JLG 520AJ Parts Manual (3121666) – PDF DOWNLOAD

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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 (SN E300000100 through E300004228)................................................................................................................................ 64
	FIGURE 2-10. TANKS INSTALLATION - DIESEL MACHINES (SN 1300007286 through 1300007383, SN E300004228 through E300007980)........................................................................... 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  (SN E300000100 through E300007543)................................................................................................................ 80
	FIGURE 2-17. BEACON LIGHT INSTALLATION - BLUE  (SN E300007543 through E300007980)................................................................................................................ 82
	FIGURE 2-18. BEACON LIGHT INSTALLATION - RED (SN E300000100 through E300007543).................................................................................................................. 84
	FIGURE 2-19. BEACON LIGHT INSTALLATION - RED (SN E300007543 through E300007980).................................................................................................................. 86
	FIGURE 2-20. BATTERY AND CABLE INSTALLATION...................................................................................................................................................... 88
	FIGURE 2-21. HOODS INSTALLATION  (SN E300000100 through E300006377).............................................................................................................................. 90
	FIGURE 2-22. HOODS INSTALLATION  (SN E300006377 through E300007980).............................................................................................................................. 94
	FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE  (SN E300000100 through E300006377)....................................................................................................................... 98
	FIGURE 2-24. HOOD ASSEMBLY - TANK SIDE  (SN E300006377 through E300007980).......................................................................................................................100
	FIGURE 2-25. HOOD ASSEMBLY - ENGINE SIDE  (SN E300000100 through E300006377).....................................................................................................................102
	FIGURE 2-26. HOOD ASSEMBLY - ENGINE SIDE  (SN E300006377 through E300007980).....................................................................................................................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  (SN E300000100 through 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 through E300007980)................................................................................................174
	FIGURE 4-8. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (SN E300000100 through E300002782)...................................................................................................176
	FIGURE 4-9. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (SN 1300007286 through 1300007383, SN E300002782 through E300007980).................................................................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 (SN E300000100 through E300007543)..........................................................................................................208
	FIGURE 5-10. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E3000007543 through E300007980)........................................................................................................210
	FIGURE 5-11. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (SN E300000100 through E300003610).................................................................................................212
	FIGURE 5-12. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (SN 1300007286 through 1300007383, SN E300003610 through E300007980)...............................................................216
	FIGURE 5-13. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300000100 through 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 through E300007980)....................................................................................................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 (SN E300000100 through E300007543).....................................................................................................................244
	FIGURE 5-22. SKYGUARD BAR INSTALLATION (SN E300007543 through E300007980)........................................................................................................................246
	FIGURE 5-23. SKYLINE INSTALLATION................................................................................................................................................................248
	FIGURE 5-24. CROSS RAIL INSTALLATION.............................................................................................................................................................250
	FIGURE 5-25. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (SN E300000100 through E300004872).......................................................................................................252
	FIGURE 5-26. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (SN 1300007286 through 1300007383, SN E300004872 through E300007980).....................................................................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 (SN E300000100 through E300004512)................................................................................................................268
	FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN 1300007286 through 1300007383, SN E300004512 through E300007980)..............................................................................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 (SN E300000100 through E300004228).....................................................................................................................282
	FIGURE 7-2. HYDRAULIC SYSTEM INSTALLATION (SN 1300007286 through 1300007383, SN E300004228 through E300007980)...................................................................................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 (SN E300000100 through E300003512)..................................................................................................298
	FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPEC) (SN E300000100 through 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 through E300007980)......................302
	FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPEC) (SN E300000100 through 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 through E300007980)........................306
	FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 70MM X 70MM BOX (CE SPEC) (SN E300000100 through E300002764)............................................................308
	FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 70MM X 70MM BOX (CE SPEC) (SN E300000100 through E300002764)............................................................310
	FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300000100 through 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 through E300007980)...........316
	FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300000100 through 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 through E300007980)...........322
	FIGURE 8-15. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND WITH 2IN X 4IN BOX (CE SPEC) (SN E300000100 through 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 through E300007980)....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 through E300007980)...........................................................330
	FIGURE 8-19. AC CABLE INSTALLATION – WITH THREE BREAKERS (CE SPECS) (SN 1300007286 through 1300007383, SN E300003512 through E300007980).........................................................332
	FIGURE 8-20. BATTERY DISCONNECT SWITCH...........................................................................................................................................................334
	FIGURE 8-21. BEACON LIGHT HARNESS................................................................................................................................................................336
	FIGURE 8-22. BEACON EXTENSION HARNESS (SN E300000100 through 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 (SN E300000100 through E300007543).....................................................................................................................366
	FIGURE 8-36. PLATFORM CONSOLE BOX HARNESS (SN E300007543 through E300007980).....................................................................................................................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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