JLG EC520AJ Parts Manual (31217108) – PDF DOWNLOAD (ENGLISH)

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JLG EC520AJ Parts Manual (31217108) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG EC520AJ Parts Manual (31217108) – PDF DOWNLOAD

SECTION 1 - FRAME.................................................................... 11
	FIGURE 1-1. AXLE INSTALLATION.................................................... 12
	FIGURE 1-2. STEER INSTALLATION................................................... 14
	FIGURE 1-3. WHEEL DRIVE INSTALLATION (2WD)....................................... 16
	FIGURE 1-4. HUB - SPINDLE ASSEMBLY............................................... 18
	FIGURE 1-5. DRIVE MOTOR ASSEMBLY................................................. 20
	FIGURE 1-6. BATTERY INSTALLATION................................................. 22
	FIGURE 1-7. FRAME SHIELD INSTALLATION............................................ 26
	FIGURE 1-8. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING........... 28
	FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED................. 30
	FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING.... 32
	FIGURE 1-11. CONTROL VALVES INSTALLATION - FRAME MOUNTED......................... 34
	FIGURE 1-12. OSCILLATING AXLE VALVE ASSEMBLY..................................... 36
SECTION 2 - TURNTABLE................................................................ 39
	FIGURE 2-1. CONTROL VALVES INSTALLATION - TURNTABLE MOUNTED...................... 40
	FIGURE 2-2. MAIN VALVE ASSEMBLY.................................................. 42
	FIGURE 2-3. AUXILIARY PUMP ASSEMBLY.............................................. 44
	FIGURE 2-4. ENCLOSURE INSTALLATION............................................... 46
	FIGURE 2-5. SWING DRIVE AND TURNTABLE BEARING INSTALLATION....................... 48
	FIGURE 2-6. SWING MOTOR ASSEMBLY................................................. 50
	FIGURE 2-7. TURNTABLE BEARING ASSEMBLY........................................... 52
	FIGURE 2-8. TURNTABLE COVERS INSTALLATION........................................ 54
	FIGURE 2-9. TURNTABLE LOCK INSTALLATION.......................................... 56
	FIGURE 2-10. TANK AND PUMPS INSTALLATION......................................... 58
	FIGURE 2-11. HYDRAULIC TANK INSTALLATION......................................... 60
	FIGURE 2-12. MOTOR ASSEMBLY...................................................... 62
	FIGURE 2-13. DRIVE ORIENTATION INSTALLATION...................................... 64
	FIGURE 2-14. GROUND CONTROL ASSEMBLY............................................. 66
	FIGURE 2-15. ELECTRICAL SYSTEM INSTALLATION...................................... 68
	FIGURE 2-16. BATTERY CHARGER INSTALLATION........................................ 72
	FIGURE 2-17. BATTERY AND CABLE INSTALLATION...................................... 74
	FIGURE 2-18. ALARM WHITE NOISE INSTALLATION...................................... 76
	FIGURE 2-19. BEACON LIGHT INSTALLATION - AMBER................................... 78
	FIGURE 2-20. BEACON LIGHT INSTALLATION - BLUE.................................... 80
	FIGURE 2-21. BEACON LIGHT INSTALLATION - RED..................................... 82
	FIGURE 2-22. HOODS INSTALLATION.................................................. 84
	FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE........................................... 88
	FIGURE 2-24. HOOD ASSEMBLY - ENGINE SIDE......................................... 90
	FIGURE 2-25. COVERS INSTALLATION - COUNTERWEIGHT................................. 92
SECTION 3 - BOOM..................................................................... 95
	FIGURE 3-1. CYLINDERS INSTALLATION............................................... 96
	FIGURE 3-2. BOOM INSTALLATION – WITHOUT AIRLINES................................. 98
	FIGURE 3-3. BOOM INSTALLATION – WITH AIRLINE.....................................100
	FIGURE 3-4. BOOM AIRLINE INSTALLATION............................................102
	FIGURE 3-5. AIRLINE FITTINGS INSTALLATION........................................104
	FIGURE 3-6. MAIN BOOM INSTALLATION...............................................106
	FIGURE 3-7. MAIN BOOM ASSEMBLY...................................................108
	FIGURE 3-8. TOWER BOOM ASSEMBLY..................................................110
	FIGURE 3-9. JIB INSTALLATION.....................................................112
	FIGURE 3-10. ROTATOR ASSEMBLY....................................................114
	FIGURE 3-11. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS.....................116
	FIGURE 3-12. BOOM VALVES INSTALLATION............................................118
	FIGURE 3-13. BOOM VALVE ASSEMBLY.................................................120
	FIGURE 3-14. UPRIGHT VALVE ASSEMBLY..............................................122
SECTION 4 - PLATFORM.................................................................125
	FIGURE 4-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY......126
	FIGURE 4-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY......128
	FIGURE 4-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY......130
	FIGURE 4-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY........132
