JLG 520AJ Boom Lift Parts Manual 31222365 PDF

JLG 520AJ Boom Lift Parts Manual 31222365 PDF

Size: 35.44 MB
Language: English
Make: JLG
Machine: Boom Lift
Document: Parts Catalog
Model: JLG 520AJ
Part Number: 31222365
Publication Date: 2025
Page: 478 Pages

Detail Contents:
SECTION 1 – FRAME
FIGURE 1-1. AXLE INSTALLATION
FIGURE 1-2. STEER INSTALLATION WITHOUT TOW PACKAGE
FIGURE 1-3. STEER INSTALLATION WITH TOW PACKAGE
FIGURE 1-4. WHEEL DRIVE INSTALLATION (4WD) (ALL SPECS EXCEPT CHINA SPEC)
FIGURE 1-5. WHEEL DRIVE INSTALLATION (4WD) (CHINA SPEC)
FIGURE 1-6. DRIVE HUB AND BRAKE ASSEMBLY – REAR
FIGURE 1-7. DRIVE HUB ASSEMBLY – FRONT
FIGURE 1-8. DRIVE MOTOR ASSEMBLY (4WD) (ALL SPECS EXCEPT CHINA SPEC)
FIGURE 1-9. DRIVE MOTOR ASSEMBLY (4WD) (CHINA SPEC)
FIGURE 1-10. FRAME SHIELD INSTALLATION
FIGURE 1-11. TIRE AND WHEEL INSTALLATION – 33 X 12-20 SOLID NON-MARKING
FIGURE 1-12. TIRE AND WHEEL INSTALLATION – 33/1550 X 16.5 FOAM-FILLED
FIGURE 1-13. TIRE AND WHEEL INSTALLATION – 315/55 D20 FOAM FILLED
FIGURE 1-14. TIRE AND WHEEL INSTALLATION – 315/55 D20 FOAM FILLED NON-MARKING
FIGURE 1-15. 4WD VALVES INSTALLATION – FRAME MOUNTED
FIGURE 1-16. TRACTION VALVE ASSEMBLY – 4WD
FIGURE 1-17. TOW PACKAGE INSTALLATION (OPTIONAL)
FIGURE 1-18. TOW BAR ASSEMBLY
SECTION 2 – TURNTABLE
FIGURE 2-1. 4WD VALVES INSTALLATION – TURNTABLE MOUNTED
FIGURE 2-2. MAIN VALVE ASSEMBLY
FIGURE 2-3. AUXILIARY PUMP ASSEMBLY
FIGURE 2-4. SWING DRIVE AND TURNTABLE BEARING INSTALLATION
FIGURE 2-5. SWING MOTOR ASSEMBLY
FIGURE 2-6. TURNTABLE BEARING ASSEMBLY
FIGURE 2-7. TURNTABLE COVERS INSTALLATION
FIGURE 2-8. TURNTABLE LOCK INSTALLATION
FIGURE 2-9. TANKS INSTALLATION
FIGURE 2-10. HYDRAULIC TANK ASSEMBLY
FIGURE 2-11. DRIVE ORIENTATION INSTALLATION
FIGURE 2-12. GROUND CONTROL ASSEMBLY (ANSI EXPORT, CHINA & AUSTRALIAN SPECS)
FIGURE 2-13. GROUND CONTROL ASSEMBLY (CE(LRC), CIS/EAC & UK CA SPECS)
FIGURE 2-14. GROUND CONTROL ASSEMBLY (CE & UK CA SPECS)
FIGURE 2-15. LIGHT PANEL INSTALLATION – GROUND CONTROL
FIGURE 2-16. ELECTRICAL SYSTEM INSTALLATION
FIGURE 2-17. BEACON LIGHT INSTALLATION – AMBER (WITHOUT CLEARSKY BEACON)
FIGURE 2-18. BEACON LIGHT INSTALLATION – BLUE (WITHOUT CLEARSKY BEACON)
FIGURE 2-19. BEACON LIGHT INSTALLATION – RED (WITHOUT CLEARSKY BEACON)
FIGURE 2-20. BATTERY AND CABLE INSTALLATION
FIGURE 2-21. HOODS INSTALLATION (ABS)
FIGURE 2-22. HOODS INSTALLATION (STEEL)
FIGURE 2-23. HOOD ASSEMBLY (ABS) – ENGINE SIDE
FIGURE 2-24. HOOD ASSEMBLY (STEEL) – ENGINE SIDE
FIGURE 2-25. HOOD ASSEMBLY (ABS) – TANK SIDE
FIGURE 2-26. HOOD ASSEMBLY (STEEL) – TANK SIDE
FIGURE 2-27. WHITE NOISE ALARM INSTALLATION
FIGURE 2-28. WHITE NOISE AMBIENT ALARM INSTALLATION
SECTION 3 – ENGINE
FIGURE 3-1. ENGINE INSTALLATION – DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, CIS/EAC & UK CA SPECS)
FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY – DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC),CIS/EAC & UK CA SPECS)
