JLG Boom Lift 520AJ Parts Catalog 3121666

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JLG Boom Lift 520AJ Parts Catalog 3121666
Size: 30.11 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 520AJ Boom Lift
Part Number: 3121666
Publication Date: 2025
Number of Pages: 434 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION​

FIGURE 1-2. STEER INSTALLATION WITHOUT TOW PACKAGE​

FIGURE 1-3. STEER INSTALLATION WITH TOW PACKAGE​

FIGURE 1-4. WHEEL DRIVE INSTALLATION, 4WD​

FIGURE 1-5. DRIVE HUB AND BRAKE ASSEMBLY - REAR​

FIGURE 1-6. DRIVE HUB ASSEMBLY - FRONT​

FIGURE 1-7. DRIVE MOTOR ASSEMBLY, 4WD​

FIGURE 1-8. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING​

FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM FILLED​

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED​

FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING​

FIGURE 1-12. VALVES INSTALLATION - FRAME MOUNTED​

FIGURE 1-13. TRACTION VALVE ASSEMBLY​

FIGURE 1-14. FRAME COVERS INSTALLATION​

FIGURE 1-15. TOW PACKAGE INSTALLATION (OPTIONAL)​

FIGURE 1-16. TOW BAR 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 (SN E300000100 through E300004228)​

FIGURE 2-10. TANKS INSTALLATION (SN 1300007286 through 1300007383, SN E300004228 through E300007980)​

FIGURE 2-11. DRIVE ORIENTATION INSTALLATION​

FIGURE 2-12. GROUND CONTROL ASSEMBLY - AUSTRALIAN SPEC​

FIGURE 2-13. GROUND CONTROL ASSEMBLY - CE SPEC​

FIGURE 2-14. ELECTRICAL SYSTEM INSTALLATION​

FIGURE 2-15. BEACON LIGHT INSTALLATION - AMBER​

FIGURE 2-16. BEACON LIGHT INSTALLATION - BLUE (SN E300000100 through E300007543)​

FIGURE 2-17. BEACON LIGHT INSTALLATION - BLUE (SN E300007543 through E300007980)​

FIGURE 2-18. BEACON LIGHT INSTALLATION - RED (SN E300000100 through E300007543)​

FIGURE 2-19. BEACON LIGHT INSTALLATION - RED (SN E300007543 through E300007980)​

FIGURE 2-20. BATTERY AND CABLE INSTALLATION​

FIGURE 2-21. HOODS INSTALLATION (SN E300000100 through E300006377)​

FIGURE 2-22. HOODS INSTALLATION (SN E300006377 through E300007980)​

FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE (SN E300000100 through E300006377)​

FIGURE 2-24. HOOD ASSEMBLY - TANK SIDE (SN E300006377 through E300007980)​

FIGURE 2-25. HOOD ASSEMBLY - ENGINE SIDE (SN E300000100 through E300006377)​

FIGURE 2-26. HOOD ASSEMBLY - ENGINE SIDE (SN E300006377 through E300007980)​

FIGURE 2-27. COVERS INSTALLATION - COUNTERWEIGHT​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2.3L3 ENGINE​

FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.3L3​

FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2.3L3 ENGINE​

FIGURE 3-4. ENGINE COMPONENTS - DEUTZ D2.3L3​

FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)​

FIGURE 3-6. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)​

FIGURE 3-7. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)​

FIGURE 3-8. ENGINE COMPONENTS - DEUTZ D2011 (STAGE V)​

FIGURE 3-9. PUMP COUPLING KIT​

FIGURE 3-10. GEAR PUMP ASSEMBLY (SN E300000100 through E300004772)​

FIGURE 3-11. PISTON PUMP ASSEMBLY​

FIGURE 3-12. CATALYTIC SPARK ARRESTOR INSTALLATION - DEUTZ D2.3L3 ENGINE​

FIGURE 3-13. SPARK ARRESTOR INSTALLATION - DEUTZ D2.3L3 ENGINE​

FIGURE 3-14. ENGINE BAFFLE INSTALLATION​

FIGURE 3-15. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2.3L3 ENGINE)​

FIGURE 3-16. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2.3L3 ENGINE)​

SECTION 4 - BOOM

FIGURE 4-1. CYLINDERS INSTALLATION​

FIGURE 4-2. BOOM INSTALLATION​

FIGURE 4-3. JIB INSTALLATION​

FIGURE 4-4. MAIN BOOM ASSEMBLY​

FIGURE 4-5. TOWER BOOM ASSEMBLY​

FIGURE 4-6. ROTATOR ASSEMBLY (SN E300002833 through E300004882)​

FIGURE 4-7. ROTATOR ASSEMBLY (SN 1300007286 through 1300007383, SN E300004883 through E300007980)​

FIGURE 4-8. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (SN E300000100 through E300002782)​

FIGURE 4-9. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (SN 1300007286 through 1300007383, SN E300002782 through E300007980)​

FIGURE 4-10. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS​

FIGURE 4-11. VALVES INSTALLATION - BOOM MOUNTED​

FIGURE 4-12. UPRIGHT VALVE ASSEMBLY​

FIGURE 4-13. BOOM VALVE ASSEMBLY​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY​

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

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY​

FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - WITH DROP BAR​

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR​

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR​

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR​

FIGURE 5-8. CONSOLE BOX INSTALLATION - WITHOUT SKYGUARD​

FIGURE 5-9. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E300000100 through E300007543)​

FIGURE 5-10. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E3000007543 through E300007980)​

FIGURE 5-11. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (SN E300000100 through E300003610)​

