Gradall 524D User Manual

Illustrated Parts ManualModels522D524DS/N 0277001P/N - 9138-4001 Revised July 6, 2007

REAR STEERING AXLE ...

522D-524DMATERIAL HANDLER7-4FROM ENGINEFROM ENGINETO HYDRAULICRESERVOIRFROMJOYSTICKTOJOYSTICKSECTION A-ATO SERVICEBRAKETO FLOWDIVIDER VALVETO PARKBRAK

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 9020-6195 11" TRIM-LOK (pre-packaged in 25'lengths)2 9020-6199 8" TRIM

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref BRAKE VALVE, (see page 10-11 fordetails)2 9116-3093 1 FOOT SWITCH (524D only)3 88

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref ELBOW, 90 DEGREES (swivel nut)(see page 6-1 for details)2 Ref TEST FITTING (see p

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part21 Ref FLOW DIVIDER VALVE (see page10-10 for details)22 8866-2106 1 ELBOW, 90 DEGREES (

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part21 Ref FLOW DIVIDER VALVE (see page10-10 for details)22 8866-2106 1 ELBOW, 90 DEGREES (

524DMATERIAL HANDLER9-2FROMREAR DRIVE(see page 9-4)FROMREAR DRIVE(see page 9-4)FROM INCHING VALVE(SEE PAGE 7-4)FROM DUMP TUBE(SEE PAGE 7-4)FROM STEERI

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref HYDRAULIC RESERVOIR (see page10-18 for details)2 8866-2106 1 ELBOW, 90 DEGREES (swivel

524DMATERIAL HANDLERHYDRAULIC CIRCUITSDump CircuitStarting Serial No. 0277086Original Issue 7-999-2JHFROMREAR DRIVE(see page 9-4)FROMREAR DRIVE(see pa

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref HYDRAULIC RESERVOIR (see page10-18 for details)2 8866-2106 1 ELBOW, 90 DEGREES (swivel

INTRODUCTIONService Kits Starting Serial No. 0277001Original Issue 1-98KG1-92 2-3 9103-5240 Steering Knuckle Kit2 2-3 9104-5152 Steering Cylinder Pin

522DMATERIAL HANDLER9-2FROM INCHING VALVE(SEE PAGE 7-4)FROM DUMP TUBE(SEE PAGE 7-4)FROM STEERINGORBITROL(SEE PAGE 9-9)HYDRAULIC CIRCUITSDump CircuitSt

522DMATERIAL HANDLER9-2Item Part No. Qty. Description Of Part1 Ref HYDRAULIC RESERVOIR (see page10-18 for details)2 8866-2106 1 ELBOW, 90 DEGREES (swi

524DMATERIAL HANDLER9-3Item Part No. Qty. Description Of Part1 9020-5792 2 CUSHION CLAMP2 8471-2738 8 SPLIT FLANGE CLAMP3 9133-3004 1 TUBE ASSY4 8320-

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part17 9105-3426 1 STRAIGHT THREAD ADAPTER(includes item 23)18 8471-7344 1 HOSE ASSY19 8471-7911

524DMATERIAL HANDLERHYDRAULIC CIRCUITSDrive Circuit - RearStarting Serial No. 0277001 thru 0277085Original Issue 1-98Revised 7-1-99PCN 980151, 980607

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part55 9108-3306 1 CONNECTOR (includes item 56)56 8859-1206 1 O-RING57 Ref TRACTION LOCK VALVE (

524DMATERIAL HANDLERNOTE: ITEM 44TO SOLENOID VALVE(see page 7-4 for details)TO DUMPCIRCUIT(see page 9-2for details)HYDRAULIC CIRCUITSDrive Circuit - R

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part55 9108-3306 1 CONNECTOR (includes item 56)56 8859-1206 1 O-RING57 Ref TRACTION LOCK VALVE (

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part13 Ref MAIN HYDRAULIC CONTROL VALVE(see page 10-7 for details)14 7713-3139 1 CLAMP SET1

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref HYDRAULIC CYLINDER ASSY CROWD(see page 10-2 for details)2 8866-2065 2 ELBOW, 90 D