FIGURE 3-3. ENGINE ASSEMBLY – DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CIS/EAC & UK CA SPECS)
FIGURE 3-4. ENGINE INSTALLATION – DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)
FIGURE 3-5. ENGINE AND PUMP SUB-ASSEMBLY – DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)
FIGURE 3-6. ENGINE ASSEMBLY – DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)
FIGURE 3-7. ENGINE INSTALLATION – DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)
FIGURE 3-8. ENGINE ASSEMBLY – DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)
FIGURE 3-9. ENGINE COMPONENTS – DEUTZ D2011
FIGURE 3-10. ENGINE COMPONENTS – DEUTZ D2.9L4 ERM5 ENGINE (ANSI, ANSI EXPORT AND CSA SPECS)
FIGURE 3-11. ENGINE INSTALLATION – DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)
FIGURE 3-12. ENGINE AND PUMP SUB-ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)
FIGURE 3-13. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)
FIGURE 3-14. ENGINE COMPONENTS – DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)
FIGURE 3-15. BRACKET ASSEMBLY – FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V)
FIGURE 3-16. BREATHER HEATER INSTALLATION – DEUTZ D2.9L4 ENGINES (STAGE V) (CE & UK CA SPECS)
FIGURE 3-17. MOTOR MOUNT INSTALLATION – (STAGE V & CHINA IV ENGINE WITHOUT GENERATOR)
FIGURE 3-18. MOTOR MOUNT INSTALLATION – (STAGE V & CHINA IV ENGINE WITH GENERATOR)
FIGURE 3-19. ENGINE INSTALLATION – DEUTZ D2.9L4 ENGINE (CHINA IV)
FIGURE 3-20. ENGINE AND PUMP SUB-ASSEMBLY – DEUTZ D2.9L4 ENGINE (CHINA IV)
FIGURE 3-21. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (CHINA IV)
FIGURE 3-22. ENGINE COMPONENTS – DEUTZ D2.9L4 (CHINA IV)
FIGURE 3-23. BRACKET ASSEMBLY – FUEL PUMP AND FILTER (DEUTZ D2.9L4 CHINA IV ENGINE)
FIGURE 3-24. FUEL/WATER SEPARATOR ASSEMBLY (DEUTZ D2.9L4 CHINA IV ENGINE)
FIGURE 3-25. PUMP COUPLING KIT – DEUTZ ENGINES
FIGURE 3-26. PISTON PUMP ASSEMBLY
FIGURE 3-27. SPARK ARRESTOR INSTALLATION – DEUTZ D2011 ENGINE
FIGURE 3-28. ENGINE BAFFLE INSTALLATION – WITH DEUTZ ENGINES
FIGURE 3-29. GENERATOR INSTALLATION – 4000W/50HZ (DEUTZ D2011 ENGINE)
FIGURE 3-30. GENERATOR INSTALLATION – 4000W/50HZ (DEUTZ ENGINE) (STAGE V)
FIGURE 3-31. GENERATOR INSTALLATION – 7500W/50HZ (DEUTZ D2011 ENGINE)
SECTION 4 – BOOM
FIGURE 4-1. CYLINDERS INSTALLATION
FIGURE 4-2. BOOM INSTALLATION
FIGURE 4-3. BOOM INSTALLATION (SN B300022158 to Present)
FIGURE 4-4. JIB INSTALLATION
FIGURE 4-5. JIB INSTALLATION (SN B300022158 to Present)
FIGURE 4-6. MAIN BOOM ASSEMBLY
FIGURE 4-7. TOWER BOOM ASSEMBLY
FIGURE 4-8. ROTATOR ASSEMBLY
FIGURE 4-9. PLATFORM SUPPORT INSTALLATION
FIGURE 4-10. VALVES INSTALLATION – BOOM MOUNTED
FIGURE 4-11. UPRIGHT VALVE ASSEMBLY
FIGURE 4-12. BOOM VALVE ASSEMBLY
SECTION 5 – PLATFORM
FIGURE 5-1. PLATFORM ASSEMBLY – 30IN X 4FT (76CM X 1.22M) – SIDE DROP-BAR ENTRY
FIGURE 5-2. PLATFORM ASSEMBLY – 30IN X 5FT (76CM X 1.52M) – SIDE GATE ENTRY
FIGURE 5-3. PLATFORM ASSEMBLY – 30IN X 5FT (76CM X 1.52M) – SIDE DROP-BAR ENTRY
