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JLG 520AJ PVC 2001 Service & Maintenance Manual (31215025) – PDF DOWNLOAD (English) 
JLG 520AJ PVC 2001 Service & Maintenance Manual (31215025) – PDF DOWNLOAD (English)
JLG 520AJ PVC 2001 Service & Maintenance Manual (31215025) – PDF DOWNLOAD (English)
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JLG 520AJ PVC 2001 Service & Maintenance Manual (31215025) – PDF DOWNLOAD
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JLG 520AJ PVC 2001 Service & Maintenance Manual (31215025) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 520AJ PVC 2001 Service & Maintenance Manual (31215025) – PDF DOWNLOAD
31215025_B_520AJ_JLG_Service_English............................................................... 1 Section A. Introduction - Maintenance Safety Precautions....................................... 3 A General.................................................................................. 3 B Hydraulic System Safety.................................................................. 3 C Maintenance.............................................................................. 3 Table of Contents.............................................................................. 5 List of Figures................................................................................ 13 List of Tables................................................................................. 20 Section 1. Specifications...................................................................... 23 1.1 Operating Specifications............................................................... 23 1.2 Dimensional Data....................................................................... 23 1.3 Capacities............................................................................. 23 1.4 Tires.................................................................................. 23 1.5 Engine Data............................................................................ 23 1.6 Hydraulic Oil.......................................................................... 25 1.7 Maintenance and Lubrication............................................................ 27 1.8 ThreadLocking Compound................................................................. 31 1.9 Torque Charts.......................................................................... 32 SAE Fastener Torque Chart.............................................................. 32 SAE Fastener Torque Chart (Continued).................................................. 33 SAE Fastener Torque Chart (Continued).................................................. 34 SAE Fastener Torque Chart (Continued).................................................. 35 SAE Fastener Torque Chart (Continued).................................................. 36 SAE Fastener Torque Chart (Continued).................................................. 37 Metric Fastener Torque Chart........................................................... 38 Metric Fastener Torque Chart (Continued)............................................... 39 Metric Fastener Torque Chart (Continued)............................................... 40 Metric Fastener Torque Chart (Continued)............................................... 41 Section 2. General............................................................................. 43 2.1 Machine Preparation, Inspection, and Maintenance....................................... 43 General................................................................................ 43 Preparation, Inspection, and Maintenance............................................... 43 Pre-Start Inspection................................................................... 43 Pre-Delivery Inspection and Frequent Inspection........................................ 43 Annual Machine Inspection.............................................................. 43 Preventive Maintenance................................................................. 43 2.2 Service and Guidelines................................................................. 44 General................................................................................ 44 Safety and Workmanship................................................................. 44 Cleanliness............................................................................ 44 Components Removal and Installation.................................................... 44 Component Disassembly and Reassembly................................................... 45 Pressure-Fit Parts..................................................................... 45 Bearings............................................................................... 45 Gaskets................................................................................ 45 Bolt Usage and Torque Application...................................................... 45 Hydraulic Lines and Electrical Wiring.................................................. 45 Hydraulic System....................................................................... 45 Lubrication............................................................................ 45 Battery................................................................................ 45 Lubrication and Servicing.............................................................. 45 2.3 Lubrication and Information............................................................ 46 Hydraulic System....................................................................... 46 Hydraulic Oil.......................................................................... 46 Changing Hydraulic Oil................................................................. 46 Lubrication Specifications............................................................. 46 2.4 Cylinder Drift......................................................................... 47 Theory................................................................................. 47 Cylinder Leakage Test.................................................................. 47 Cylinder Thermal Drift................................................................. 47 2.5 Pins and Composite Bearing Repair Guidelines........................................... 48 2.6 Welding on JLG Equipment............................................................... 48 Do the Following When Welding on JLG Equipment......................................... 48 Do Not Do The Following When Welding On JLG Equipment.................................. 48 Section 3. Chassis & Turntable................................................................. 55 3.1 Tires and Wheels....................................................................... 55 Tire Damage............................................................................ 55 Wheel and Tire Replacement............................................................. 55 Wheel Installation..................................................................... 55 3.2 Oscillating Axle System................................................................ 56 3.3 Lockout Cylinder Bleeding.............................................................. 56 3.4 Oscillating Axle Lockout Test.......................................................... 56 3.5 Cold Start System (Diesel)............................................................. 57 3.6 Drive Orientation System............................................................... 57 3.7 Chassis Tilt Indicator System.......................................................... 57 3.8 Drive System........................................................................... 58 3.9 Wheel Drive Assembly................................................................... 62 Removal................................................................................ 62 Installation........................................................................... 62 3.10 Torque Hub............................................................................ 63 Roll and Leak Testing.................................................................. 63 Tightening and Torquing Bolts.......................................................... 63 Main Disassembly for “B” Drives........................................................ 64 Hub-Spindle Disassembly................................................................ 64 Cover Disassembly...................................................................... 71 Carrier Disassembly.................................................................... 71 Assemble Carrier....................................................................... 71 Cover Sub-Assembly..................................................................... 73 Hub-Spindle Sub-Assembly............................................................... 74 Main Assembly.......................................................................... 