JLG Gradall 522 524 Telehandler Parts Manual – PDF DOWNLOAD
FILE DETAILS:
JLG Gradall 522 524 Telehandler Parts Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: JLG
DESCRIPTION:
JLG Gradall 522 524 Telehandler Parts Manual – PDF DOWNLOAD
S/N 0177005 thru 0177427
P/N – 9108-4020
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
JLG Gradall 522 524 Telehandler Parts Manual – PDF DOWNLOAD
SECTION 1 — INTRODUCTION
Table of Contents 1-1 thru 1-4
Alphabetical Index 1-5 thru 1-8
Service Kits 1-9
Part Number Index 1-10 thru 1-15
SECTION 2 — CHASSIS & ATTACHING PARTS
Frame Shrouding & Trim 2-1
Rear Axle & Attaching Parts 2-2
Front Axle Mounting 2-3
Cab Glass 2-4
SECTION 3 — BOOM
First Boom Section 3-1
Second Boom Section 3-2
Quick Switch 3-3
SECTION 4 — ATTACHMENTS
Carriage Assembly 4-1
Quick Switch Mounted Carriage Assembly 4-2
Buckets 4-3
Slope Piler Carriage 4-4
SECTION 5 — ENGINE & ATTACHING PARTS
Engine Left Side View (522) 5-1
Engine Right Side View (522) 5-2
Engine Left Side View (524) 5-3
Engine Right Side View (524) 5-4
Fuel Tank & Lines 5-5
Radiator & Hoses 5-6
Air Cleaner Piping 5-7
Air Cleaner 5-8
Exhaust System 5-9
SECTION 6 — DRIVE TRAIN
Front Axle Assembly 6-1
Front Axle Housing 6-2
1-1
1-2
INTRODUCTION
Table of Contents
Starting Serial No 0177005
Original Issue 1-90
Revised 3-14-96
SECTION 6 — DRIVE TRAIN (continued)
Front Axle Differential Carrier 6-3
Brake Assembly 6-4
Front Axle Shaft & Planetary Wheel End 6-5
Rear Steering Axle Drive Hub (524) 6-6
Rear Steering Axle Non-Drive Hub (522) 6-7
Wheels & Tires 6-8
SECTION 7 — CONTROLS
Tilt & Sway 7-1
Lift & Crowd 7-2
Accelerator Linkage/Pedal Assembly 7-3
Steering Column 7-4, 7-5
Floorplate Assembly 7-6
Brake and Inching Linkage 7-7
SECTION 8 — BRAKES
Service Brake Lines 8-1
Service Brake 8-2
Brake & Inching Linkage (see page 7-7) 8-3
Inching & Parking Brake Lines (522) 8-4
Inchine & Parking Brake Lines (524) 8-5
SECTION 9 — HYDRAULIC CIRCUITS
Oil Supply & Pressure Lines 9-1
Dump Circuit (524) 9-2
Dump Circuit (522) 9-3
Drive Circuit (524) 9-4
Drive Circuit (522) 9-5
Lift Cylinder 9-6
Crowd Cylinder 9-7
Tilt & Tilt Compensating Cylinder 9-8
Sway Cylinder 9-9
Steering 9-10
Joystick Circuit 9-11
SECTION 10 — HYDRAULIC COMPONENTS
Lift Cylinder Assembly 10-1
Crowd Cylinder Assembly 10-2
KG
* Changed page numbers in section 8
*
INTRODUCTION
Table of Contents
Starting Serial No 0177005
Original Issue 1-90
Revised 3-14-96
KG 1-3
SECTION 10 — HYDRAULIC COMPONENTS (Continued)
Tilt Cylinder Assembly 10-3
Compensating Cylinder Assembly 10-4
Sway Cylinder Assembly 10-5
Steering Cylinder Assembly 10-6
Main Hydraulic Control Valve Assembly 10-7
Priority Flow Control Valve 10-8
Flow Divider Valve 10-9
Brake Valve 10-10
Solenoid Valve 10-11
Dual P O Check Valve 10-12
Inching Valve 10-13
Main Hydraulic Pump 10-14
Hydrostatic Transmission Pump 10-15
Front Drive Motor (524) 10-16
Front Drive Motor (522) 10-17
Manifold Assembly 10-18
Hydraulic Reservoir & Filters 10-19
Steering Orbitrol 10-20
Rear Drive Motor 10-21
