JLG 520AJ Parts Manual (3121666) – PDF DOWNLOAD (english)

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JLG 520AJ Parts Manual (3121666) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 520AJ Parts Manual (3121666) – PDF DOWNLOAD

SECTION 1 - FRAME............................................................................................................................................................................ 11
	FIGURE 1-1. AXLE INSTALLATION............................................................................................................................................................ 12
	FIGURE 1-2. STEER INSTALLATION WITHOUT TOW PACKAGE....................................................................................................................................... 14
	FIGURE 1-3. STEER INSTALLATION WITH TOW PACKAGE.......................................................................................................................................... 16
	FIGURE 1-4. WHEEL DRIVE INSTALLATION, 4WD................................................................................................................................................ 18
	FIGURE 1-5. DRIVE HUB AND BRAKE ASSEMBLY - REAR.......................................................................................................................................... 20
	FIGURE 1-6. DRIVE HUB ASSEMBLY - FRONT................................................................................................................................................... 24
	FIGURE 1-7. DRIVE MOTOR ASSEMBLY, 4WD.................................................................................................................................................... 26
	FIGURE 1-8. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING................................................................................................................... 28
	FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM FILLED..................................................................................................................... 30
	FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED........................................................................................................................ 32
	FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING............................................................................................................ 34
	FIGURE 1-12. VALVES INSTALLATION - FRAME MOUNTED......................................................................................................................................... 36
	FIGURE 1-13. TRACTION VALVE ASSEMBLY..................................................................................................................................................... 38
	FIGURE 1-14. FRAME COVERS INSTALLATION................................................................................................................................................... 40
	FIGURE 1-15. TOW PACKAGE INSTALLATION (OPTIONAL)......................................................................................................................................... 42
	FIGURE 1-16. TOW BAR ASSEMBLY............................................................................................................................................................ 44
SECTION 2 - TURNTABLE........................................................................................................................................................................ 47
	FIGURE 2-1. VALVES INSTALLATION - TURNTABLE MOUNTED...................................................................................................................................... 48
	FIGURE 2-2. MAIN VALVE ASSEMBLY.......................................................................................................................................................... 50
	FIGURE 2-3. AUXILIARY PUMP ASSEMBLY...................................................................................................................................................... 52
	FIGURE 2-4. SWING DRIVE AND TURNTABLE BEARING INSTALLATION............................................................................................................................... 54
	FIGURE 2-5. SWING MOTOR ASSEMBLY......................................................................................................................................................... 56
	FIGURE 2-6. TURNTABLE BEARING ASSEMBLY................................................................................................................................................... 58
	FIGURE 2-7. TURNTABLE COVERS INSTALLATION................................................................................................................................................ 60
	FIGURE 2-8. TURNTABLE LOCK INSTALLATION.................................................................................................................................................. 62
	FIGURE 2-9. TANKS INSTALLATION (Prior to SN E300004228).................................................................................................................................. 64
	FIGURE 2-10. TANKS INSTALLATION - DIESEL MACHINES (SN 1300007286 through 1300007383, SN E300004228 to Present)........................................................................... 66
	FIGURE 2-11. DRIVE ORIENTATION INSTALLATION.............................................................................................................................................. 68
	FIGURE 2-12. GROUND CONTROL ASSEMBLY - AUSTRALIAN SPEC................................................................................................................................... 70
	FIGURE 2-13. GROUND CONTROL ASSEMBLY - CE SPEC........................................................................................................................................... 72
	FIGURE 2-14. ELECTRICAL SYSTEM INSTALLATION.............................................................................................................................................. 74
	FIGURE 2-15. BEACON LIGHT INSTALLATION - AMBER........................................................................................................................................... 78
	FIGURE 2-16. BEACON LIGHT INSTALLATION - BLUE  (Prior to SN E300007543).................................................................................................................. 80
	FIGURE 2-17. BEACON LIGHT INSTALLATION - BLUE  (SN E300007543 to Present)................................................................................................................ 82
	FIGURE 2-18. BEACON LIGHT INSTALLATION - RED (Prior to SN E300007543).................................................................................................................... 84
	FIGURE 2-19. BEACON LIGHT INSTALLATION - RED (SN E300007543 to Present).................................................................................................................. 86
	FIGURE 2-20. BATTERY AND CABLE INSTALLATION.............................................................................................................................................. 88
	FIGURE 2-21. HOODS INSTALLATION  (Prior to SN E300006377)................................................................................................................................ 90
	FIGURE 2-22. HOODS INSTALLATION  (SN E300006377 to Present).............................................................................................................................. 94
	FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE  (Prior to SN E300006377)......................................................................................................................... 98
	FIGURE 2-24. HOOD ASSEMBLY - TANK SIDE  (SN E300006377 to Present).......................................................................................................................100
	FIGURE 2-25. HOOD ASSEMBLY - ENGINE SIDE  (Prior to SN E300006377).......................................................................................................................102
	FIGURE 2-26. HOOD ASSEMBLY - ENGINE SIDE  (SN E300006377 to Present).....................................................................................................................104
