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JLG 520AJ Boom Lift Parts Manual

434 pages · Publication 31215026

$69.67
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Models
520AJ
Manual type
Parts Manual
Pages
434
Publication
31215026
Condition
Brand new
JLG 520AJ Boom Lift Parts Manual, publication 31215026

What's inside

From the manual's own table of contents: 69 sections, 167 entries. See sample pages (PDF, 659 KB)

General49 topics
  • 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)
  • FIGURE 1-5. DRIVE HUB AND BRAKE ASSEMBLY - REAR
  • FIGURE 1-6. DRIVE HUB ASSEMBLY - FRONT
  • FIGURE 1-7. DRIVE MOTOR ASSEMBLY (4WD)
  • FIGURE 1-8. FRAME SHIELD INSTALLATION
  • SPECS)
  • CHINA SPECS)
  • AUSTRALIAN, CE AND CHINA SPECS)
  • FIGURE 1-12. 4WD VALVES INSTALLATION - FRAME MOUNTED
  • FIGURE 1-13. TRACTION VALVE ASSEMBLY - 4WD
  • FIGURE 1-14. TOW PACKAGE INSTALLATION (OPTIONAL)
  • FIGURE 1-15. TOW BAR ASSEMBLY
  • SECTION 2 - TURNTABLE
  • FIGURE 2-1. 4WD VALVES INSTALLATION - 450AJ 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. DRIVE ORIENTATION INSTALLATION
  • FIGURE 2-11. GROUND CONTROL ASSEMBLY (ANSI EXPORT AND AUSTRALIAN SPECS)
  • FIGURE 2-12. GROUND CONTROL ASSEMBLY (CE SPECS) (PVC 2001)
  • FIGURE 2-13. GROUND CONTROL ASSEMBLY - 450AJ WITH DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)
  • FIGURE 2-14. LIGHT PANEL INSTALLATION – GROUND CONTROL
  • FIGURE 2-15. ELECTRICAL SYSTEM INSTALLATION
  • FIGURE 2-16. WHITE NOISE ALARM INSTALLATION
  • FIGURE 2-17. BEACON LIGHT INSTALLATION - AMBER
  • FIGURE 2-18. BEACON LIGHT INSTALLATION - BLUE
  • FIGURE 2-19. BEACON LIGHT INSTALLATION - RED
  • FIGURE 2-20. BATTERY AND CABLE INSTALLATION (PVC 2001)
  • FIGURE 2-21. BATTERY AND CABLE INSTALLATION (PVC 2007)
  • FIGURE 2-22. HOODS INSTALLATION
  • FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE (ROMANIAN BUILT MACHINES)
  • FIGURE 2-24. HOOD ASSEMBLY - ENGINE SIDE (ROMANIAN BUILT MACHINES)
  • SECTION 3 - ENGINE
  • AUSTRALIAN, CE (LRC) AND CHINA SPECS)
  • AUSTRALIAN AND CHINA SPECS)
  • AND CHINA SPECS)
  • FIGURE 3-4. ENGINE COMPONENTS - DEUTZ D2011
  • FIGURE 3-8. ENGINE COMPONENTS - DEUTZ D2011 (STAGE V) (PVC 2001)
  • FIGURE 3-9. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)
  • FIGURE 3-10. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)
FIGURE 3-11. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)
FIGURE 3-12. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V)
FIGURE 3-13. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES (STAGE V) (CE SPECS)
FIGURE 3-14. PUMP COUPLING KIT – DEUTZ ENGINES
FIGURE 3-15. PISTON PUMP ASSEMBLY
FIGURE 3-16. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE
FIGURE 3-17. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES
FIGURE 3-18. GENERATOR INSTALLATION - 2500W/50HZ (DEUTZ D2011 ENGINE)
FIGURE 3-19. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)
FIGURE 3-20. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ ENGINE) (STAGE V)
FIGURE 3-21. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2001)
FIGURE 3-22. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2007)
FIGURE 3-23. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ ENGINE) (STAGE V)
SECTION 4 - BOOM
FIGURE 4-1. CYLINDERS INSTALLATION
FIGURE 4-2. BOOM INSTALLATION
FIGURE 4-3. JIB INSTALLATION
FIGURE 4-4. MAIN BOOM ASSEMBLY
FIGURE 4-5. TOWER BOOM ASSEMBLY
FIGURE 4-6. ROTATOR ASSEMBLY
FIGURE 4-7. PLATFORM SUPPORT INSTALLATION
FIGURE 4-8. VALVES INSTALLATION - BOOM MOUNTED
FIGURE 4-9. UPRIGHT VALVE ASSEMBLY
Show all 70 sections
FIGURE 4-10. BOOM VALVE ASSEMBLY
SECTION 5 - PLATFORM
MACHINES)
FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)
FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)
FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)
FIGURE 5-8. CONSOLE BOX INSTALLATION
FIGURE 5-9. PLATFORM CONSOLE BOX ASSEMBLY
FIGURE 5-10. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE
FIGURE 5-11. CONTROLLER ASSEMBLY - DRIVE AND STEER
FIGURE 5-12. CONTROLLER ASSEMBLY - LIFT AND SWING
FIGURE 5-13. FOOTSWITCH ASSEMBLY
FIGURE 5-14. TRAY ASSEMBLY
FIGURE 5-15. SOFT TOUCH INSTALLATION - 6FT/1.8M PLATFORM (ANSI EXPORT SPECS) (PVC 2001)
FIGURE 5-17. SKYEYE INSTALLATION
FIGURE 5-18. SKYGUARD BAR INSTALLATION
FIGURE 5-19. SKYLINE INSTALLATION
FIGURE 5-20. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS)
FIGURE 5-21. PIPE RACK INSTALLATION (ANSI EXPORT & CE SPECS)
FIGURE 5-22. PIPE RACK INSTALLATION (AUSTRALIAN SPEC)
FIGURE 5-23. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)
FIGURE 5-24. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)
