JLG 520AJ PVC 2001 2007 Parts Manual (31215026) – PDF DOWNLOAD

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JLG 520AJ PVC 2001 2007 Parts Manual (31215026) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 520AJ PVC 2001 2007 Parts Manual (31215026) – 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. FRAME SHIELD INSTALLATION................................................................................................ 28
	FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING (AVAILABLE ON AUSTRALIAN AND CE SPECS)........................ 30
	FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED (AVAILABLE ON AUSTRALIAN, CE AND CHINA SPECS)...................... 32
	FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING (AVAILABLE ON AUSTRALIAN, CE AND CHINA SPECS).......... 34
	FIGURE 1-12. 4WD VALVES INSTALLATION - FRAME MOUNTED................................................................................. 36
	FIGURE 1-13. TRACTION VALVE ASSEMBLY - 4WD........................................................................................... 38
	FIGURE 1-14. TOW PACKAGE INSTALLATION (OPTIONAL)..................................................................................... 40
	FIGURE 1-15. TOW BAR ASSEMBLY........................................................................................................ 42
SECTION 2 - TURNTABLE.................................................................................................................... 45
	FIGURE 2-1. 4WD VALVES INSTALLATION - 450AJ TURNTABLE MOUNTED........................................................................ 46
	FIGURE 2-2. MAIN VALVE ASSEMBLY...................................................................................................... 48
	FIGURE 2-3. AUXILIARY PUMP ASSEMBLY.................................................................................................. 50
	FIGURE 2-4. SWING DRIVE AND TURNTABLE BEARING INSTALLATION........................................................................... 52
	FIGURE 2-5. SWING MOTOR ASSEMBLY..................................................................................................... 54
	FIGURE 2-6. TURNTABLE BEARING ASSEMBLY............................................................................................... 56
	FIGURE 2-7. TURNTABLE COVERS INSTALLATION............................................................................................ 58
	FIGURE 2-8. TURNTABLE LOCK INSTALLATION.............................................................................................. 60
	FIGURE 2-9. TANKS INSTALLATION....................................................................................................... 62
	FIGURE 2-10. DRIVE ORIENTATION INSTALLATION.......................................................................................... 64
	FIGURE 2-11. GROUND CONTROL ASSEMBLY (ANSI EXPORT AND AUSTRALIAN SPECS).............................................................. 66
	FIGURE 2-12. GROUND CONTROL ASSEMBLY (CE SPECS) (PVC 2001)........................................................................... 68
	FIGURE 2-13. GROUND CONTROL ASSEMBLY - 450AJ WITH DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)........................................... 70
	FIGURE 2-14. LIGHT PANEL INSTALLATION – GROUND CONTROL............................................................................... 72
	FIGURE 2-15. ELECTRICAL SYSTEM INSTALLATION.......................................................................................... 74
	FIGURE 2-16. WHITE NOISE ALARM INSTALLATION.......................................................................................... 78
	FIGURE 2-17. BEACON LIGHT INSTALLATION - AMBER....................................................................................... 80
	FIGURE 2-18. BEACON LIGHT INSTALLATION - BLUE........................................................................................ 82
	FIGURE 2-19. BEACON LIGHT INSTALLATION - RED......................................................................................... 84
	FIGURE 2-20. BATTERY AND CABLE INSTALLATION (PVC 2001)............................................................................... 86
	FIGURE 2-21. BATTERY AND CABLE INSTALLATION (PVC 2007)............................................................................... 88
	FIGURE 2-22. HOODS INSTALLATION...................................................................................................... 90
	FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE (ROMANIAN BUILT MACHINES)..................................................................... 94
	FIGURE 2-24. HOOD ASSEMBLY - ENGINE SIDE (ROMANIAN BUILT MACHINES)................................................................... 96
SECTION 3 - ENGINE....................................................................................................................... 99
	FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC) AND CHINA SPECS)....100
	FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN AND CHINA SPECS)............104
	FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN AND CHINA SPECS)..................106
	FIGURE 3-4. ENGINE COMPONENTS - DEUTZ D2011..........................................................................................110
	FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS) (PVC 2001)........................114
	FIGURE 3-6. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS) (PVC 2001)......................118
	FIGURE 3-7. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS) (PVC 2001)............................120
	FIGURE 3-8. ENGINE COMPONENTS - DEUTZ D2011 (STAGE V) (PVC 2001).....................................................................124
	FIGURE 3-9. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)...........................................................128
	FIGURE 3-10. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS).................................................134
	FIGURE 3-11. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)..............................................................136
	FIGURE 3-12. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V).................................................142
	FIGURE 3-13. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES (STAGE V) (CE SPECS)................................................144
	FIGURE 3-14. PUMP COUPLING KIT – DEUTZ ENGINES.......................................................................................146
	FIGURE 3-15. PISTON PUMP ASSEMBLY....................................................................................................148
	FIGURE 3-16. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE........................................................................152
	FIGURE 3-17. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES.........................................................................154
	FIGURE 3-18. GENERATOR INSTALLATION - 2500W/50HZ (DEUTZ D2011 ENGINE)................................................................156
	FIGURE 3-19. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)................................................................160
	FIGURE 3-20. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ ENGINE) (STAGE V)............................................................164
	FIGURE 3-21. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2001).....................................................168
	FIGURE 3-22. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2007).....................................................172
	FIGURE 3-23. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ ENGINE) (STAGE V)............................................................176
