JLG Boom Lift 520AJ Parts Manual 31219922

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JLG Boom Lift 520AJ Parts Manual 31219922
Size: 31.66 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG 520AJ Boom Lift
Part Number: 31219922
Publication Date: 2024
Number of Pages: 444 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. FRAME SHIELD INSTALLATION​

FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING​

FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM-FILLED​

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

FIGURE 1-12. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING​

FIGURE 1-13. 4WD VALVES INSTALLATION - FRAME MOUNTED​

FIGURE 1-14. TRACTION VALVE ASSEMBLY - 4WD​

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

FIGURE 1-16. TOW BAR ASSEMBLY​

SECTION 2 - TURNTABLE

FIGURE 2-1. 4WD 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​

FIGURE 2-10. HYDRAULIC TANK ASSEMBLY​

FIGURE 2-11. DRIVE ORIENTATION INSTALLATION​

FIGURE 2-12. GROUND CONTROL ASSEMBLY (ANSI EXPORT, CHINA & AUSTRALIAN SPECS)​

FIGURE 2-13. GROUND CONTROL ASSEMBLY (CE(LRC), CIS/EAC & UK CA SPECS)​

FIGURE 2-14. GROUND CONTROL ASSEMBLY (CE & UK CA SPECS)​

FIGURE 2-15. LIGHT PANEL INSTALLATION – GROUND CONTROL​

FIGURE 2-16. ELECTRICAL SYSTEM INSTALLATION (WITH 1001170094 GROUND CONTROL MODULE)​

FIGURE 2-17. ELECTRICAL SYSTEM INSTALLATION (WITH 1001280340 GROUND CONTROL MODULE)​

FIGURE 2-18. ELECTRICAL SYSTEM INSTALLATION (WITH 1001280340 GROUND CONTROL MODULE)​

FIGURE 2-19. BREAKER BOX KIT - THREE BREAKERS​

FIGURE 2-20. BEACON LIGHT INSTALLATION - AMBER​

FIGURE 2-21. BEACON LIGHT INSTALLATION - BLUE​

FIGURE 2-22. BEACON LIGHT INSTALLATION - RED​

FIGURE 2-23. BATTERY AND CABLE INSTALLATION​

FIGURE 2-24. HOODS INSTALLATION (ABS)​

FIGURE 2-25. HOODS INSTALLATION (STEEL)​

FIGURE 2-26. HOOD ASSEMBLY (ABS) - TANK SIDE​

FIGURE 2-27. HOOD ASSEMBLY (ABS) - ENGINE SIDE​

FIGURE 2-28. HOOD ASSEMBLY (STEEL) - ENGINE SIDE​

FIGURE 2-29. HOOD ASSEMBLY (STEEL) - TANK SIDE​

FIGURE 2-30. WHITE NOISE ALARM INSTALLATION​

FIGURE 2-31. WHITE NOISE AMBIENT ALARM INSTALLATION​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, CIS/EAC & UK CA SPECS)​

FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC),CIS/EAC & UK CA SPECS)​

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

FIGURE 3-4. ENGINE COMPONENTS - DEUTZ D2011​

FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-6. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-7. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-8. ENGINE COMPONENTS - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)​

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

FIGURE 3-10. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES (STAGE V) (CE & UK CA SPECS)​

FIGURE 3-11. MOTOR MOUNT INSTALLATION - (STAGE V & CHINA IV ENGINE WITHOUT GENERATOR)​

FIGURE 3-12. MOTOR MOUNT INSTALLATION - (STAGE V & CHINA IV ENGINE WITH GENERATOR)​

FIGURE 3-13. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-14. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-15. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-16. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-17. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-18. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV)​

FIGURE 3-19. ENGINE COMPONENTS - DEUTZ D2.9L4 (CHINA IV)​

FIGURE 3-20. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 CHINA IV ENGINE)​

FIGURE 3-21. FUEL/WATER SEPARATOR ASSEMBLY (DEUTZ D2.9L4 CHINA IV ENGINE)​

FIGURE 3-22. PUMP COUPLING KIT – DEUTZ ENGINES​

FIGURE 3-23. PISTON PUMP ASSEMBLY​

FIGURE 3-24. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE​

FIGURE 3-25. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES​

FIGURE 3-26. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-27. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ ENGINE) (STAGE V)​

FIGURE 3-28. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE)​

SECTION 4 - BOOM

FIGURE 4-1. CYLINDERS INSTALLATION (Prior to SN B300015268, Except SN B300014977 through B300014987, Except SN B300015050 through B300015051, Except SN B300015062 through B300015099, Including B300015409, Excluding B300015056 and B300015158)​

FIGURE 4-2. CYLINDERS INSTALLATION (SN B300015268 to Present, SN B300014977 through B300014987, SN B300015050 through B300015051, SN B300015062 through B300015099, Including B300015056 and B300015158, Excluding B300015409)​