	FIGURE 2-27. COVERS INSTALLATION - COUNTERWEIGHT.........................................................................................................................................106
SECTION 3 - ENGINE...........................................................................................................................................................................109
	FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2.3L3 ENGINE....................................................................................................................................110
	FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.3L3..................................................................................................................................114
	FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2.3L3 ENGINE........................................................................................................................................116
	FIGURE 3-4. ENGINE COMPONENTS - DEUTZ D2.3L3.............................................................................................................................................120
	FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS).......................................................................................124
	FIGURE 3-6. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS).....................................................................................128
	FIGURE 3-7. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)...........................................................................................130
	FIGURE 3-8. ENGINE COMPONENTS - DEUTZ D2011 (STAGE V)....................................................................................................................................134
	FIGURE 3-9. PUMP COUPLING KIT............................................................................................................................................................138
	FIGURE 3-10. GEAR PUMP ASSEMBLY  (Prior to SN E300004772)................................................................................................................................140
	FIGURE 3-11. PISTON PUMP ASSEMBLY........................................................................................................................................................142
	FIGURE 3-12. CATALYTIC SPARK ARRESTOR INSTALLATION - DEUTZ D2.3L3 ENGINE.................................................................................................................146
	FIGURE 3-13. SPARK ARRESTOR INSTALLATION - DEUTZ D2.3L3 ENGINE...........................................................................................................................148
	FIGURE 3-14. ENGINE BAFFLE INSTALLATION..................................................................................................................................................150
	FIGURE 3-15. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2.3L3 ENGINE)...................................................................................................................152
	FIGURE 3-16. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2.3L3 ENGINE)...................................................................................................................156
SECTION 4 - BOOM.............................................................................................................................................................................161
	FIGURE 4-1. CYLINDERS INSTALLATION.......................................................................................................................................................162
	FIGURE 4-2. BOOM INSTALLATION............................................................................................................................................................164
	FIGURE 4-3. JIB INSTALLATION.............................................................................................................................................................166
	FIGURE 4-4. MAIN BOOM ASSEMBLY...........................................................................................................................................................168
	FIGURE 4-5. TOWER BOOM ASSEMBLY..........................................................................................................................................................170
	FIGURE 4-6. ROTATOR ASSEMBLY (SN E300002833 through E300004882)..........................................................................................................................172
	FIGURE 4-7. ROTATOR ASSEMBLY (SN 1300007286 through 1300007383, SN E300004883 to Present)................................................................................................174
	FIGURE 4-8. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (Prior to SN E300002782).....................................................................................................176
	FIGURE 4-9. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (SN 1300007286 through 1300007383, SN E300002782 to Present).................................................................180
	FIGURE 4-10. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS.............................................................................................................................182
	FIGURE 4-11. VALVES INSTALLATION - BOOM MOUNTED..........................................................................................................................................184
	FIGURE 4-12. UPRIGHT VALVE ASSEMBLY......................................................................................................................................................186
	FIGURE 4-13. BOOM VALVE ASSEMBLY.........................................................................................................................................................188
SECTION 5 - PLATFORM.........................................................................................................................................................................191
	FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY..............................................................................................................192
	FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY..............................................................................................................194
	FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY..............................................................................................................196
	FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - WITH DROP BAR.................................................................................................................198
	FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR................................................................................................................200
	FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR................................................................................................................202
	FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR................................................................................................................204
	FIGURE 5-8. CONSOLE BOX INSTALLATION - WITHOUT SKYGUARD..................................................................................................................................206
	FIGURE 5-9. CONSOLE BOX INSTALLATION - WITH SKYGUARD (Prior to SN E300007543)............................................................................................................208
	FIGURE 5-10. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E3000007543 to Present)........................................................................................................210
	FIGURE 5-11. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (Prior to SN E300003610)...................................................................................................212
	FIGURE 5-12. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (SN 1300007286 through 1300007383, SN E300003610 to Present)...............................................................216
	FIGURE 5-13. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (Prior to SN E300003610)......................................................................................................220