Joystick Assembly 10-22
Traction Lock Valve 10-23
SECTION 11 — ELECTRICAL
Engine Wiring (522) 11-1
Engine Wiring (524) 11-2
Dash Panel (522) 11-3
Dash Panel (524) 11-4
Battery & Cables 11-5
Gauge Panel Assembly(522) 11-6
Gauge Panel Assembly(524) 11-7
Dash Harness(522) 11-8
Dash Harness(524) 11-9
SECTION 12 — MISCELLANEOUS
Complete Decal Lists 12-1
Frame Decals 12-1
Boom Decals 12-2
*
* Changed page numbers in section 12
INTRODUCTION
Table of Contents
Starting Serial No 0177005
Original Issue 1-90
Revised 8-12-99
SVC 1-4
SECTION 13 — OPTIONAL EQUIPMENT
Ether Starting Kit 13-1
Left Hand Tilt/Sway Control 13-2
Glow Plug Installation 13-3
Vandal Cover/Kit 13-4
Work Light Package 13-5
Quick Hook Assembly 13-6
Auxiliary Hydraulics 13-7
Cab Enclosure 13-8
Joystick Installation 13-9
Joystick 13-10
Rear Axle Stabilizer 13-11
Stabilizer Cylinder 13-12
Auxiliary Hydraulics with Electrics 13-13
Slope Piler Carriage 13-14
Sway Cylinder Assembly 13-15
Dual P O Check Valve 13-16
Six Foot Mast 13-17
Drywall Swing Forks 13-18
Swing Cylinder 13-19
100 Degree Swing Forks 13-20
Deluxe Light Package 13-21
Beacon Light Package 13-22
Drywall Carriage Assembly 13-23
Three Section Boom 13-24
Crowd Cylinder Assembly 13-25
Pintle Hook 13-26
Tilt on Joystick 13-27
Auxiliary Hydraulics – 3S Boom 13-28
Control Valve Assembly 13-29
Block Heater 13-30
Hydraulic Reservoir Heater 13-31
Inline Bypass (9112-5056) 13-32
Low Profile Machine Package (522-2S) 13-33
Low Profile Machine Package (524-2S) 13-34
Rear Axle Rework Kit 13-35
Rear Axle Advantage Kit 13-36
5-Button Handle (9103-3387) 13-37
(9103-4404) Rail Cylinder Assy 13-38
(9045-3031 & 9045-3032) Carriage Weldment 13-39
(9045-3030) Outer Rail Assy 13-40
* Added pages 13-38, 13-39 & 13-40
*
*
*
INTRODUCTION
Alphabetical Index
Starting Serial No 0177005
Original Issue 1-90
Revised 5-3-94
RS 1-5
ACCELERATOR CABLE 7-3
ACCELERATOR PEDAL 7-3
AIR CLEANER 5-8
AIR CLEANER ELEMENT 5-8
AIR CLEANER SERVICE INDICATOR 5-7
ALTERNATOR 5-2, 5-4, 11-1, 11-2
ALTERNATOR FAN 5-2, 5-4
ATTACHMENTS 4-1 thru 4-4, 13-6, 13-14, 13-17, 13-18, 13-20, 13-23
BATTERY 11-5
BATTERY HOLD DOWN 11-5
BATTERY CABLES 11-5
BEACON LIGHT PACKAGE 13-22
BEARING PADS (Boom Sections)(2S) 3-1, 3-2
BEARING PADS (Boom Sections)(3S) 13-24
BOOM DECALS 12-3
BOOM SECTIONS (2S) 3-1, 3-2
BOOM SECTIONS (3S) 13-24
BRAKE ASSEMBLY 6-4
BRAKE PEDAL 7-7
BRAKE VALVE 10-10
BRAKE WARNING LIGHT 11-3
BREATHER (Filler cap 10-19
BUCKETS 4-3
CARRIAGE & FORKS (VARIOUS) 4-1
CIRCUIT BREAKERS 11-3
COMPENSATING CYLINDER 10-4
COMPENSATING CYLINDER HYDRAULIC CIRCUIT 9-8
CONTROL VALVES 10-7, 10-8, 10-9
CROWD CYLINDER (2S) 10-2
CROWD CYLINDER (3S) 13-25
CROWD CYLINDER HYDRAULIC CIRCUIT 9-7
DECALS 12-1, 12-2, 12-3
DECK 2-1
DELUXE LIGHT PACKAGE 13-21
DRIVE BELT 5-2, 5-4
DRIVE CIRCUIT (524) 9-4
DRIVE CIRCUIT (522) 9-5
DRYWALL CARRIAGE ASSEMBLY 13-23
INTRODUCTION
Alphabetical Index
Starting Serial No 0177005
Original Issue 1-90
Revised 5-3-94
RS 1-6
DRYWALL SWING FORKS 13-18
DUAL P O CHECK VALVE 10-12, 13-16
