACKAGE)​

FIGURE 3-35. FORD ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE (Prior to SN 0300329918)​

FIGURE 3-36. FORD ENGINE ASSEMBLY - WITHOUT ARCTIC PACKAGE (SN 0300329919 to Present)​

FIGURE 3-37. FORD ENGINE ASSEMBLY - WITH ARCTIC PACKAGE (Prior to SN 0300329918)​

FIGURE 3-38. FORD ENGINE ASSEMBLY - WITH ARCTIC PACKAGE (SN 0300329919 to Present)​

FIGURE 3-39. PUMP COUPLING AND FUEL SYSTEM ASSEMBLY (FORD ENGINES)​

FIGURE 3-40. FORD ENGINE COMPONENTS​

FIGURE 3-41. DRIVE BELT INSTALLATION - FORD ENGINES MACHINES WITHOUT GENERATORS​

FIGURE 3-42. PUMP COUPLING KIT - DEUTZ ENGINES​

FIGURE 3-43. PISTON PUMP ASSEMBLY - DANFOSS​

FIGURE 3-44. PISTON PUMP AND FITTINGS SUB-ASSEMBLY - DEUTZ ENGINES - HENGLI​

FIGURE 3-45. PISTON PUMP AND FITTINGS SUB-ASSEMBLY - FORD ENGINES - HENGLI​

FIGURE 3-46. PISTON PUMP ASSEMBLY - HENGLI​

FIGURE 3-47. GEAR PUMP ASSEMBLY​

FIGURE 3-48. GEAR PUMP ASSEMBLY WITH FITTINGS​

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 (Prior to SN 0300332866)​

FIGURE 3-67. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (SN 0300332867 to Present)​

FIGURE 3-68. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-69. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.2L3 ENGINES​

FIGURE 3-70. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES (Prior to SN 0300332866)​

FIGURE 3-71. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES (SN 0300332867 to Present)​

FIGURE 3-72. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 3-73. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (Prior to SN 0300332866)​

FIGURE 3-74. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (SN 0300332867 to Present)​

FIGURE 3-75. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (Prior to SN 0300332866)​

FIGURE 3-76. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (SN 0300332867 to Present)​

FIGURE 3-77. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.2L3 STAGE V ENGINES​

FIGURE 3-78. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES (Prior to SN 0300332866)​

FIGURE 3-79. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES (SN 0300332867 to Present)​

FIGURE 3-80. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD ENGINES (Prior to SN 0300332866)​

FIGURE 3-81. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD ENGINES (SN 0300332867 to Present)​

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 (Prior to SN 0300328415)​

FIGURE 4-7. TRADITIONAL PLATFORM SUPPORT INSTALLATION (SN 0300328416 through 0300332866)​

FIGURE 4-8. RAPID REPLACEABLE PLATFORM SUPPORT (SN 0300332867 through 0300336388)​

FIGURE 4-9. RAPID REPLACEABLE PLATFORM SUPPORT (SN 0300336389 to Present)​

FIGURE 4-10. POWER TRACK INSTALLATION - MAIN BOOM​

FIGURE 4-11. POWER TRACK INSTALLATION - TOWER BOOM​

FIGURE 4-12. CONTROL VALVES INSTALLATION - DEUTZ D2011 AND STAGE V ENGINES​

FIGURE 4-13. CONTROL VALVES INSTALLATION - DEUTZ D2011 AND STAGE V ENGINES (SN 0300332867 to Present)​

FIGURE 4-14. CONTROL VALVES INSTALLATION - DEUTZ TD2.9L4 & FORD ENGINES​

FIGURE 4-15. CONTROL VALVES INSTALLATION - DEUTZ TD2.9L4 & FORD ENGINES (SN 0300332867 to Present)​

FIGURE 4-16. BOOM VALVE ASSEMBLY​

FIGURE 4-17. BOOM VALVES AND LIMIT SWITCHES INSTALLATION​

FIGURE 4-18. BOOM SENSOR INSTALLATION (TOWER STOW)​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76.2CM X 1.22M) WITH SWING GATE (Prior to SN 0300332866)​

FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - GATE ENTRY (Prior to SN 0300332866)​

FIGURE 5-3. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH SWING GATE (Prior to SN 0300332866)​

FIGURE 5-4. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH SWING GATE (Prior to SN 0300332866)​

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY (Prior to SN 0300332866)​

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 4FT (76.2CM X 1.22M) WITH DROP BAR (Prior to SN 0300332866)​

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - DROP BAR ENTRY (Prior to SN 0300332866)​

FIGURE 5-8. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH DROP BAR (Prior to SN 0300332866)​