	FIGURE 5-14. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN 1300007286 through 1300007383, SN E300003610 through E300007542)..........................................................224
	FIGURE 5-15. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300007543 to Present)....................................................................................................228
	FIGURE 5-16. CONTROLLER ASSEMBLY - DRIVE AND STEER.......................................................................................................................................232
	FIGURE 5-17. CONTROLLER ASSEMBLY - LIFT AND SWING........................................................................................................................................234
	FIGURE 5-18. FOOTSWITCH ASSEMBLY.........................................................................................................................................................238
	FIGURE 5-19. TRAY ASSEMBLY...............................................................................................................................................................240
	FIGURE 5-20. SKYEYE INSTALLATION.........................................................................................................................................................242
	FIGURE 5-21. SKYGUARD SYSTEM INSTALLATION (Prior to SN E300007543).......................................................................................................................244
	FIGURE 5-22. SKYGUARD BAR INSTALLATION (SN E300007543 to Present)........................................................................................................................246
	FIGURE 5-23. SKYLINE INSTALLATION........................................................................................................................................................248
	FIGURE 5-24. CROSS RAIL INSTALLATION.....................................................................................................................................................250
	FIGURE 5-25. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (Prior to SN E300004872).........................................................................................................252
	FIGURE 5-26. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (SN 1300007286 through 1300007383, SN E300004872 to Present).....................................................................254
	FIGURE 5-27. PIPE RACK INSTALLATION (AUSTRALIAN SPEC)....................................................................................................................................256
	FIGURE 5-28. PIPE RACK INSTALLATION (CE SPECS)...........................................................................................................................................258
SECTION 6 - CYLINDER.........................................................................................................................................................................261
	FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY...............................................................................................................................................262
	FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY.....................................................................................................................................264
	FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB.................................................................................................................................................266
	FIGURE 6-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM (Prior to SN E300004512)..................................................................................................................268
	FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN 1300007286 through 1300007383, SN E300004512 to Present)..............................................................................270
	FIGURE 6-6. LIFT CYLINDER ASSEMBLY - TOWER BOOM..........................................................................................................................................272
	FIGURE 6-7. MASTER CYLINDER ASSEMBLY.....................................................................................................................................................274
	FIGURE 6-8. STEER CYLINDER ASSEMBLY......................................................................................................................................................276
	FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY..................................................................................................................................................278
SECTION 7 - HYDRAULIC........................................................................................................................................................................281
	FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION (Prior to SN E300004228).......................................................................................................................282
	FIGURE 7-2. HYDRAULIC SYSTEM INSTALLATION (SN 1300007286 through 1300007383, SN E300004228 to Present)...................................................................................288
	FIGURE 7-3. HYDRAULIC DIAGRAM LIST.......................................................................................................................................................294
SECTION 8 - ELECTRICAL.......................................................................................................................................................................295
	FIGURE 8-1. ELECTRICAL DIAGRAM LIST......................................................................................................................................................296
	FIGURE 8-2. AC BOX AT PLATFORM - LOCALLY SUPPLIED COMPONENTS (Prior to SN E300003512)....................................................................................................298
	FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPEC) (Prior to SN E300003512).........................................................................................300
	FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 to Present)......................302
	FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPEC) (Prior to SN E300003512)...........................................................................................304
	FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 to Present)........................306
	FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 70MM X 70MM BOX (CE SPEC) (Prior to SN E300002764)..............................................................308
	FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 70MM X 70MM BOX (CE SPEC) (Prior to SN E300002764)..............................................................310
	FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 2IN X 4IN BOX (CE SPEC) (Prior to SN E300002764)................................................................312
	FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300002764 through E300003511).....................................................314
	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 to Present)...........316
	FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 2IN X 4IN BOX (CE SPEC) (Prior to SN E300002764)...............................................................318
	FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300002764 through E300003511).....................................................320
	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 to Present)...........322
	FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND WITH 2IN X 4IN BOX (CE SPEC) (Prior to SN E300003512)........................................................324
	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 to Present)....326
	FIGURE 8-17. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ANSI EXPORT, CE AND CHINA SPECS).......................................................................328
	FIGURE 8-18. AC CABLE INSTALLATION – WITH TWO BREAKERS (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 to Present)...........................................................330
	FIGURE 8-19. AC CABLE INSTALLATION – WITH THREE BREAKERS (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 to Present).........................................................332