SECTION PAGE NO. PART NUMBER DESCRIPTION10 10-20 9108-4284 Traction Lock Valve Seal Kit12 12-1 9108-5133 Decal Kit13 13-13 9104-4

522D-524DMATERIAL HANDLER9-7HYDRAULIC CIRCUITSTilt & Tilt Compensating Cylinder Starting Serial No. 0277001Original Issue 1-98Revised 10-5-01ECN 0

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref SWAY CYLINDER (see page 10-5for details)2 Ref SWAY CYLINDER VALVE (seepage 10-13

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 Ref STEERING CYLINDER (see page10-6 for details)2 8471-9056 1 HOSE ASSY3 8866-2240 2

522D-524DMATERIAL HANDLERFROM SOLENOID VALVE(see page 7-4 for details)TO HYDRAULIC TUBE(see page 7-4 for details)HYDRAULIC CIRCUITSJoystick Circuit St

522D-524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9108-3469) Lift Cylinder - Iowa Starting Serial No. 0277001Original Issue 1-98Revised 7-1-9910-1Item Par

522D-524DMATERIAL HANDLER10-2HYDRAULIC COMPONENTS(9108-3468) Crowd CylinderStarting Serial No. 0277001Original Issue 1-98JHItem Part No. Qty. Descript

522D-524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9108-3513) Tilt Cylinder - IowaStarting Serial No. 0277001Original Issue 1-98Revised 6-27-0710-3JMItem P

522D-524DMATERIAL HANDLER10-4HYDRAULIC COMPONENTS(9108-3470) Compensating Cylinder Starting Serial No. 0277001Original Issue 1-98JHItem Part No. Qty.

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9112-3133 1 SWAY CYLINDER ASSY, (includesall items)9108-4308 1 SEAL KIT, (includes item

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9108-3532 2 STEERING CYLINDER ASSY(includes all items)9108-4305 1 SEAL KIT (includes it

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLER10-7HYDRAULIC COMPONENTS(9108-3417) Main Hydraulic Control Valve Assembly Starting Serial No. 0277001Original Issue 1-98Revis

522D-524DMATERIAL HANDLER10-7Item Part No. Qty. Description Of Part28 2 SPRING29 9108-4005 4 SPOOL SEAL KIT(includes items 30,31 & 32)30 4 RETAINE

524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9108-3401) Rear Drive Motor Starting Serial No. 0277001Original Issue 1-98JH10-8Item Part No. Qty. Descriptio

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9103-3240 1 PRIORITY FLOW CONTROL VALVEASSY (includes all items) (2500 PSIrelief settin

522D-524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9108-3521) Flow Divider Valve Starting Serial No. 0277001Original Issue 1-98Item Part No. Qty. Descripti

522D-524DMATERIAL HANDLER10-11HYDRAULIC COMPONENTS(9114-3201) Brake Valve Starting Serial No. 0277001Original Issue 1-98JHItem Part No. Qty. Descripti

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9104-3446 1 3-WAY SOLENOID VALVE(includesall items)1 9020-8066 1 NUT2 9114-4158 1 COIL3

522D-524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9116-3027) Sway Cylinder Valve Starting Serial No. 0277001Original Issue 1-98Item Part No. Qty. Descript

522D-524DMATERIAL HANDLER10-14HYDRAULIC COMPONENTS(9114-3140) Inching Valve Starting Serial No. 0277001Original Issue 1-98JHItem Part No. Qty. Descrip

522D-524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9108-3296) Main Hydraulic Pump Starting Serial No. 0277001Original Issue 1-98JH10-15Item Part No. Qty. D

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9108-3499) Hydrostatic Transmission Pump Starting Serial No. 0277001Original Issue 1-98Revised 1-17-0710

522D-524DMATERIAL HANDLER Item Part No. Qty. Description Of Part23 9114-4095 1 ECCENTRIC SCREW24 9108-4326 1 ROTARY GROUP ASSY25 1 O-RING26 9108-4327

524DMATERIAL HANDLERHYDRAULIC COMPONENTS(9116-3044) Front Drive MotorStarting Serial No. 0277001Original Issue 1-98JH10-17Item Part No. Qty. Descripti

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9112-5069 1 HYDRAULIC RESERVOIR ASSY(includes all items except 30, 31 & 32)1 9114-