FIGURE 5-9. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH DROP BAR (Prior to SN 0300332866)​

FIGURE 5-10. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (Prior to SN 0300332866)​

FIGURE 5-11. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (Prior to SN 0300332866)​

FIGURE 5-12. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH SWING GATE (Prior to SN 0300332866)​

FIGURE 5-13. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH SWING GATE (Prior to SN 0300332866)​

FIGURE 5-14. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH DROPBAR (Prior to SN 0300332866)​

FIGURE 5-15. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH DROPBAR (Prior to SN 0300332866)​

FIGURE 5-16. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (SN 0300332867 to Present)​

FIGURE 5-17. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (SN 0300332867 to Present)​

FIGURE 5-18. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH TRI-ENTRY (SN 0300332867 to Present)​

FIGURE 5-19. PLATFORM - SWING GATE INSTALLATION (SN 0300332867 to Present)​

FIGURE 5-20. PLATFORM - DROP BAR INSTALLATION (SN 0300332867 to Present)​

FIGURE 5-21. RAPID REPLACEABLE PLATFORM (30IN X 5FT (76.2CM X 1.52M) (SN 0300332867 to Present)​

FIGURE 5-22. RAPID REPLACEABLE PLATFORM (36IN X 6FT (91.5CM X 1.83M) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 5-23. RAPID REPLACEABLE PLATFORM (36IN X 8FT (91.5CM X 2.44M) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 5-24. RAPID REPLACEABLE PLATFORM (30IN X 4FT (76.2CM X 1.22M) (SN 0300332867 to Present)​

FIGURE 5-25. TRAY ASSEMBLY​

FIGURE 5-26. CONSOLE AND FOOTSWITCH INSTALLATION (Prior to SN 0300332866)​

FIGURE 5-27. CONSOLE AND FOOTSWITCH INSTALLATION (SN 0300332867 to Present)​

FIGURE 5-28. CONSOLE BOX AND FOOTSWITCH ASSEMBLY (SN 0300332867 to Present)​

FIGURE 5-29. CONSOLE AND FOOTSWITCH INSTALLATION (WITH TOWER STOW) (SN 0300332867 to Present)​

FIGURE 5-30. CONSOLE BOX AND FOOTSWITCH ASSEMBLY (WITH TOWER STOW) (SN 0300332867 to Present)​

FIGURE 5-31. CONSOLE AND FOOTSWITCH INSTALLATION (TOWER STOW) (Prior to SN 0300332866)​

FIGURE 5-32. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITHOUT TOWER STOW) (Prior to SN 0300330810)​

FIGURE 5-33. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITHOUT TOWER STOW) (SN 0300330811 through 0300332866)​

FIGURE 5-34. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITH TOWER STOW) (Prior to SN 0300330810)​

FIGURE 5-35. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (WITH TOWER STOW) (SN 0300330811 through 0300332866)​

FIGURE 5-36. FOOTSWITCH ASSEMBLY​

FIGURE 5-37. CRAB STEER SWITCH INSTALLATION - 4WS (WITHOUT TOW PACKAGE)​

FIGURE 5-38. CRAB STEER SWITCH INSTALLATION - 4WS (WITH TOW PACKAGE)​

FIGURE 5-39. LIGHT PANEL INSTALLATION​

FIGURE 5-40. STEER SWITCH INSTALLATION – 4WS​

FIGURE 5-41. SKYEYE INSTALLATION​

FIGURE 5-42. SKYGUARD BAR INSTALLATION​

FIGURE 5-43. SKYLINE INSTALLATION (Prior to SN 0300332866)​

FIGURE 5-44. SKYLINE INSTALLATION (SN 0300332867 to Present)​

FIGURE 5-45. SKYGLAZIER INSTALLATION​

FIGURE 5-46. SKYGLAZIER INSTALLATION (ALL SPECS EXCEPT CHINA, JAPANESE, CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-47. SKYCUTTER INSTALLATION (OPTIONAL) (Prior to SN 0300332866)​

FIGURE 5-48. PLASMA CUTTER ASSEMBLY​

FIGURE 5-49. PLATFORM BEACON INSTALLATION (SN 0300332867 to Present)​

FIGURE 5-50. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ) (OPTIONAL) (Prior to SN 0300332866)​

FIGURE 5-51. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ) (OPTIONAL) (Prior to SN 0300332866)​

FIGURE 5-52. SKYWELDER INSTALLATION (50HZ) (OPTIONAL)​

FIGURE 5-53. SKYWELDER INSTALLATION (60HZ) (OPTIONAL)​

FIGURE 5-54. WELDER ASSEMBLY​

FIGURE 5-55. WELDER ASSEMBLY (CST282)​

FIGURE 5-56. SKYWELDER PREP PACKAGE (60HZ) (OPTIONAL)​

FIGURE 5-57. SKYWELDER LOCKING BRACKET INSTALLATION (OPTIONAL)​

FIGURE 5-58. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M PLATFORMS (OPTIONAL)​