	FIGURE 8-20. BATTERY DISCONNECT SWITCH...................................................................................................................................................334
	FIGURE 8-21. BEACON LIGHT HARNESS........................................................................................................................................................336
	FIGURE 8-22. BEACON EXTENSION HARNESS (Prior to SN E600003882)...........................................................................................................................338
	FIGURE 8-23. BOOM CABLES AND CLAMPS INSTALLATION.........................................................................................................................................340
	FIGURE 8-24. BOOM HARNESS - MAIN BOOM....................................................................................................................................................344
	FIGURE 8-25. BOOM HARNESS - MAIN BOOM AC CABLE...........................................................................................................................................346
	FIGURE 8-26. BOOM HARNESS - TOWER BOOM...................................................................................................................................................348
	FIGURE 8-27. BOOM HARNESS - TOWER BOOM AC CABLE..........................................................................................................................................350
	FIGURE 8-28. BOOM VALVE HARNESS..........................................................................................................................................................352
	FIGURE 8-29. BREAKER BOX KIT - CE SPEC...................................................................................................................................................354
	FIGURE 8-30. BREAKER BOX KIT - 30MA/16AMP................................................................................................................................................356
	FIGURE 8-31. CHASSIS SOLENOID HARNESS....................................................................................................................................................358
	FIGURE 8-32. ENGINE HARNESS - DEUTZ D2.3L3...............................................................................................................................................360
	FIGURE 8-33. GENERATOR HARNESS - 4000W GENERATOR.........................................................................................................................................362
	FIGURE 8-34. GROUND CONTROL PANEL HARNESS................................................................................................................................................364
	FIGURE 8-35. PLATFORM CONSOLE BOX HARNESS (Prior to SN E300007543).......................................................................................................................366
	FIGURE 8-36. PLATFORM CONSOLE BOX HARNESS (SN E300007543 to Present).....................................................................................................................368
	FIGURE 8-37. PLATFORM INTERFACE HARNESS..................................................................................................................................................370
	FIGURE 8-38. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)..............................................................................................................................372
	FIGURE 8-39. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)................................................................................................................................374
	FIGURE 8-40. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 (CE SPEC)....................................................................................................................376
	FIGURE 8-41. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 (CE SPEC)....................................................................................................................378
	FIGURE 8-42. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 70MMX70MM (CE SPEC)..............................................................................................................380
	FIGURE 8-43. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 70MMX70MM (CE SPEC)..............................................................................................................382
	FIGURE 8-44. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)..............................................................................................................................384
	FIGURE 8-45. SKYEYE INTERMEDIATE HARNESS.................................................................................................................................................386
	FIGURE 8-46. SKYEYE RECEIVER HARNESS.....................................................................................................................................................388
	FIGURE 8-47. SKYEYE EMITTER HARNESS......................................................................................................................................................390
	FIGURE 8-48. SKYLINE HARNESS.............................................................................................................................................................392
	FIGURE 8-49. SKYGUARD HARNESS............................................................................................................................................................394
	FIGURE 8-50. TURNTABLE HARNESS...........................................................................................................................................................396
	FIGURE 8-51. VALVE HARNESS - MAIN VALVE..................................................................................................................................................400
	FIGURE 8-52. VALVE HARNESS - PLATFORM VALVE..............................................................................................................................................402
SECTION 9 - DECAL............................................................................................................................................................................405
	FIGURE 9-1. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH)...............................................................................................................................406
	FIGURE 9-2. DECAL INSTALLATION - CE SPEC (ENGLISH).......................................................................................................................................408
	FIGURE 9-3. DECAL INSTALLATION - OPTIONS.................................................................................................................................................410
	FIGURE 9-4. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI, ANSI EXPORT AND CE SPECS)...............................................................................................412
	FIGURE 9-5. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (CE SPECS).....................................................................................................................414
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK.................................................................................................................................................417
	FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK.............................................................................................................................................418
SECTION 11 - SPECIAL OPTIONS.................................................................................................................................................................419
	FIGURE 11-1. SPECIAL OPTIONS.............................................................................................................................................................420
PART NUMBER INDEX............................................................................................................................................................................423

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