FIGURE 5-4. PLATFORM ASSEMBLY – 30IN X 6FT (76CM X 1.83M) – SIDE GATE ENTRY
FIGURE 5-5. PLATFORM ASSEMBLY – 30IN X 6FT (76CM X 1.83M) – SIDE DROP-BAR ENTRY
FIGURE 5-6. CONSOLE BOX INSTALLATION
FIGURE 5-7. PLATFORM CONSOLE BOX ASSEMBLY
FIGURE 5-8. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE
FIGURE 5-9. FOOTSWITCH ASSEMBLY
FIGURE 5-10. TRAY ASSEMBLY
FIGURE 5-11. SKYEYE INSTALLATION
FIGURE 5-12. SKYGUARD BAR INSTALLATION
FIGURE 5-13. SKYLINE INSTALLATION
FIGURE 5-14. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS)
FIGURE 5-15. SKYSENSE MID TUBE SENSOR ASSEMBLY
FIGURE 5-16. SKYSENSE OVERHEAD SENSOR ASSEMBLY
FIGURE 5-17. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)
FIGURE 5-18. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)
FIGURE 5-19. USB CHARGER INSTALLATION
SECTION 6 – CYLINDER
FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY
FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY
FIGURE 6-3. LIFT CYLINDER ASSEMBLY – JIB
FIGURE 6-4. LIFT CYLINDER ASSEMBLY – MAIN BOOM
FIGURE 6-5. LIFT CYLINDER ASSEMBLY – TOWER BOOM
FIGURE 6-6. MASTER CYLINDER ASSEMBLY
FIGURE 6-7. STEER CYLINDER ASSEMBLY
FIGURE 6-8. TELESCOPE CYLINDER ASSEMBLY
SECTION 7 – HYDRAULIC
FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION
SECTION 8 – ELECTRICAL
FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION – 110V IEC YELLOW (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)
FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION – 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)
FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION – 220V IEC BLUE (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)
FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION – 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)
FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION – 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)
FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION – 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, CIS/EAC & UK CA SPECS)
FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION – 220V CEE7 2IN X 4IN POST GROUND (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)
FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION – 220V CEE7 2IN X 4IN SIDE GROUND (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)
FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION – 220V AFSINT107 (CE, CIS/EAC & UK CA SPECS WITH 4000W/50HZ GENERATOR)
FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION – 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE AND RUSSIA SPECS)
FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION – 220V CUSTOMER SUPPLIED COMPONENTS (ALL SPECS)
FIGURE 8-12. AC CABLE INSTALLATION – WITH TWO BREAKERS (CE, CIS/EAC & UK CA SPECS)
FIGURE 8-13. AC CABLE INSTALLATION – WITH THREE BREAKERS (CE, CIS/EAC & UK CA SPECS)
FIGURE 8-14. BATTERY DISCONNECT SWITCH
FIGURE 8-15. BEACON JUMPER HARNESS (AMBER LIGHT)