SECTION 4 - BOOM.........................................................................................................................179
	FIGURE 4-1. CYLINDERS INSTALLATION...................................................................................................180
	FIGURE 4-2. BOOM INSTALLATION........................................................................................................182
	FIGURE 4-3. JIB INSTALLATION.........................................................................................................184
	FIGURE 4-4. MAIN BOOM ASSEMBLY.......................................................................................................186
	FIGURE 4-5. TOWER BOOM ASSEMBLY......................................................................................................188
	FIGURE 4-6. ROTATOR ASSEMBLY.........................................................................................................190
	FIGURE 4-7. PLATFORM SUPPORT INSTALLATION............................................................................................192
	FIGURE 4-8. VALVES INSTALLATION - BOOM MOUNTED.......................................................................................194
	FIGURE 4-9. UPRIGHT VALVE ASSEMBLY...................................................................................................196
	FIGURE 4-10. BOOM VALVE ASSEMBLY.....................................................................................................198
SECTION 5 - PLATFORM.....................................................................................................................201
	FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY (ROMANIAN BUILT MACHINES)................................202
	FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY (ROMANIAN BUILT MACHINES)................................204
	FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY (ROMANIAN BUILT MACHINES)................................206
	FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY (USA AND ROMANIAN BUILT MACHINES)..........................208
	FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)..................................210
	FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)..................................212
	FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)..................................214
	FIGURE 5-8. CONSOLE BOX INSTALLATION.................................................................................................216
	FIGURE 5-9. PLATFORM CONSOLE BOX ASSEMBLY............................................................................................218
	FIGURE 5-10. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE.............................................................................222
	FIGURE 5-11. CONTROLLER ASSEMBLY - DRIVE AND STEER...................................................................................224
	FIGURE 5-12. CONTROLLER ASSEMBLY - LIFT AND SWING....................................................................................226
	FIGURE 5-13. FOOTSWITCH ASSEMBLY.....................................................................................................230
	FIGURE 5-14. TRAY ASSEMBLY...........................................................................................................232
	FIGURE 5-15. SOFT TOUCH INSTALLATION - 6FT/1.8M PLATFORM (ANSI EXPORT SPECS) (PVC 2001)..............................................234
	FIGURE 5-16. SOFT TOUCH INSTALLATION - 5FT/1.52M PLATFORM WITH FALL ARREST (ANSI EXPORT SPECS) (PVC 2001)............................236
	FIGURE 5-17. SKYEYE INSTALLATION.....................................................................................................238
	FIGURE 5-18. SKYGUARD BAR INSTALLATION...............................................................................................240
	FIGURE 5-19. SKYLINE INSTALLATION....................................................................................................242
	FIGURE 5-20. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS)..............................................................................244
	FIGURE 5-21. PIPE RACK INSTALLATION (ANSI EXPORT & CE SPECS).........................................................................246
	FIGURE 5-22. PIPE RACK INSTALLATION (AUSTRALIAN SPEC)................................................................................248
	FIGURE 5-23. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM).................................................................250
	FIGURE 5-24. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM).................................................................252
	FIGURE 5-25. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.83M PLATFORM).................................................................254
SECTION 6 - CYLINDER.....................................................................................................................257
	FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY...........................................................................................258
	FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY.................................................................................260
	FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB.............................................................................................262
	FIGURE 6-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM.......................................................................................264
	FIGURE 6-5. LIFT CYLINDER ASSEMBLY - TOWER BOOM......................................................................................266
	FIGURE 6-6. MASTER CYLINDER ASSEMBLY.................................................................................................268
	FIGURE 6-7. STEER CYLINDER ASSEMBLY..................................................................................................270
	FIGURE 6-8. TELESCOPE CYLINDER ASSEMBLY..............................................................................................272
SECTION 7 - HYDRAULIC....................................................................................................................275
	FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION............................................................................................276
	FIGURE 7-2. HYDRAULIC SYSTEM INSTALLATION............................................................................................278
	FIGURE 7-3. HYDRAULIC SYSTEM INSTALLATION............................................................................................280
	FIGURE 7-4. HYDRAULIC SYSTEM INSTALLATION............................................................................................282
SECTION 8 - ELECTRICAL...................................................................................................................285
	FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V - ANSI EXPORT SPECS...............................................................286
	FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS WITH 4000W/50HZ GENERATOR)...................................288
	FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE SPECS)...............................290
	FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS WITH 4000W/50HZ GENERATOR).....................................292
	FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE SPECS).................................294
	FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS).....................296
	FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS).....................298
	FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN POST GROUND (CE SPECS WITH 4000W/50HZ GENERATOR)...................300
	FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN SIDE GROUND (CE SPECS WITH 4000W/50HZ GENERATOR)...................302
	FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE SPECS WITH 4000W/50HZ GENERATOR)...................................304
	FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS).............306
	FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ANSI EXPORT, AUSTRALIAN & CE SPECS)................308
	FIGURE 8-13. AC CABLE INSTALLATION - WITH TWO BREAKERS (CE SPECS)....................................................................310
	FIGURE 8-14. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE SPECS)..................................................................312
	FIGURE 8-15. BATTERY DISCONNECT SWITCH...............................................................................................314
	FIGURE 8-16. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)........................................................................316
	FIGURE 8-17. BOOM CABLES & CLAMPS INSTALLATION (4000W GENERATOR) (PVC 2001)..........................................................318
	FIGURE 8-18. BOOM CABLES & CLAMPS INSTALLATION (4000W GENERATOR) (PVC 2007)..........................................................322
	FIGURE 8-19. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR) (PVC 2001).................................................326
	FIGURE 8-20. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR) (PVC 2007).................................................330
	FIGURE 8-21. BOOM HARNESS - MAIN BOOM................................................................................................334
	FIGURE 8-22. BOOM HARNESS - MAIN BOOM (8/5 4000W GENERATOR)..........................................................................336
	FIGURE 8-23. BOOM HARNESS - TOWER BOOM...............................................................................................338
	FIGURE 8-24. BOOM HARNESS - TOWER BOOM (8/5 4000W GENERATOR).........................................................................340
	FIGURE 8-25. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER - CE SPEC...............................................................342
	FIGURE 8-26. BREAKER BOX KIT WITH THREE BREAKERS - CE SPEC...........................................................................344
	FIGURE 8-27. BREAKER BOX KIT - 30MA/16 AMP...........................................................................................346
	FIGURE 8-28. CHASSIS SOLENOID HARNESS................................................................................................348
	FIGURE 8-29. ENGINE HARNESS - DEUTZ D2011............................................................................................350
	FIGURE 8-30. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)..........................................................................352
	FIGURE 8-31. FUEL HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)............................................................................356
	FIGURE 8-32. GENERATOR HARNESS - 2500W GENERATOR (50HZ)..............................................................................358
	FIGURE 8-33. GENERATOR HARNESS - 4000W GENERATOR.....................................................................................360
	FIGURE 8-34. GROUND CONTROL PANEL HARNESS............................................................................................362
	FIGURE 8-35. PLATFORM CONSOLE BOX HARNESS............................................................................................364
	FIGURE 8-36. PLATFORM INTERFACE HARNESS..............................................................................................366
	FIGURE 8-37. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)..........................................................................368
	FIGURE 8-38. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)............................................................................370
	FIGURE 8-39. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE SPEC)......................................................372
	FIGURE 8-40. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE SPEC)......................................................374
	FIGURE 8-41. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)..........................................................................376
	FIGURE 8-42. SKYEYE INTERMEDIATE HARNESS.............................................................................................378
	FIGURE 8-43. SKYEYE RECEIVER HARNESS (PVC 2001)......................................................................................380
	FIGURE 8-44. SKYEYE RECEIVER HARNESS (PVC 2007)......................................................................................382
	FIGURE 8-45. SKYEYE EMITTER HARNESS (PVC 2001).......................................................................................384
	FIGURE 8-46. SKYEYE EMITTER HARNESS (PVC 2007).......................................................................................386
	FIGURE 8-47. SKYLINE HARNESS.........................................................................................................388
	FIGURE 8-48. TURNTABLE HARNESS.......................................................................................................390
	FIGURE 8-49. VALVE HARNESS - BOOM VALVE..............................................................................................394
	FIGURE 8-50. VALVE HARNESS - MAIN VALVE..............................................................................................396
	FIGURE 8-51. VALVE HARNESS - PLATFORM VALVE..........................................................................................398
SECTION 9 - DECALS.......................................................................................................................401
	FIGURE 9-1. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH............................................................................402
	FIGURE 9-2. DECAL INSTALLATION - CE SPEC (ENGLISH)...................................................................................404
	FIGURE 9-3. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH)......................................................................406
	FIGURE 9-4. DECAL INSTALLATION - OPTIONS.............................................................................................408
	FIGURE 9-5. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI EXPORT & CE SPECS)...................................................410
	FIGURE 9-6. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (CE SPECS).................................................................412
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK.............................................................................................415
	FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK.........................................................................................416
SECTION 11 - SPECIAL OPTIONS.............................................................................................................419
	FIGURE 11-1. SPECIAL OPTIONS.........................................................................................................420
PART NUMBER INDEX........................................................................................................................423

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