JLG 520AJ Boom Lift Parts Manual

Name: JLG 520AJ Boom Lift Parts Manual
Brand: MidWestTech
SKU: 3121666_Rev_Q
Price: 69.51 USD
Availability: InStock

432 pages · Publication 3121666_Rev_Q

$69.51

Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.

Models: 520AJ
Serial coverage: E300000100-E300007980
Manual type: Parts Manual
Pages: 432
Publication: 3121666_Rev_Q
Condition: Brand new

JLG 520AJ Boom Lift Parts Manual, publication 3121666_Rev_Q

What's inside

From the manual's own table of contents: 70 sections, 145 entries. See sample pages (PDF, 626 KB)

Search the contents

General47 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. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING
FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM FILLED
FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED
FIGURE 1-11. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING
FIGURE 1-12. VALVES INSTALLATION - FRAME MOUNTED
FIGURE 1-13. TRACTION VALVE ASSEMBLY
FIGURE 1-14. FRAME COVERS INSTALLATION
FIGURE 1-15. TOW PACKAGE INSTALLATION (OPTIONAL)
FIGURE 1-16. TOW BAR ASSEMBLY
SECTION 2 - TURNTABLE
FIGURE 2-1. 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 2-11. DRIVE ORIENTATION INSTALLATION
FIGURE 2-12. GROUND CONTROL ASSEMBLY - AUSTRALIAN SPEC
FIGURE 2-13. GROUND CONTROL ASSEMBLY - CE SPEC
FIGURE 2-14. ELECTRICAL SYSTEM INSTALLATION
FIGURE 2-15. BEACON LIGHT INSTALLATION - AMBER
FIGURE 2-16. BEACON LIGHT INSTALLATION - BLUE (SN E300000100 through E300007543)
FIGURE 2-17. BEACON LIGHT INSTALLATION - BLUE (SN E300007543 through E300007980)
FIGURE 2-20. BATTERY AND CABLE INSTALLATION
FIGURE 2-27. COVERS INSTALLATION - COUNTERWEIGHT
SECTION 3 - ENGINE
FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2.3L3 ENGINE
FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.3L3
FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2.3L3 ENGINE
FIGURE 3-4. ENGINE COMPONENTS - DEUTZ D2.3L3
FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)
FIGURE 3-7. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)
FIGURE 3-8. ENGINE COMPONENTS - DEUTZ D2011 (STAGE V)
FIGURE 3-9. PUMP COUPLING KIT
FIGURE 3-11. PISTON PUMP ASSEMBLY
FIGURE 3-12. CATALYTIC SPARK ARRESTOR INSTALLATION - DEUTZ D2.3L3 ENGINE
FIGURE 3-13. SPARK ARRESTOR INSTALLATION - DEUTZ D2.3L3 ENGINE

FIGURE 3-14. ENGINE BAFFLE INSTALLATION

FIGURE 3-15. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2.3L3 ENGINE)

FIGURE 3-16. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2.3L3 ENGINE)

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 4-8. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (SN E300000100 through E300002782)

FIGURE 4-10. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS

FIGURE 4-11. VALVES INSTALLATION - BOOM MOUNTED

FIGURE 4-12. UPRIGHT VALVE ASSEMBLY

FIGURE 4-13. BOOM VALVE ASSEMBLY

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY

FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY

FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - WITH DROP BAR

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR

FIGURE 5-8. CONSOLE BOX INSTALLATION - WITHOUT SKYGUARD

Show all 71 sections

FIGURE 5-9. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E300000100 through E300007543)

FIGURE 5-10. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E3000007543 through E300007980)

FIGURE 5-11. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (SN E300000100 through E300003610)

FIGURE 5-13. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300000100 through E300003610)

FIGURE 5-15. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300007543 through E300007980)

FIGURE 5-16. CONTROLLER ASSEMBLY - DRIVE AND STEER

FIGURE 5-17. CONTROLLER ASSEMBLY - LIFT AND SWING

FIGURE 5-18. FOOTSWITCH ASSEMBLY

FIGURE 5-19. TRAY ASSEMBLY

FIGURE 5-20. SKYEYE INSTALLATION

FIGURE 5-21. SKYGUARD SYSTEM INSTALLATION (SN E300000100 through E300007543)

FIGURE 5-23. SKYLINE INSTALLATION

FIGURE 5-24. CROSS RAIL INSTALLATION

FIGURE 5-25. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (SN E300000100 through E300004872)