522D-524DMATERIAL HANDLER12345678921511121314161710HYDRAULIC COMPONENTS(9130-3037) Joystick Assembly Starting Serial No. 0277001Original Issue 1-98Rev

524DMATERIAL HANDLER123456781234510111213141415161718192021232428252627293031229HYDRAULIC COMPONENTS(9108-3459) Traction Lock Valve Starting Serial No

522D-524DMATERIAL HANDLER141312 9101167548412315Item Part No. Qty. Description Of Part9133-5020 1 QUICK START CYLINDER & VALVEASSY, (includes all

522DMATERIAL HANDLER891076543211191718191620151415142321222524272628291312HYDRAULIC COMPONENTS(9109-3016) Front Drive MotorStarting Serial No. 0277001

524DMATERIAL HANDLER14564342HYDRAULIC COMPONENTS(9136-5028) Optional Stabilizer Valve AssyStarting Serial No. 0277539Original Issue 1-03SVC10-23Item P

522D-524DMATERIAL HANDLERELECTRICALDash PanelStarting Serial No. 0277001 thru 0277119Original Issue 1-98Revised 8-13-9911-1* Changed Starting S/N in u

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLERELECTRICALDash PanelStarting Serial No. 0277120Original Issue 8-9911-1 JHItem Part No. Qty. Description Of Part1 Ref DASH HAR

522D-524DMATERIAL HANDLERELECTRICAL(9112-3166) Engine Wiring HarnessStarting Serial No. 0277001 thru 0277085Original Issue 1-98Revised 8-1-9911-2Wire

522D-524DMATERIAL HANDLERELECTRICAL(9133-3013) Engine Wiring HarnessStarting Serial No. 0277086Original Issue 8-9911-2Item Part No. Qty. Description O

522D-524DMATERIAL HANDLERELECTRICAL(9114-5092) Dash Harness AssemblyStarting Serial No. 0277001 thru 0277119Original Issue 1-98Revised 8-1-9911-3JHIte

522D-524DMATERIAL HANDLERELECTRICAL(9136-5013) Dash Harness AssemblyStarting Serial No. 0277120Original Issue 8-99Revised 6-27-0711-3JMPIN DESIGNATION

524DMATERIAL HANDLERELECTRICAL(9114-3331) Gauge Panel AssemblyStarting Serial No. 0277001 thru 0277119Original Issue 1-98Revised 8-1-9911-4JHItem Part

524DMATERIAL HANDLERELECTRICAL(9136-5012) Gauge Panel AssemblyStarting Serial No. 0277120Original Issue 8-9911-4JHItem Part No. Qty. Description Of Pa

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part9109-3037 1 GAUGE PANEL (includes all items)1 9136-4004 1 PANEL ASSY (includes front & b

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part9139-5002 1 GAUGE PANEL ASSY (includes allitems)9109-3037 1 GAUGE PANEL (includes all itemse

522D-524DMATERIAL HANDLER1102356789245811-5ELECTRICALBattery & CablesStarting Serial No. 0277001Original Issue 1-98Revised 12-23-04DSItem Part No.

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

524DMATERIAL HANDLER12-1MISCELLANEOUSCab & Frame DecalsStarting Serial No. 0277001Original Issue 1-98Revised 6-22-01PCN 010240-SVC* Revised illust

524DMATERIAL HANDLER12-1MISCELLANEOUSCab & Frame DecalsStarting Serial No. 0277001Original Issue 1-98Revised 6-22-01Item Part No. Qty. Description

522DMATERIAL HANDLER12-1PCN 010240-SVCMISCELLANEOUSCab & Frame DecalsStarting Serial No. 0277001Original Issue 5-98Revised 6-22-01* Revised illust

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part22 9114-3282 3 WARNING DECAL23 9114-3280 1 WARNING DECAL24 9114-3281 1 WARNING DECAL25 9114-

524DMATERIAL HANDLERRDR08-04-974YES..49109-9007..7-5 (89)6538 1/41724(TYP)5 1/2(TYP)9 1/4(TYP)7 (84)603625(TYP)9 (108)1 1/2(TYP)2857

