JLG Boom Lift 520AJ HC3 Parts Manual 31219155

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JLG Boom Lift 520AJ HC3 Parts Manual 31219155
Size: 31.54 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG 520AJ HC3 Boom Lift
Part Number: 31219155
Publication Date: 2024
Number of Pages: 444 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION​

FIGURE 1-2. STEER INSTALLATION​

FIGURE 1-3. WHEEL DRIVE INSTALLATION​

FIGURE 1-4. DRIVE MOTOR ASSEMBLY​

FIGURE 1-5. DRIVE HUB ASSEMBLY​

FIGURE 1-6. FRAME SHIELD INSTALLATION​

FIGURE 1-7. TIRE AND WHEEL INSTALLATION - 14 X17.5 FOAM FILLED​

FIGURE 1-8. TIRE AND WHEEL INSTALLATION - 14 X17.5 FOAM FILLED NON-MARKING​

FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 33 X 12-20 FOAM FILLED​

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING​

FIGURE 1-11. VALVES INSTALLATION - FRAME MOUNTED​

FIGURE 1-12. TRACTION VALVE ASSEMBLY​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVES INSTALLATION - TURNTABLE MOUNTED​

FIGURE 2-2. MAIN VALVE ASSEMBLY​

FIGURE 2-3. AUXILIARY PUMP ASSEMBLY​

FIGURE 2-4. SWING DRIVE AND TURNTABLE BEARING INSTALLATION​

FIGURE 2-5. SWING MOTOR ASSEMBLY​

FIGURE 2-6. TURNTABLE BEARING ASSEMBLY​

FIGURE 2-7. TURNTABLE COVERS INSTALLATION​

FIGURE 2-8. TURNTABLE LOCK INSTALLATION​

FIGURE 2-9. TANKS INSTALLATION (HYDRAULIC TANK WITH 4 INCH BREATHER)​

FIGURE 2-10. TANKS INSTALLATION (HYDRAULIC TANK WITH 6 INCH BREATHER)​

FIGURE 2-11. HYDRAULIC TANK ASSEMBLY - WITH 4 INCH BREATHER​

FIGURE 2-12. DRIVE ORIENTATION INSTALLATION​

FIGURE 2-13. GROUND CONTROL ASSEMBLY (ANSI EXPORT AND AUSTRALIAN SPECS)​

FIGURE 2-14. GROUND CONTROL ASSEMBLY (CE(LRC), CIS/EAC & UK CA SPECS)​

FIGURE 2-15. GROUND CONTROL ASSEMBLY (CE & UK CA SPECS) (Prior to SN B300012344, Except SN B300012042 through B300012233)​

FIGURE 2-16. LIGHT PANEL INSTALLATION – GROUND CONTROL (SN B300012344 to Present)​

FIGURE 2-17. LIGHT PANEL INSTALLATION – GROUND CONTROL​

FIGURE 2-18. ELECTRICAL SYSTEM INSTALLATION​

FIGURE 2-19. BEACON LIGHT INSTALLATION - AMBER​

FIGURE 2-20. BEACON LIGHT INSTALLATION - BLUE​

FIGURE 2-21. BEACON LIGHT INSTALLATION - RED​

FIGURE 2-22. NO BEACON INSTALLATION​

FIGURE 2-23. WHITE NOISE AMBIENT ALARM INSTALLATION​

FIGURE 2-24. WHITE NOISE ALARM INSTALLATION​

FIGURE 2-25. BATTERY AND CABLE INSTALLATION​

FIGURE 2-26. HOODS INSTALLATION​

FIGURE 2-27. HOODS INSTALLATION (STEEL)​

FIGURE 2-28. HOOD ASSEMBLY - TANK SIDE (ROMANIAN BUILT MACHINES) (Prior to SN B300017702)​

FIGURE 2-29. HOOD ASSEMBLY - TANK SIDE (SN B300017702 to Present)​

FIGURE 2-30. HOOD ASSEMBLY (STEEL) - ENGINE SIDE​

FIGURE 2-31. HOOD ASSEMBLY - ENGINE SIDE (ROMANIAN BUILT MACHINES)​

FIGURE 2-32. HOOD ASSEMBLY (STEEL) - TANK SIDE​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-2. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-3. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-4. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-6. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-7. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-8. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.3L3 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-9. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-10. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-11. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)​

FIGURE 3-12. ENGINE COMPONENTS - DEUTZ D2011​

FIGURE 3-13. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-14. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-15. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-16. ENGINE COMPONENTS - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-17. MOTOR MOUNT INSTALLATION (STAGE V ENGINES WITHOUT GENERATOR)​

FIGURE 3-18. MOTOR MOUNT INSTALLATION (STAGE V ENGINES WITH GENERATOR)​

FIGURE 3-19. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V)​

FIGURE 3-20. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES (STAGE V) (CE SPECS)​

FIGURE 3-21. PUMP COUPLING KIT – DEUTZ ENGINES​

FIGURE 3-22. PISTON PUMP ASSEMBLY​

FIGURE 3-23. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE​

FIGURE 3-24. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES​

FIGURE 3-25. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-26. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE)​

SECTION 4 - BOOM

FIGURE 4-1. BOOMS AND CYLINDERS INSTALLATION​

FIGURE 4-2. JIB INSTALLATION​

FIGURE 4-3. MAIN BOOM ASSEMBLY​

FIGURE 4-4. TOWER BOOM ASSEMBLY​

FIGURE 4-5. ROTATOR ASSEMBLY​

FIGURE 4-6. PLATFORM SUPPORT INSTALLATION​

FIGURE 4-7. VALVES INSTALLATION - BOOM MOUNTED​

FIGURE 4-8. UPRIGHT VALVE ASSEMBLY​

FIGURE 4-9. BOOM VALVE ASSEMBLY​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 3FT- SIDE DROP BAR ENTRY​

FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 4FT- SIDE DROP BAR ENTRY​

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 5FT- SIDE DROP BAR ENTRY​

FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 5FT- SIDE GATE ENTRY​

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.22M) - FALL ARREST REAR ENTRY​