76 Tool List.............................................................................. 81 3.11 Re-Align Torque Hub Input Coupling.................................................... 82 Equipment Required..................................................................... 82 Procedure.............................................................................. 82 3.12 Drive Motor........................................................................... 82 Description............................................................................ 82 Shaft Seal Replacement................................................................. 83 Loop Flushing Valve.................................................................... 83 Troubleshooting........................................................................ 84 Disassembly............................................................................ 85 Inspection............................................................................. 89 Assembly............................................................................... 91 Initial Start-Up Procedures............................................................ 95 3.13 Drive Brake........................................................................... 96 Disassembly............................................................................ 96 Inspection............................................................................. 96 Assembly............................................................................... 96 3.14 Swing Bearing......................................................................... 98 Description............................................................................ 98 Removal................................................................................ 98 Disassembly............................................................................100 Assembly...............................................................................102 Installation...........................................................................104 Turntable Bearing Mounting Bolt Checks.................................................105 Check Frame To Bearing Bolts...........................................................105 Check Turntable To Bearing Bolts.......................................................105 Wear Tolerance.........................................................................105 3.15 Swing Motor...........................................................................109 Removal................................................................................111 Preparation Before Disassembly.........................................................113 Disassembly and Inspection.............................................................113 Assembly...............................................................................120 One Piece Stator Assembly..............................................................126 Two Piece Stator Assembly..............................................................127 Final Checks...........................................................................127 Installation...........................................................................127 3.16 Generator.............................................................................128 Every 250 hours........................................................................128 Every 500 hours........................................................................128 Overload Protection....................................................................128 Brushes and Slip Rings.................................................................129 Troubleshooting........................................................................131 Generator Disassembly and Assembly.....................................................132 Lead Connection List for Generator.....................................................140 Generator Pulley.......................................................................141 Removal................................................................................141 Installation...........................................................................141 Removal................................................................................142 Installation...........................................................................142 Removal................................................................................143 Installation...........................................................................143 Removal................................................................................144 Installation...........................................................................144 3.17 Deutz Engine D2011L03.................................................................145 Checking Oil Level.....................................................................148 Changing Engine Oil....................................................................148 Changing Oil Filter....................................................................149 Deutz EMR 2............................................................................150 3.18 Deutz Engine D2.9L4 (STAGE V).........................................................162 General Maintenance....................................................................164 Check Oil Level........................................................................164 Replacing Engine Oil...................................................................164 Replacing the Oil Filter...............................................................164 Replacing the Fuel Filters.............................................................165 Deutz EMR5.............................................................................166 3.19 HRC Engine Emission Characteristics...................................................193 Terminology for Removing Soot..........................................................193 3.20 Diesel Particulate Filter (If Equipped)...............................................194 Standstill Cleaning....................................................................195 Maintenance Standstill Cleaning Initiation Methods.....................................196 Canceling Maintenance Standstill.......................................................196 Unsuccessful Cleaning Event............................................................196 DPF Filter Replacement due to Ash Load.................................................196 Ash Load...............................................................................199 3.22 Bio Fuel in Deutz Engines.............................................................200 General................................................................................200 Bio Fuel...............................................................................200 Biological Contamination In Fuels......................................................200 3.23 DGC Diagnostic Support and Trouble Code Definitions...................................201 Section Layout.........................................................................201 Fault Code Broadcast...................................................................203 Diagnostic Trouble Codes...............................................................203 CAN....................................................................................203 MIL Output.............................................................................204 Diagnostic Calibration Configuration and Corrective Actions............................204 Fault/Diagnostic Trouble Code Interaction..............................................205 DBW Diagnostic Test....................................................................208 3.24 Diagnostic Trouble Code Fault Descriptions............................................211 DTC 116- ECT Higher Than Expected Stage 1..............................................211 DTC 117- ECT/CHT Low Voltage...........................................................212 DTC 118- ECT/CHT High Voltage..........................................................214 DTC 122- TPS1 Signal Voltage Low.......................................................216 DTC 123- TPS1 Signal Voltage High......................................................218 DTC 217- ECT Higher Than Expected 2....................................................220 DTC 219- RPM Higher Than Max Allowed Governed Speed....................................221 DTC 336- Crank Signal Input Noise......................................................222 DTC 337- Loss of Crank Input Signal....................................................224 DTC 521- Oil Pressure Sender/Switch High Pressure......................................225 DTC 524- Oil Pressure Low..............................................................228 DTC 562- Battery Voltage (VBat) Low....................................................232 DTC 563- Battery Voltage (VBat) High...................................................234 DTC 601- Microprocessor Failure - FLASH................................................236 DTC 604- Microprocessor Failure - RAM..................................................238 DTC 606- Microprocessor Failure - COP..................................................240 DTC 642- 5 Volt External Low Voltage...................................................241 DTC 643- 5 Volt External High Voltage..................................................242 DTC 1612- Microprocessor Failure - RTI 1...............................................243 DTC 1613- Microprocessor Failure - RTI 2...............................................243 DTC 1614- Microprocessor Failure - RTI 3...............................................245 DTC 1615- Microprocessor Failure - A/D.................................................247 DTC 1616- Microprocessor Failure - Interrupt...........................................249 DTC 1625- CAN J1939 Shutdown Request...................................................251 DTC 1626- CAN J1939 Transmit (Tx) Fault................................................251 DTC 1627- CAN J1939 Receive (Rx) Fault.................................................252 DTC 1628- CAN Address Conflict Failure.................................................253 DTC 1629- J1939 TSC1 Message Receipt Loss..............................................255 DTC 1652- TPS1 Loss of Communications.................................................. 0 DTC 2111- Unable to Reach Lower TPS.................................................... 0 DTC 2112- Unable to Reach Higher TPS...................................................258 DTC 9999- Throttle Actuator Failsafe Spring Failure....................................259 DTC to SPN/FMI Table...................................................................260 3.25 Counterweight.........................................................................261 Section 4. Boom & Platform.....................................................................263 4.1 Boom Systems...........................................................................263 Platform Control Enable System.........................................................263 Transport Position Sensing System......................................................263 Platform Load Sensing System (LSS).....................................................263 Beyond Transport Position - Drive Speed Cutback System.................................263 Drive/Steer – Boom Function Interlock System...........................................263 Jib Lift End of Stroke Dampening (if equipped).........................................263 Main Boom Lift End of Stroke Dampening.................................................263 Emergency Decent System................................................................263 4.2 Platform...............................................................................264 Platform/Support Removal...............................................................264 Platform/Support Installation..........................................................265 4.3 Rotator................................................................................267 Removal................................................................................267 Installation...........................................................................267 4.4 Jib....................................................................................268 Removal................................................................................268 Disassembly............................................................................268 Inspection.............................................................................268 Assembly...............................................................................269 Installation...........................................................................269 4.5 Platform Level Cylinder................................................................270 Removal................................................................................270 Installation...........................................................................270 4.6 Main Boom Powertrack...................................................................271 Removal................................................................................271 Installation...........................................................................271 4.7 Powertrack Maintenance.................................................................272 Remove Link............................................................................272 Install New Link.......................................................................275 Replace Fixed End Brackets.............................................................278 Replace Moving End Brackets............................................................279 4.8 Boom Cleanliness Guidelines............................................................286 4.9 Boom Shimming Procedure................................................................287 4.10 Boom Assembly.........................................................................296 Upper Boom Removal.....................................................................296 Mid Boom Removal.......................................................................297 Lower Boom Removal.....................................................................299 Upper Boom Disassembly.................................................................299 Inspection.............................................................................301 Upper Boom Assembly....................................................................301 Lower Boom Installation................................................................302 Mid Boom Installation..................................................................303 Upper Boom Installation................................................................304 4.11 Rotary Actuator.......................................................................306 Theory of Operation....................................................................306 Required Tools.........................................................................307 Before Disassembly.....................................................................307 Disassembly............................................................................310 Inspection.............................................................................314 Assembly...............................................................................314 Installing Counterbalance Valve........................................................320 Greasing Thrust Washers................................................................321 Testing the Actuator...................................................................321 Installation and Bleeding..............................................................322 4.12 Foot Switch Adjustment................................................................322 Troubleshooting........................................................................323 4.13 Skyguard..............................................................................324 Operation..............................................................................324 Function Test..........................................................................324 Diagnostics & Troubleshooting..........................................................325 Section 5. Basic Hydraulics Information & Schematics...........................................327 5.1 Lubricating O-rings In The Hydraulic System............................................327 Cup and Brush..........................................................................327 Dip Method.............................................................................328 Spray Method...........................................................................328 Brush-on Method........................................................................328 5.2 Hydraulic Connection Assembly And Torque Specification.................................329 Tapered Thread Types...................................................................329 Straight Thread Types, Tube and Hose Connections.......................................329 Straight Thread Types, Port Connections................................................330 Flange Connection Types................................................................330 Tightening Methods.....................................................................330 Assembly And Torque Specifications.....................................................331 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....332 