FIGURE 5-12. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (SN 1300007286 through 1300007383, SN E300003610 through E300007980)​

FIGURE 5-13. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300000100 through E300003610)​

FIGURE 5-14. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN 1300007286 through 1300007383, SN E300003610 through E300007542)​

FIGURE 5-15. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300007543 through E300007980)​

FIGURE 5-16. CONTROLLER ASSEMBLY - DRIVE AND STEER​

FIGURE 5-17. CONTROLLER ASSEMBLY - LIFT AND SWING​

FIGURE 5-18. FOOTSWITCH ASSEMBLY​

FIGURE 5-19. TRAY ASSEMBLY​

FIGURE 5-20. SKYEYE INSTALLATION (520AJ)​

FIGURE 5-21. SKYGUARD SYSTEM INSTALLATION (SN E300000100 through E300007543)​

FIGURE 5-22. SKYGUARD BAR INSTALLATION (SN E300007543 through E300007980)​

FIGURE 5-23. SKYLINE INSTALLATION (520AJ)​

FIGURE 5-24. CROSS RAIL INSTALLATION​

FIGURE 5-25. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (SN E300000100 through E300004872)​

FIGURE 5-26. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (SN 1300007286 through 1300007383, SN E300004872 through E300007980)​

FIGURE 5-27. PIPE RACK INSTALLATION (AUSTRALIAN SPEC)​

FIGURE 5-28. PIPE RACK INSTALLATION (CE SPECS)​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY​

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

FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN E300000100 through E300004512)​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN 1300007286 through 1300007383, SN E300004512 through E300007980)​

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

FIGURE 6-7. MASTER CYLINDER ASSEMBLY​

FIGURE 6-8. STEER CYLINDER ASSEMBLY​

FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION (SN E300000100 through E300004228)​

FIGURE 7-2. HYDRAULIC SYSTEM INSTALLATION (SN 1300007286 through 1300007383, SN E300004228 through E300007980)​

FIGURE 7-3. HYDRAULIC DIAGRAM LIST​

SECTION 8 - ELECTRICAL

FIGURE 8-1. ELECTRICAL DIAGRAM LIST​

FIGURE 8-2. AC BOX AT PLATFORM - LOCALLY SUPPLIED COMPONENTS (SN E300000100 through E300003512)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPEC) (SN E300000100 through E300003512)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPEC) (SN E300000100 through E300003512)​

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 70MM X 70MM BOX (CE SPEC) (SN E300000100 through E300002764)​

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 70MM X 70MM BOX (CE SPEC) (SN E300000100 through E300002764)​

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300000100 through E300002764)​

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300002764 through E300003511)​

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300000100 through E300002764)​

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300002764 through E300003511)​

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300000100 through E300003512)​

FIGURE 8-16. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ANSI EXPORT, CE AND CHINA SPECS)​

FIGURE 8-18. AC CABLE INSTALLATION – WITH TWO BREAKERS (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-19. AC CABLE INSTALLATION – WITH THREE BREAKERS (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980)​

FIGURE 8-20. BATTERY DISCONNECT SWITCH​

FIGURE 8-21. BEACON LIGHT HARNESS​

FIGURE 8-22. BEACON EXTENSION HARNESS (SN E300000100 through E600003882)​

FIGURE 8-23. BOOM CABLES AND CLAMPS INSTALLATION​

FIGURE 8-24. BOOM HARNESS - MAIN BOOM​

FIGURE 8-25. BOOM HARNESS - MAIN BOOM AC CABLE​

FIGURE 8-26. BOOM HARNESS - TOWER BOOM​

FIGURE 8-27. BOOM HARNESS - TOWER BOOM AC CABLE​

FIGURE 8-28. BOOM VALVE HARNESS​

FIGURE 8-29. BREAKER BOX KIT - CE SPEC​

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

FIGURE 8-31. CHASSIS SOLENOID HARNESS​

FIGURE 8-32. ENGINE HARNESS - DEUTZ D2.3L3​

FIGURE 8-33. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-34. GROUND CONTROL PANEL HARNESS​

FIGURE 8-35. PLATFORM CONSOLE BOX HARNESS (SN E300000100 through E300007543)​

FIGURE 8-36. PLATFORM CONSOLE BOX HARNESS (SN E300007543 through E300007980)​

FIGURE 8-37. PLATFORM INTERFACE HARNESS​

FIGURE 8-38. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)​

FIGURE 8-39. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)​

FIGURE 8-40. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 (CE SPEC)​

FIGURE 8-41. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 (CE SPEC)​

FIGURE 8-42. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 70MMX70MM (CE SPEC)​

FIGURE 8-43. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 70MMX70MM (CE SPEC)​

FIGURE 8-44. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)​

FIGURE 8-45. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-46. SKYEYE RECEIVER HARNESS​

FIGURE 8-47. SKYEYE EMITTER HARNESS​

FIGURE 8-48. SKYLINE HARNESS​

FIGURE 8-49. SKYGUARD HARNESS​

FIGURE 8-50. TURNTABLE HARNESS​

FIGURE 8-51. VALVE HARNESS - MAIN VALVE​

FIGURE 8-52. VALVE HARNESS - PLATFORM VALVE​

SECTION 9 - DECAL

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

FIGURE 9-2. DECAL INSTALLATION - CE SPEC (ENGLISH)​

FIGURE 9-3. DECAL INSTALLATION - OPTIONS​

FIGURE 9-4. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI, ANSI EXPORT AND CE SPECS)​

FIGURE 9-5. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (CE SPECS)​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS​

PART NUMBER INDEX