DUMP CIRCUIT 9-2, 9-3
ELECTRICAL SYSTEMS 11-1 thru 11-9
ENGINE LEFT SIDE VIEW 5-1, 5-3
ENGINE MOUNT 5-1, 5-3
ENGINE RIGHT SIDE VIEW 5-2, 5-4
ENGINE THROTTLE CONTROL 7-3
ETHER STARTING KIT 13-1
EXHAUST MANIFOLD 5-9
EXHAUST PIPE 5-9
EXHAUST STACK 5-9
EXHAUST SYSTEM 5-9
FAN BELT 5-2, 5-4
FILTERS 5-1, 5-2, 5-3, 5-4, 5-5, 5-8, 10-19
FILTER ELEMENT 10-19
FIRST BOOM SECTION 3-1
FIRST BOOM SECTION MOUNTING PIN 3-1
FRAME 2-1
FRAME SHROUDING & TRIM 2-1
FRONT AXLE 6-1
FRONT AXLE MOUNTING 2-3
FRONT AXLE DIFFERENTIAL CARRIER 6-3
FRONT AXLE HOUSING 6-2
FRONT AXLE SHAFT & PLANETARY WHEEL END 6-5
FRONT DISC WHEEL & RIM 6-8
FUEL GAUGE 11-3, 11-4, 11-6, 11-7
FUEL LEVEL SENDER 5-5
FUEL LINES 5-5
FUEL TANK & CAP 5-5
GROUND CABLE 5-2, 5-4
HOOD 2-1
HORN 11-1, 11-2
HORN BUTTON 11-3, 11-4
HORN WIRING 11-1, 11-2
HOSE CARRIER 9-8
HOURMETER 11-3, 11-4, 11-6, 11-7
INTRODUCTION
Alphabetical Index
Starting Serial No 0177005
Original Issue 1-90
Revised 5-3-94
RS 1-7
HYDRAULIC CIRCUITS 9-1 THRU 9-11
HYDRAULIC RESERVOIR, FILLER-BREATHER 10-19
HYDRAULIC FILTERS 10-19
HYDRAULIC RESERVOIR HEATER 13-31
INCHING VALVE 8-3, 10-13
INSTRUMENT PANEL 11-3, 11-4, 11-6, 11-7
JOYSTICK 10-22, 13-9, 13-10, 13-27
KITS 1-9
LEFT HAND TILT/SWAY CONTROL 13-2
LIFT CYLINDER 10-1
LIFT CYLINDER HYDRAULIC CIRCUIT 9-6
MAIN BOOM SECTIONS 3-1, 3-2
MAIN HYDRAULIC PUMP 5-1, 5-3, 10-14
MISCELLANEOUS ELECTRICAL COMPONENTS 11-3, 11-4
MUFFLER 5-9
NEGATIVE BATTERY CABLE 11-5
OIL COOLER 5-6, 9-2, 9-3
OIL FILTER 5-1, 5-3, 10-19
OIL PRESSURE GAUGE 11-3, 11-4, 11-6, 11-7
OIL PRESSURE SENDER 5-1, 5-3, 11-1, 11-2
OIL RESERVOIR 10-19
OIL SUPPLY & PRESSURE LINES 9-1
PINTLE HOOK 13-26
POSITIVE BATTERY CABLE 11-5
PRIORITY FLOW CONTROL VALVE 10-8
QUICK SWITCH ASSEMBLY 3-3
QUICK SWITCH MOUNTED CARRIAGE ASSEMBLY 4-2
RADIATOR & HOSES 5-6
REPAIR KITS 1-9
REAR AXLE FRAME 2-2
REAR AXLE MOUNTING PIN 2-2
INTRODUCTION
Alphabetical Index
Starting Serial No 0177005
Original Issue 1-90
Revised 5-3-94
RS 1-8
REAR DRIVE MOTOR 10-21
REAR STEERING AXLE 2-2
REAR STEERING AXLE NON DRIVE HUB 6-7
RESERVOIR SUPPLY CIRCUIT 9-1
REVERSING MASTER SWITCH 7-4
SEAT 2-1
SEAT BELT 2-1
SECOND BOOM SECTION 3-2
SERVICE BRAKE LINES 8-1
SERVICE KITS 1-9
SIX FOOT MAST 13-17
SLOPE PILER CARRIAGE 13-18
SOLENOID VALVES 10-11
STARTER MOTOR 5-2, 5-4, 11-2, 11-2
STEERING COLUMN 7-4, 7-5
STEERING CYLINDER 10-6
STEERING CYLINDER HYDRAULIC CIRCUIT 9-10
STEERING KNUCKLES 2-2
STEERING ORBITROL 7-4, 7-5, 10-20
STEERING WHEEL 7-5
SUPPLY HYDRAULIC CIRCUIT 9-1
SWAY CONTROL HANDLE & LINKAGE 7-1
SWAY CYLINDER 10-5, 13-15
SWAY CYLINDER HYDRAULIC CIRCUIT 9-9
SWING CYLINDER 13-19
SWING FORKS (100 DEGREE) 13-20
TIE ROD ARM 2-2
TILT CONTROL HANDLE & LINKAGE 7-1
TILT CYLINDER 10-3
TILT CYLINDER HYDRAULIC CIRCUIT 9-8
TILT ON JOYSTICK 13-27
TRACTION LOCK VALVE 10-23
TRAVEL ALARM 11-1, 11-2
WATER TEMPERATURE GAUGE 11-3, 11-4, 11-6, 11-7
WATER TEMPERATURE SENDER 5-2, 5-4
WHEELS & TIRES 6-8
WIRING HARNESS 5-1, 5-3, 11-1, 11-2, 11-8, 11-9
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