FIGURE 5-59. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.8M FALL ARREST PLATFORMS (OPTIONAL)​

FIGURE 5-60. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM (OPTIONAL)​

FIGURE 5-61. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM (OPTIONAL)​

FIGURE 5-62. PLATFORM PADDING INSTALLATION (30IN/76CM DEPTH PLATFORMS) (ANSI, ANSI EXPORT, CSA AND CHINA SPECS) (OPTIONAL)​

FIGURE 5-63. FALL ARREST (BOLT-ON) INSTALLATION - 30IN X 4FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-64. FALL ARREST (BOLT-ON) INSTALLATION - 30IN X 5FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-65. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 6FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-66. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 6FT TRI-ENTRY PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL) (Prior to SN 0300332866)​

FIGURE 5-67. FALL ARREST (BOLT-ON) INSTALLATION - 36IN X 8FT PLATFORM (ALL SPECS EXCEPT CE & UK CA SPECS) (OPTIONAL)​

FIGURE 5-68. USB CHARGER INSTALLATION (Prior to SN 0300332866)​

FIGURE 5-69. USB CHARGER INSTALLATION (SN 0300332867 to Present)​

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 – DUAL AC 110V GFI (MACHINES WITH 2500W GENERATOR) (ANSI EXPORT AND CHINA SPECS)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - BOX WITH COVER (2X4 BOX) (ANSI EXPORT SPECS) (4000W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE & UK CA SPECS) (Prior to SN 0300332866)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW (CE & UK CA SPECS) (4000W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE& UK CA SPECS) (Prior to SN 0300332866)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE & UK CA SPECS) (2500W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE (CE & UK CA SPECS) (4000W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE & UK CA SPECS) (Prior to SN 0300332866)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE & UK CA SPECS) (2500W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) (CE & UK CA SPECS) (4000W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE & UK CA SPECS) (Prior to SN 0300332866)​

FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE & UK CA SPECS) (2500W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-18. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) (CE & UK CA SPECS) (4000W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-19. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE & UK CA SPECS) (Prior to SN 0300332866)​

FIGURE 8-20. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE & UK CA SPECS) (2500W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-21. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) (CE & UK CA SPECS) (4000W GENERATOR) (Prior to SN 0300332866)​

FIGURE 8-22. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-23. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-24. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-25. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-26. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-27. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND(2500W GENERATOR)(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-28. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND(2500W GENERATOR)(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-29. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107(2500W GENERATOR)(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-30. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (2500W GENERATOR)(CE & UK CA & RUSSIA SPECS) (MACHINES WITH SN STARTING WITH 03) (SN 0300332867 to Present)​

FIGURE 8-31. AC BOX AT PLATFORM – 220V CEE7 2IN X 4IN POST GROUND (CE & UK CA SPEC WITH 4000W/50HZ GENERATOR) (SN 0300332867 to Present)​

FIGURE 8-32. AC BOX AT PLATFORM – 220V CEE7 2IN X 4IN SIDE GROUND (CE & UK CA SPEC WITH 4000W/50HZ GENERATOR) (SN 0300332867 to Present)​

FIGURE 8-33. AC BOX AT PLATFORM – 220V AFSINT107 (CE & UK CA SPEC WITH 4000W/50HZ GENERATOR) (SN 0300332867 to Present)​

FIGURE 8-34. AC BOX AT PLATFORM – 110V IEC YELLOW (CE & UK CA SPEC WITH 4000W/50HZ GENERATOR) (SN 0300332867 to Present)​

FIGURE 8-35. AC BOX AT PLATFORM – 220V IEC BLUE (CE & UK CA SPEC WITH 4000W/50HZ GENERATOR) (SN 0300332867 to Present)​

FIGURE 8-36. AC BOX AT PLATFORM – 220V CUSTOMER SUPPLIED COMPONENTS(ALL SPECS EXCEPT CSA SPECS) (SN 0300332867 to Present)​

FIGURE 8-37. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS WITH 4000W SKYPOWER GENERATOR)​

FIGURE 8-38. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI AND CSA SPECS WITH 7500W SKYPOWER GENERATOR)​

FIGURE 8-39. BATTERY DISCONNECT SWITCH INSTALLATION – DEUTZ D2011 ENGINES​

FIGURE 8-40. BATTERY DISCONNECT SWITCH INSTALLATION (DEUTZ TD2.9L4, DEUTZ D2.9L4, DEUTZ TD2.2L3 STAGE V AND FORD DF2.5L ENGINES)​