	FIGURE 4-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR........134
	FIGURE 4-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR........136
	FIGURE 4-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR........138
	FIGURE 4-8. CONSOLE BOX INSTALLATION - WITH SKYGUARD.............................140
	FIGURE 4-9. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD........................142
	FIGURE 4-10. CONTROLLER ASSEMBLY - DRIVE AND STEER...............................146
	FIGURE 4-11. CONTROLLER ASSEMBLY - LIFT AND SWING................................148
	FIGURE 4-12. FOOTSWITCH ASSEMBLY.................................................152
	FIGURE 4-13. TRAY ASSEMBLY.......................................................154
	FIGURE 4-14. SKYEYE INSTALLATION.................................................156
	FIGURE 4-15. SKYGUARD BAR INSTALLATION...........................................158
	FIGURE 4-16. SKYLINE INSTALLATION................................................160
	FIGURE 4-17. PIPE RACK INSTALLATION..............................................162
SECTION 5 - CYLINDER.................................................................165
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY.......................................166
	FIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY.............................168
	FIGURE 5-3. LIFT CYLINDER ASSEMBLY - JIB.........................................170
	FIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM...................................172
	FIGURE 5-5. LIFT CYLINDER ASSEMBLY - TOWER BOOM..................................174
	FIGURE 5-6. MASTER CYLINDER ASSEMBLY.............................................176
	FIGURE 5-7. STEER CYLINDER ASSEMBLY..............................................178
	FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY..........................................180
SECTION 6 - HYDRAULIC................................................................183
	FIGURE 6-1. BOOM HYDRAULIC SYSTEM INSTALLATION...................................184
	FIGURE 6-2. CHASSIS HYDRAULIC SYSTEM INSTALLATION................................188
SECTION 7 - ELECTRICAL...............................................................191
	FIGURE 7-1. BEACON LIGHT HARNESS.................................................192
	FIGURE 7-2. BMS HARNESS..........................................................194
	FIGURE 7-3. BOOM CABLES AND CLAMPS...............................................196
	FIGURE 7-4. BOOM HARNESS - MAIN BOOM.............................................200
	FIGURE 7-5. BOOM HARNESS - MAIN BOOM AC CABLE....................................202
	FIGURE 7-6. BOOM HARNESS - TOWER BOOM............................................204
	FIGURE 7-7. BOOM HARNESS - TOWER BOOM AC CABLE...................................206
	FIGURE 7-8. BOOM VALVE HARNESS...................................................208
	FIGURE 7-9. CHARGER HARNESS......................................................210
	FIGURE 7-10. CHASSIS HARNESS ASSEMBLY............................................212
	FIGURE 7-11. CONTROLLER BRACKET ASSEMBLY.........................................218
	FIGURE 7-12. DRIVE MOTOR HARNESS (RIGHT REAR)....................................220
	FIGURE 7-13. DRIVE MOTOR HARNESS (LEFT REAR).....................................222
	FIGURE 7-14. FUSE PLATE ASSEMBLY.................................................224
	FIGURE 7-15. PLATFORM CONSOLE HARNESS - WITH SKYGUARD............................226
	FIGURE 7-16. PLATFORM TO BOOM VALVE HARNESS......................................228
	FIGURE 7-17. PLATFORM CONSOLE BOX HARNESS........................................230
	FIGURE 7-18. PLATFORM INTERFACE HARNESS..........................................232
	FIGURE 7-19. STEER SENSOR HARNESS................................................234
	FIGURE 7-20. SKYEYE INTERMEDIATE HARNESS.........................................236
	FIGURE 7-21. SKYEYE RECEIVER HARNESS.............................................238
	FIGURE 7-22. SKYEYE EMITTER HARNESS..............................................240
	FIGURE 7-23. SKYLINE HARNESS.....................................................242
	FIGURE 7-24. SKYGUARD HARNESS....................................................244
	FIGURE 7-25. TRACTION HARNESS....................................................246
	FIGURE 7-26. WHEEL DRIVE ELECTRICAL HARNESS INSTALLATION (2WD)...................248
SECTION 8 - DECALS...................................................................251
	FIGURE 8-1. DECAL INSTALLATION – CE SPECS........................................252
	FIGURE 8-2. DECAL INSTALLATION - OPTIONS.........................................254
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK..........................................257
	FIGURE 9-1. RECOMMENDED SERVICE PARTS STOCK......................................258
SECTION 10 - SPECIAL OPTIONS.........................................................259
	FIGURE 10-1. SPECIAL OPTIONS.....................................................260
PART NUMBER INDEX....................................................................261

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