FIGURE 4-3. BOOM INSTALLATION​

FIGURE 4-4. JIB INSTALLATION​

FIGURE 4-5. MAIN BOOM ASSEMBLY​

FIGURE 4-6. TOWER BOOM ASSEMBLY​

FIGURE 4-7. ROTATOR ASSEMBLY​

FIGURE 4-8. PLATFORM SUPPORT INSTALLATION​

FIGURE 4-9. VALVES INSTALLATION - BOOM MOUNTED​

FIGURE 4-10. UPRIGHT VALVE ASSEMBLY​

FIGURE 4-11. BOOM VALVE ASSEMBLY​

SECTION 5 - PLATFORM

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

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

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE DROP-BAR ENTRY​

FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY​

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

FIGURE 5-6. CONSOLE BOX INSTALLATION​

FIGURE 5-7. PLATFORM CONSOLE BOX ASSEMBLY​

FIGURE 5-8. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE​

FIGURE 5-9. CONTROLLER ASSEMBLY - DRIVE AND STEER​

FIGURE 5-10. CONTROLLER ASSEMBLY - LIFT AND SWING​

FIGURE 5-11. FOOTSWITCH ASSEMBLY​

FIGURE 5-12. TRAY ASSEMBLY​

FIGURE 5-13. SKYEYE INSTALLATION​

FIGURE 5-14. SKYGUARD BAR INSTALLATION​

FIGURE 5-15. SKYLINE INSTALLATION​

FIGURE 5-16. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS)​

FIGURE 5-17. SKYSENSE MID TUBE SENSOR ASSEMBLY​

FIGURE 5-18. SKYSENSE OVERHEAD SENSOR ASSEMBLY​

FIGURE 5-19. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)​

FIGURE 5-20. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)​

FIGURE 5-21. USB CHARGER INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY​

FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (Prior to SN B300015268, Except SN B300014977 through B300014987, Except SN B300015050 through B300015051, Except SN B300015062 through B300015099, Including B300015409, Excluding B300015056 and B30...​

FIGURE 6-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (SN B300015268 to Present, SN B300014977 through B300014987, SN B300015050 through B300015051, SN B300015062 through B300015099, Including B300015056 and B300015158, Excluding B300015409)​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB (Prior to SN B300015268, Except SN B300014977 through B300014987, Except SN B300015050 through B300015051, Except SN B300015062 through B300015099, Including B300015409, Excluding B300015056 and B300015158)​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB (SN B300015268 to Present, SN B300014977 through B300014987, SN B300015050 through B300015051, SN B300015062 through B300015099, Including B300015056 and B300015158, Excluding B300015409)​

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

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - TOWER BOOM​

FIGURE 6-8. MASTER CYLINDER ASSEMBLY (Prior to SN B300015268, Except SN B300014977 through B300014987, Except SN B300015050 through B300015051, Except SN B300015062 through B300015099, Including B300015409, Excluding B300015056 and B300015158)​

FIGURE 6-9. MASTER CYLINDER ASSEMBLY (SN B300015268 to Present, SN B300014977 through B300014987, SN B300015050 through B300015051, SN B300015062 through B300015099, Including B300015056 and B300015158, Excluding B300015409)​

FIGURE 6-10. STEER CYLINDER ASSEMBLY​

FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION​

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 AND RUSSIA 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. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER (CE & UK CA SPEC)​

FIGURE 8-23. BREAKER BOX KIT WITH THREE BREAKERS (CE & UK CA SPEC)​

FIGURE 8-24. BREAKER BOX KIT - 30MA/16 AMP​

FIGURE 8-25. CHASSIS SOLENOID HARNESS​

FIGURE 8-26. ENGINE HARNESS - DEUTZ D2011​

FIGURE 8-27. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)​

FIGURE 8-28. FUEL HARNESS - DEUTZ D2.9L4 ENGINE​

FIGURE 8-29. GENERATOR HARNESS - 2500W GENERATOR (50HZ)​

FIGURE 8-30. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-31. GROUND CONTROL PANEL HARNESS​

FIGURE 8-32. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-33. PLATFORM INTERFACE HARNESS​

FIGURE 8-34. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-35. RECEPTACLE BOX KIT - 220V IEC BLUE (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-36. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-37. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-38. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE, CIS/EAC & UK CA SPEC)​

FIGURE 8-39. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-40. SKYEYE RECEIVER HARNESS​

FIGURE 8-41. SKYEYE EMITTER HARNESS​

FIGURE 8-42. SKYLINE HARNESS​

FIGURE 8-43. TURNTABLE HARNESS​

FIGURE 8-44. VALVE HARNESS - BOOM VALVE​

FIGURE 8-45. VALVE HARNESS - MAIN VALVE​

FIGURE 8-46. VALVE HARNESS - PLATFORM VALVE​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION – ANSI, ANSI EXPORT AND CSA SPECS (ENGLISH)​

FIGURE 9-2. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH​

FIGURE 9-3. DECAL INSTALLATION - CE & UK CA SPEC (ENGLISH)​

FIGURE 9-4. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH)​

FIGURE 9-5. DECAL INSTALLATION - OPTIONS​

FIGURE 9-6. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI EXPORT, CE, CIS/EAC & UK CA SPECS)​

FIGURE 9-7. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (CE, CIS/EAC & UK CA SPECS)​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

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

PART NUMBER INDEX