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 6FT- SIDE DROP BAR ENTRY​

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT- SIDE GATE ENTRY​

FIGURE 5-8. CONSOLE BOX INSTALLATION​

FIGURE 5-9. PLATFORM CONSOLE BOX ASSEMBLY​

FIGURE 5-10. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE (Prior to SN B300012344, Except SN B300012042 through B300012233)​

FIGURE 5-11. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE (SN B300012344 to Present)​

FIGURE 5-12. CONTROLLER ASSEMBLY - DRIVE AND STEER​

FIGURE 5-13. CONTROLLER ASSEMBLY - LIFT AND SWING​

FIGURE 5-14. FOOTSWITCH ASSEMBLY​

FIGURE 5-15. TRAY ASSEMBLY​

FIGURE 5-16. SKYEYE INSTALLATION​

FIGURE 5-17. SKYGUARD BAR INSTALLATION​

FIGURE 5-18. SKYLINE INSTALLATION​

FIGURE 5-19. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS)​

FIGURE 5-20. SOFT TOUCH INSTALLATION (WITHOUT FALL ARREST)​

FIGURE 5-21. SOFT TOUCH INSTALLATION (WITH FALL ARREST)​

FIGURE 5-22. PIPE RACK INSTALLATION (ANSI EXPORT,CHINA & RUSSIAN /CIS SPECS)​

FIGURE 5-23. PIPE RACK INSTALLATION (AUSTRALIAN SPECS)​

FIGURE 5-24. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)​

FIGURE 5-25. USB CHARGER INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY​

FIGURE 6-2. LEVEL CYLINDER ASSEMBLY​

FIGURE 6-3. MASTER CYLINDER ASSEMBLY​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY​

FIGURE 6-5. STEER CYLINDER ASSEMBLY​

FIGURE 6-6. TELESCOPE CYLINDER ASSEMBLY​

FIGURE 6-7. TOWER LIFT CYLINDER​

FIGURE 6-8. LIFT JIB CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION​

FIGURE 7-2. HYDRAULIC SYSTEM INSTALLATION - 450AJ 4WD​

FIGURE 7-3. HYDRAULIC SYSTEM INSTALLATION - 450AJ 4WD​

FIGURE 7-4. HYDRAULIC SYSTEM INSTALLATION - 450AJ 4WD​

FIGURE 7-5. HYDRAULIC SYSTEM INSTALLATION - 450AJ 4WD​

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

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

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN POST GROUND (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

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

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ALL SPECS)​

FIGURE 8-12. AC CABLE INSTALLATION - WITH TWO BREAKERS (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-13. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE, CIS/EAC & UK CA SPECS)​

FIGURE 8-14. BATTERY DISCONNECT SWITCH​

FIGURE 8-15. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)​

FIGURE 8-16. BOOM CABLES & CLAMPS INSTALLATION (4000W GENERATOR)​

FIGURE 8-17. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR)​

FIGURE 8-18. BOOM HARNESS - MAIN BOOM​

FIGURE 8-19. BOOM HARNESS - MAIN BOOM (8/5 4000W GENERATOR)​

FIGURE 8-20. BOOM HARNESS - TOWER BOOM​

FIGURE 8-21. BOOM HARNESS - TOWER BOOM (8/5 4000W GENERATOR)​

FIGURE 8-22. BOOM SENSORS INSTALLATION​

FIGURE 8-23. BOOM SENSOR HARNESS​

FIGURE 8-24. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-25. BREAKER BOX KIT WITH THREE BREAKERS (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-26. BREAKER BOX KIT - 30MA/16 AMP​

FIGURE 8-27. CAPACITY HARNESS​

FIGURE 8-28. CHASSIS SOLENOID HARNESS​

FIGURE 8-29. CLEARSKY 3-WIRE CONNECTION INSTALLATION​

FIGURE 8-30. CLEARSKY TELEMATICS HARNESS​

FIGURE 8-31. ENGINE HARNESS - DEUTZ D2011​

FIGURE 8-32. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)​

FIGURE 8-33. FUEL HARNESS - DEUTZ D2.9L4 ENGINE​

FIGURE 8-34. GENERATOR HARNESS - 2500W GENERATOR (50HZ)​

FIGURE 8-35. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-36. GROUND CONTROL PANEL HARNESS​

FIGURE 8-37. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-38. PLATFORM INTERFACE HARNESS​

FIGURE 8-39. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-40. RECEPTACLE BOX KIT - 220V IEC BLUE (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-41. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-42. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-43. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-44. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-45. SKYEYE RECEIVER HARNESS​

FIGURE 8-46. SKYEYE EMITTER HARNESS​

FIGURE 8-47. SKYLINE HARNESS​

FIGURE 8-48. TRANSPORT HARNESS​

FIGURE 8-49. TURNTABLE HARNESS​

FIGURE 8-50. VALVE HARNESS - BOOM VALVE​

FIGURE 8-51. VALVE HARNESS - MAIN VALVE​

FIGURE 8-52. VALVE HARNESS - PLATFORM VALVE​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH LANGUAGE)​

FIGURE 9-2. DECAL INSTALLATION - CE, CIS/EAC & UK CA SPEC (ENGLISH LANGUAGE)​

FIGURE 9-3. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH LANGUAGES)​

FIGURE 9-4. DECAL INSTALLATION - OPTIONS​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

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

PART NUMBER INDEX