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JLG 520AJ Boom Lift Parts Manual

432 pages · Publication 3121666

$69.75
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Models
520AJ
Serial coverage
1300007286-1300007383, E300000100-E300007980
Manual type
Parts Manual
Pages
432
Publication
3121666
Condition
Brand new
JLG 520AJ Boom Lift Parts Manual, publication 3121666

What's inside

From the manual's own table of contents: 69 sections, 161 entries. See sample pages (PDF, 624 KB)

General58 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 2-9. TANKS INSTALLATION (Prior to SN E300004228)
  • Present)
  • 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 (Prior to SN E300007543)
  • FIGURE 2-17. BEACON LIGHT INSTALLATION - BLUE (SN E300007543 to Present)
  • FIGURE 2-18. BEACON LIGHT INSTALLATION - RED (Prior to SN E300007543)
  • FIGURE 2-19. BEACON LIGHT INSTALLATION - RED (SN E300007543 to Present)
  • FIGURE 2-20. BATTERY AND CABLE INSTALLATION
  • FIGURE 2-21. HOODS INSTALLATION (Prior to SN E300006377)
  • FIGURE 2-22. HOODS INSTALLATION (SN E300006377 to Present)
  • FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE (Prior to SN E300006377)
  • FIGURE 2-24. HOOD ASSEMBLY - TANK SIDE (SN E300006377 to Present)
  • FIGURE 2-25. HOOD ASSEMBLY - ENGINE SIDE (Prior to SN E300006377)
  • FIGURE 2-26. HOOD ASSEMBLY - ENGINE SIDE (SN E300006377 to Present)
  • 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 3-10. GEAR PUMP ASSEMBLY (Prior to SN E300004772)
  • 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 (Prior to SN 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 70 sections
FIGURE 5-9. CONSOLE BOX INSTALLATION - WITH SKYGUARD (Prior to SN E300007543)
FIGURE 5-10. CONSOLE BOX INSTALLATION - WITH SKYGUARD (SN E3000007543 to Present)
FIGURE 5-11. PLATFORM CONSOLE BOX ASSEMBLY - WITHOUT SKYGUARD (Prior to SN E300003610)
FIGURE 5-13. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (Prior to SN E300003610)
FIGURE 5-15. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD (SN E300007543 to Present)
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 (Prior to SN E300007543)
FIGURE 5-22. SKYGUARD BAR INSTALLATION (SN E300007543 to Present)
FIGURE 5-23. SKYLINE INSTALLATION
FIGURE 5-24. CROSS RAIL INSTALLATION
FIGURE 5-25. SKYGLAZIER INSTALLATION (AUSTRALIAN SPECS) (Prior to SN E300004872)
to Present)
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 (Prior to SN 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 ASSEMBLY34 topics
  • SECTION 7 - HYDRAULIC
  • FIGURE 7-1. HYDRAULIC SYSTEM INSTALLATION (Prior to SN 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 (Prior to SN E300003512)
  • FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPEC) (Prior to SN E300003512)
  • FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPEC) (Prior to SN E300003512)
  • AND CHINA SPECS)
  • FIGURE 8-20. BATTERY DISCONNECT SWITCH
  • FIGURE 8-21. BEACON LIGHT HARNESS
  • FIGURE 8-22. BEACON EXTENSION HARNESS (Prior to SN E600003882)
  • 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 (Prior to SN E300007543)
  • FIGURE 8-36. PLATFORM CONSOLE BOX HARNESS (SN E300007543 to Present)
  • 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, 623 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

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This manual: Parts Manual 3121666$69.75
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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, 432 pages

Quantity one is the manual described above.

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Other editions and similar models

JLG 520AJParts Manual · 31215026 · $69.67JLG 520AJParts Manual · 3121666_Rev_Q · $69.51

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