FIGURE 8-16. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)
FIGURE 8-17. BOOM CABLES & CLAMPS INSTALLATION (4000W GENERATOR)
FIGURE 8-18. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR)
FIGURE 8-19. BOOM HARNESS – MAIN BOOM
FIGURE 8-20. BOOM HARNESS – MAIN BOOM (8/5 4000W GENERATOR)
FIGURE 8-21. BOOM HARNESS – TOWER BOOM
FIGURE 8-22. BOOM HARNESS – TOWER BOOM (8/5 4000W GENERATOR)
FIGURE 8-23. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER (CE & UK CA SPEC)
FIGURE 8-24. BREAKER BOX KIT WITH THREE BREAKERS (CE & UK CA SPEC)
FIGURE 8-25. BREAKER BOX KIT – 30MA/16 AMP
FIGURE 8-26. CHASSIS SOLENOID HARNESS
FIGURE 8-27. CLEARSKY 3-WIRE TELEMATICS INSTALLATION
FIGURE 8-28. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION
FIGURE 8-29. CLEARSKY HARNESS – 3-WIRE TELEMATICS
FIGURE 8-30. CLEARSKY HARNESS – CANBUS TELEMATICS
FIGURE 8-31. ENGINE HARNESS – DEUTZ D2011
FIGURE 8-32. ENGINE HARNESS – DEUTZ D2.9L4 (STAGE V)
FIGURE 8-33. ENGINE HARNESS – DEUTZ D2.9L4 (CHINA IV)
FIGURE 8-34. FUEL HARNESS – DEUTZ D2.9L4 ENGINE
FIGURE 8-35. GENERATOR HARNESS – 2500W GENERATOR (50HZ)
FIGURE 8-36. GENERATOR HARNESS – 4000W GENERATOR
FIGURE 8-37. GROUND CONTROL PANEL HARNESS
FIGURE 8-38. HOUR METER JUMPER HARNESS
FIGURE 8-39. PLATFORM CONSOLE BOX HARNESS
FIGURE 8-40. PLATFORM INTERFACE HARNESS
FIGURE 8-41. RECEPTACLE BOX KIT – 110V IEC YELLOW (CE, CIS/EAC & UK CA SPEC)
FIGURE 8-42. RECEPTACLE BOX KIT – 220V IEC BLUE (CE, CIS/EAC & UK CA SPEC)
FIGURE 8-43. RECEPTACLE BOX KIT – 220V CEE7 POST GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPEC)
FIGURE 8-44. RECEPTACLE BOX KIT – 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE, CIS/EAC & UK CA SPEC)
FIGURE 8-45. RECEPTACLE BOX KIT – 220V AFSINT 107 (CE, CIS/EAC & UK CA SPEC)
FIGURE 8-46. SKYEYE INTERMEDIATE HARNESS
FIGURE 8-47. SKYEYE RECEIVER HARNESS
FIGURE 8-48. SKYEYE EMITTER HARNESS
FIGURE 8-49. SKYLINE HARNESS
FIGURE 8-50. TURNTABLE HARNESS
FIGURE 8-51. VALVE HARNESS – BOOM VALVE
FIGURE 8-52. VALVE HARNESS – MAIN VALVE
FIGURE 8-53. VALVE HARNESS – PLATFORM VALVE
SECTION 9 – DECALS
FIGURE 9-1. DECAL INSTALLATION – ANSI, ANSI EXPORT AND CSA SPECS (ENGLISH)
FIGURE 9-2. DECAL INSTALLATION – AUSTRALIAN SPEC (ENGLISH
FIGURE 9-3. DECAL INSTALLATION – BRAZIL SPEC (ENGLISH)
FIGURE 9-4. DECAL INSTALLATION – CE & UK CA SPEC (ENGLISH)
FIGURE 9-5. DECAL INSTALLATION – CHINESE SPEC (CHINESE/ENGLISH)
FIGURE 9-6. DECAL INSTALLATION – LATIN AMERICA SPEC (SPANISH/ENGLISH)
FIGURE 9-7. DECAL INSTALLATION – OPTIONS
FIGURE 9-8. TOW BAR DECAL INSTALLATION – ENGLISH LANGUAGE (ANSI EXPORT, CE, CIS/EAC & UK CA SPECS)
FIGURE 9-9. TOW BAR DECAL INSTALLATION – SPANISH LANGUAGE (CE, CIS/EAC & UK CA SPECS)
SECTION 10 – RECOMMENDED SERVICE PARTS STOCK
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK
SECTION 11 – SPECIAL OPTIONS/ACCESSORIES/KITS
FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS
PART NUMBER INDEX

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