FIGURE 5-27. PIPE RACK INSTALLATION (AUSTRALIAN SPEC)

FIGURE 5-28. PIPE RACK INSTALLATION (CE SPECS)

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 (SN E300000100 through E300004512)

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - TOWER BOOM

FIGURE 6-7. MASTER CYLINDER ASSEMBLY

FIGURE 6-8. STEER CYLINDER ASSEMBLY

FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY28 topics

SECTION 7 - HYDRAULIC
FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION (SN E300000100 through E300004228)
FIGURE 7-3. HYDRAULIC DIAGRAM LIST
SECTION 8 - ELECTRICAL
FIGURE 8-1. ELECTRICAL DIAGRAM LIST
FIGURE 8-2. AC BOX AT PLATFORM - LOCALLY SUPPLIED COMPONENTS (SN E300000100 through E300003512)
AND CHINA SPECS)
FIGURE 8-20. BATTERY DISCONNECT SWITCH
FIGURE 8-21. BEACON LIGHT HARNESS
FIGURE 8-23. BOOM CABLES AND CLAMPS INSTALLATION
FIGURE 8-24. BOOM HARNESS - MAIN BOOM
FIGURE 8-25. BOOM HARNESS - MAIN BOOM AC CABLE
FIGURE 8-26. BOOM HARNESS - TOWER BOOM
FIGURE 8-27. BOOM HARNESS - TOWER BOOM AC CABLE
FIGURE 8-28. BOOM VALVE HARNESS
FIGURE 8-29. BREAKER BOX KIT - CE SPEC
FIGURE 8-30. BREAKER BOX KIT - 30MA/16AMP
FIGURE 8-31. CHASSIS SOLENOID HARNESS
FIGURE 8-32. ENGINE HARNESS - DEUTZ D2.3L3
FIGURE 8-33. GENERATOR HARNESS - 4000W GENERATOR
FIGURE 8-34. GROUND CONTROL PANEL HARNESS
FIGURE 8-35. PLATFORM CONSOLE BOX HARNESS (SN E300000100 through E300007543)
FIGURE 8-36. PLATFORM CONSOLE BOX HARNESS (SN E300007543 through E300007980)
FIGURE 8-37. PLATFORM INTERFACE HARNESS
FIGURE 8-38. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)
FIGURE 8-39. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)
FIGURE 8-40. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 (CE SPEC)
FIGURE 8-41. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 (CE SPEC)

FIGURE 8-42. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 70MMX70MM (CE SPEC)

FIGURE 8-43. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 70MMX70MM (CE SPEC)

FIGURE 8-44. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)

FIGURE 8-45. SKYEYE INTERMEDIATE HARNESS

FIGURE 8-46. SKYEYE RECEIVER HARNESS

FIGURE 8-47. SKYEYE EMITTER HARNESS

FIGURE 8-48. SKYLINE HARNESS

FIGURE 8-49. SKYGUARD HARNESS

FIGURE 8-50. TURNTABLE HARNESS

FIGURE 8-51. VALVE HARNESS - MAIN VALVE

FIGURE 8-52. VALVE HARNESS - PLATFORM VALVE

SECTION 9 - DECAL

FIGURE 9-1. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH)

FIGURE 9-2. DECAL INSTALLATION - CE SPEC (ENGLISH)

FIGURE 9-3. DECAL INSTALLATION - OPTIONS

FIGURE 9-4. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI, ANSI EXPORT AND CE SPECS)

FIGURE 9-5. 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 (432 pages). Open the sample pages (PDF, 624 KB)

Sample pages from the JLG 520AJ Boom Lift Parts Manual: Parts illustration, Parts illustration, Parts illustration

Parts illustration, page 92: SECTION 2 - TURNTABLE
Parts illustration, page 158: SECTION 3 - ENGINE
Parts illustration, page 296: FIGURE 8-1. ELECTRICAL DIAGRAM LIST

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 520AJ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Parts Manual 3121666_Rev_Q$69.51

Service manuals

Service Manual 3121665 · 608 pagesCovers 520AJSerial: 1300007286-1300007383, E300000100-E300007980$69.91Details

Service Manual 31215025 · 682 pagesCovers 520AJ$69.59Details

Service Manual 31217155 · 682 pagesCovers 520AJ$69.75Details

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, 432 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).