FIGURE 8-41. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)​

FIGURE 8-42. BOOM CABLES INSTALLATION - WITH 2500W GENERATOR OR NO GENERATOR​

FIGURE 8-43. BOOM CABLE INSTALLATION - WITH 4000W/50HZ GENERATOR​

FIGURE 8-44. BOOM CABLES INSTALLATION - WITH 4000W/60HZ GENERATOR​

FIGURE 8-45. BOOM CABLE INSTALLATION - WITH 7500W GENERATOR​

FIGURE 8-46. BOOM CABLE - MAIN BOOM​

FIGURE 8-47. BOOM CABLE - TOWER BOOM (WITHOUT ARCTIC PACKAGE)​

FIGURE 8-48. BREAKER BOX KIT - SINGLE DOUBLE POLE BREAKER (WITH 4000W/50HZ GENERATOR)​

FIGURE 8-49. BREAKER BOX KIT - 30MA/16 AMP (WITH GENERATOR)​

FIGURE 8-50. CSB HARNESS​

FIGURE 8-51. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-52. ENGINE HARNESS ASSEMBLY (DEUTZ TD2.L4 ENGINES)​

FIGURE 8-53. ENGINE HARNESS ASSEMBLY (DEUTZ D2011 ENGINES)​

FIGURE 8-54. ENGINE HARNESS ASSEMBLY (DEUTZ TD2.9L4 & DEUTZ DT2.2L3 STAGE V ENGINES)​

FIGURE 8-55. ENGINE HARNESS - DEUTZ TD2.2L3 ENGINES​

FIGURE 8-56. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES​

FIGURE 8-57. ENGINE HARNESS ASSEMBLY (FORD DF2.5L ENGINES)​

FIGURE 8-58. ECU POWER JUMPER HARNESS​

FIGURE 8-59. FUEL HARNESS - DEUTZ TD2.2L3 (STAGE V) ENGINE​

FIGURE 8-60. FUEL HARNESS - DEUTZ TD2.9L4 ENGINES​

FIGURE 8-61. FULL EXTENSION PROXIMITY HARNESS​

FIGURE 8-62. GENERATOR TO CONTROL BOX HARNESS - 4000W​

FIGURE 8-63. GENERATOR TO CONTROL BOX HARNESS - 7500W GENERATOR​

FIGURE 8-64. GENERATOR HARNESS - 7500W GENERATOR (FORD ENGINES)​

FIGURE 8-65. GENERATOR HARNESS - 7500W GENERATOR (DEUTZ TD2.9L4 ENGINES)​

FIGURE 8-66. GENERATOR TO ENGINE HARNESS - 2500W​

FIGURE 8-67. GENERATOR TO ENGINE HARNESS - 4000W​

FIGURE 8-68. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ONLY)​

FIGURE 8-69. GENERATOR TO REAR OF BOOM HARNESS - 110V​

FIGURE 8-70. GENERATOR TO REAR OF BOOM HARNESS - 220V​

FIGURE 8-71. GROUND CONTROL BOX HARNESS​

FIGURE 8-72. MID PROXIMITY HARNESS​

FIGURE 8-73. PLATFORM BEACON HARNESS​

FIGURE 8-74. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-75. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE & UK CA SPEC)​

FIGURE 8-76. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPEC)​

FIGURE 8-77. RECEPTACLE BOX KIT - 220V IEC BLUE (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-78. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND WITHOUT 2500W GENERSTOR (2X4 BOX) (CE & UK CA SPECS)​

FIGURE 8-79. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-80. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE & UK CA SPEC)​

FIGURE 8-81. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-82. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE & UK CA SPEC)​

FIGURE 8-83. RECEPTACLE BOX KIT - 220V AFSINT 107 KEYED GROUND (2X4 BOX) (CE & UK CA SPECS) (2500W GENERATOR)​

FIGURE 8-84. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-85. SKYEYE EMITTER HARNESS​

FIGURE 8-86. SKYEYE RECEIVER HARNESS​

FIGURE 8-87. SKYLINE HARNESS​

FIGURE 8-88. SKYGUARD INTERFACE HARNESS​

FIGURE 8-89. STROBE LIGHT JUMPER HARNESS​

FIGURE 8-90. TILT SENSOR HARNESS​

FIGURE 8-91. USB HARNESS​

FIGURE 8-92. VALVE HARNESS - BOOM VALVE​

FIGURE 8-93. VALVE HARNESS​

FIGURE 8-94. WHITE NOISE ALARM HARNESS​

FIGURE 8-95. WORKLIGHT 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