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......333 Assembly Instructions for 37° (JIC) Flare Fittings.....................................334 Assembly Instructions for 45° SAE Flare Fittings.......................................338 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings.............................340 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............342 Assembly Instructions for Bulkhead (BH) Fittings.......................................344 Assembly Instructions for O-Ring Boss (ORB) Fittings...................................348 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings....................356 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................364 Assembly instructions for Adjustable Port End (BSPP) Fittings..........................368 Assembly Instructions for Flange Connections: (FL61 and FL62)..........................376 Double Wrench Method...................................................................379 FFWR and TFFT Methods..................................................................380 Adjustable Stud End Assembly...........................................................380 O-ring Installation (Replacement)......................................................381 5.3 Hydraulic Cylinders....................................................................382 Axle Lockout Cylinder..................................................................382 Platform Level Cylinder................................................................384 Jib Lift Cylinder......................................................................389 Main Lift Cylinder.....................................................................394 Tower Boom Lift Cylinder...............................................................399 Master Cylinder........................................................................404 Steer Cylinder.........................................................................409 Telescope Cylinder.....................................................................412 5.4 Pressure Setting Procedure.............................................................445 Main System Relief.....................................................................445 Steer Left Relief......................................................................445 Steer Right Relief.....................................................................445 Boom Swing Relief......................................................................446 Jib Lift Down Relief...................................................................446 Platform Level Up Relief...............................................................446 Platform Level Down Relief.............................................................447 5.5 Drive Pump Pre-Fill Procedure..........................................................447 5.6 Hydraulic Schematics...................................................................454 Section 6. JLG Control System..................................................................459 6.1 JLG Control System Analyzer Kit Instructions...........................................459 Introduction...........................................................................459 To Connect the JLG Control System Analyzer.............................................460 Using the Analyzer.....................................................................460 Changing the Access Level of the Hand Held Analyzer....................................461 Adjusting Parameters Using the Hand Held Analyzer......................................462 Machine Setup..........................................................................463 Level Vehicle Description..............................................................463 Tilt Sensor Calibration................................................................464 Ground Control Keyswitch System........................................................467 Diagnostics/Controller Programming.....................................................467 Ground Control Console Display Gauge...................................................467 6.2 LSS System.............................................................................495 Diagnostic Menu........................................................................496 Calibration Procedure..................................................................497 Testing & Evaluation...................................................................501 Troubleshooting........................................................................502 6.3 Resetting the MSSO System..............................................................503 6.4 Function Speed Control System..........................................................504 6.5 Fuel Reserve / Cut-out System..........................................................504 6.6 Machine Model Adjustment...............................................................505 Adjustment Notes.......................................................................505 Machine Orientation When Performing Test...............................................505 Section 7. Basic Electrical Information & Electrical Schematics................................539 7.1 General................................................................................539 7.2 Multimeter Basics......................................................................539 Grounding..............................................................................539 Backprobing............................................................................539 Min/Max................................................................................539 Polarity...............................................................................539 Scale..................................................................................539 Voltage Measurement....................................................................539 Resistance Measurement.................................................................540 Continuity Measurement.................................................................540 Current Measurement....................................................................541 7.3 Applying Silicone Dielectric Compound to Electrical Connections........................541 7.4 Dielectric Grease Application..........................................................542 Installation...........................................................................542 AMP Mate-N-Lok.........................................................................542 AMP Faston.............................................................................542 AMP Micro-Fit..........................................................................542 AMP Mini Fit Jr........................................................................543 Mini Fit Sr............................................................................543 DIN Connectors.........................................................................543 Exceptions.............................................................................543 7.5 AMP Connector..........................................................................544 Applying Silicone Dielectric Compound to AMP Connectors................................544 Assembly...............................................................................544 Disassembly............................................................................546 Wedge Lock.............................................................................546 Service - Voltage Reading..............................................................546 7.6 Deutsch Connectors.....................................................................548 DT/DTP Series Assembly.................................................................548 DT/DTP Series Disassembly..............................................................548 HD30/HDP20 Series Assembly.............................................................549 HD30/HDP20 Series Disassembly..........................................................549 7.7 Telematics Gateway.....................................................................550 Telematics - Ready (TCU) Plug..........................................................550 7.8 Wiring Harness Connector Labels........................................................554 Connector Labels.......................................................................554 Component Labels.......................................................................554 7.9 Electrical Installation................................................................556 7.10 Wiring Harness........................................................................566 7.11 Electrical Schematics.................................................................663
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