FIGURE 5-25. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.83M PLATFORM)
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 ASSEMBLY49 topics
  • SECTION 7 - HYDRAULIC
  • FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION
  • FIGURE 7-2. HYDRAULIC SYSTEM INSTALLATION
  • FIGURE 7-3. HYDRAULIC SYSTEM INSTALLATION
  • FIGURE 7-4. HYDRAULIC SYSTEM INSTALLATION
  • SECTION 8 - ELECTRICAL
  • FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V - ANSI EXPORT SPECS
  • FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS WITH 4000W/50HZ GENERATOR)
  • GENERATOR (CE SPECS)
  • 4000W/50HZ GENERATOR)
  • GENERATOR)
  • AUSTRALIAN & CE SPECS)
  • FIGURE 8-13. AC CABLE INSTALLATION - WITH TWO BREAKERS (CE SPECS)
  • FIGURE 8-14. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE SPECS)
  • FIGURE 8-15. BATTERY DISCONNECT SWITCH
  • FIGURE 8-16. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)
  • FIGURE 8-17. BOOM CABLES & CLAMPS INSTALLATION (4000W GENERATOR) (PVC 2001)
  • FIGURE 8-18. BOOM CABLES & CLAMPS INSTALLATION (4000W GENERATOR) (PVC 2007)
  • FIGURE 8-19. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR) (PVC 2001)
  • FIGURE 8-20. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR) (PVC 2007)
  • FIGURE 8-21. BOOM HARNESS - MAIN BOOM
  • FIGURE 8-22. BOOM HARNESS - MAIN BOOM (8/5 4000W GENERATOR)
  • FIGURE 8-23. BOOM HARNESS - TOWER BOOM
  • FIGURE 8-24. BOOM HARNESS - TOWER BOOM (8/5 4000W GENERATOR)
  • FIGURE 8-25. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER - CE SPEC
  • FIGURE 8-26. BREAKER BOX KIT WITH THREE BREAKERS - CE SPEC
  • FIGURE 8-27. BREAKER BOX KIT - 30MA/16 AMP
  • FIGURE 8-28. CHASSIS SOLENOID HARNESS
  • FIGURE 8-29. ENGINE HARNESS - DEUTZ D2011
  • FIGURE 8-30. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)
  • FIGURE 8-31. FUEL HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)
  • FIGURE 8-32. GENERATOR HARNESS - 2500W GENERATOR (50HZ)
  • FIGURE 8-33. GENERATOR HARNESS - 4000W GENERATOR
  • FIGURE 8-34. GROUND CONTROL PANEL HARNESS
  • FIGURE 8-35. PLATFORM CONSOLE BOX HARNESS
  • FIGURE 8-36. PLATFORM INTERFACE HARNESS
  • FIGURE 8-37. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)
  • FIGURE 8-38. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)
  • FIGURE 8-39. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE SPEC)
  • FIGURE 8-40. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE SPEC)
  • FIGURE 8-41. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)
  • FIGURE 8-42. SKYEYE INTERMEDIATE HARNESS
  • FIGURE 8-43. SKYEYE RECEIVER HARNESS (PVC 2001)
  • FIGURE 8-44. SKYEYE RECEIVER HARNESS (PVC 2007)
  • FIGURE 8-45. SKYEYE EMITTER HARNESS (PVC 2001)
  • FIGURE 8-46. SKYEYE EMITTER HARNESS (PVC 2007)
  • FIGURE 8-47. SKYLINE HARNESS
  • FIGURE 8-48. TURNTABLE HARNESS
  • FIGURE 8-49. VALVE HARNESS - BOOM VALVE
FIGURE 8-50. VALVE HARNESS - MAIN VALVE
FIGURE 8-51. VALVE HARNESS - PLATFORM VALVE
SECTION 9 - DECALS
FIGURE 9-1. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH
FIGURE 9-2. DECAL INSTALLATION - CE SPEC (ENGLISH)
FIGURE 9-3. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH)
FIGURE 9-4. DECAL INSTALLATION - OPTIONS
FIGURE 9-5. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI EXPORT & CE SPECS)
FIGURE 9-6. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (CE SPECS)
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK
SECTION 11 - SPECIAL OPTIONS
FIGURE 11-1. SPECIAL OPTIONS
PART NUMBER INDEX

Inside this manual

Real pages from this parts manual (434 pages). Open the sample pages (PDF, 658 KB)

Sample pages from the JLG 520AJ Boom Lift Parts Manual: Parts illustration, Parts illustration, Parts illustration
  • Parts illustration, page 122: SECTION 3 - ENGINE
  • Parts illustration, page 332: FIGURE 8-20. BOOM CABLES & CLAMPS INSTALLATION (7500W SKYPOWER GENERATOR) (PVC
  • Parts illustration, page 416: SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

Other manuals for this machine

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This manual: Parts Manual 31215026$69.67
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This is a parts manual

Here's how it compares to the other manual types.

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

This manual

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 434 pages

Quantity one is the manual described above.

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Other editions and similar models

JLG 520AJParts Manual · 3121666 · $69.75JLG 520AJParts Manual · 3121666_Rev_Q · $69.51

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