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9108-5133 1 524D DECAL KIT, WHITE (std.)(includes all items on page 12-1 except18 thru 20, 3

522DMATERIAL HANDLER12-2PCN 010240-SVCMISCELLANEOUSBoom DecalsStarting Serial No. 0277001Original Issue 5-98Revised 6-22-01TOP VIEW OF3 SECTION BOOM2

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part9109-5032 1 522D DECAL KIT, WHITE, (std.),(includes all items on page 12-1 exceptitems 11, 1

522D-524DMATERIAL HANDLERMISCELLANEOUSCUSHION CLAMPS & CLAMP SETSStarting Serial No. 0277001Original Issue 5-98Part No. A9020-6085 49020-6086 5902

522D-524DMATERIAL HANDLERMISCELLANEOUSCUSHION CLAMPS & CLAMP SETS Starting Serial No. 0277001Original Issue 5-98JH12-3Part No. Description Of Part

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLEROPTIONAL EQUIPMENT(9112-5056) Inline BypassOriginal Issue 1-98GHItem Part No. Qty. Description Of Part9112-5056 1 INLINE BYP

522D-524DMATERIAL HANDLER13-2OPTIONAL EQUIPMENT(9136-5001) L.H. Tilt AssemblyOriginal Issue 1-98Revised 1-10-01MPC 3766-AKItem Part No. Qty. Descript

522D-524DMATERIAL HANDLER48256713TILT9114-33R-+240100FE8001610TEMPFUELOILVOLTS000000QUARTZDRIVEALT4X44X2ONOFFPARKBRAKE13-3OPTIONAL EQUIPMENT(9112-5081

522D-524DMATERIAL HANDLER13-4OPTIONAL EQUIPMENT(9136-5023) L.H. Tilt/ Sway Field KitOriginal Issue 1-98Revised 8-30-02TTItem Part No. Qty. Description

522D-524DMATERIAL HANDLERGH13-5OPTIONAL EQUIPMENT(9136-3019) Overhead WindowOriginal Issue 1-98Item Part No. Qty. Description Of Part9136-3019 1 OVERH

522D-524DMATERIAL HANDLERGH13-6OPTIONAL EQUIPMENT(9104-3353) Engine Block HeaterOriginal Issue 1-98Item Part No. Qty. Description Of Part9104-3353 1 B

522D-524DMATERIAL HANDLERPCN 990032, 990164 - JH13-7OPTIONAL EQUIPMENT(9108-5073) Hydraulic Reservoir Heater InstallationOriginal Issue 1-98Revised 7-

522D-524DMATERIAL HANDLERNOTE: IF YOUR MACHINE CAME WITH AUXILIARY HYDRAULICS (9108-5123)USE AUXILIARY HYDRAULICS FIELD KIT (9138-5018) FOR SERVIC

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9138-5018 1 AUX. HYDRAULICS FIELD KIT,(2 section boom),(includes all items)9134-5010 1

522D-524DMATERIAL HANDLER13-9TTOPTIONAL EQUIPMENT(9108-5124) Auxiliary Hydraulics & L.H. Sway Assy2 SECTION BOOM ONLYOriginal Issue 1-98Revised 8-

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLERTT13-9OPTIONAL EQUIPMENT(9108-5124) Auxiliary Hydraulics & L.H. Sway Assy2 SECTION BOOM ONLYOriginal Issue 1-98Revised 8-

522D-524DMATERIAL HANDLERMB13-10OPTIONAL EQUIPMENT(9108-5129) Main Control Valve AssyOriginal Issue 1-98Item Part No. Qty. Description Of Part9108-512

522D-524DMATERIAL HANDLER13-11OPTIONAL EQUIPMENT(9138-5002) 3 Section Boom AssemblyOriginal Issue 1-98Revised 11-08-05JD * Added seal kits to item 4

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9138-5002 1 3 SECTION BOOM ASSY1 9108-6140 1 BOOM WELDMENT (1 st.)2 9108-6141 1 BOOM WE

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part105 9112-1082 8 SHIM106 9112-3021 2 BEARING PAD, 1/2-x6”107 9108-3063 4 BEARING PAD, 5/

522D-524DMATERIAL HANDLERNOTE: IF YOUR MACHINE CAME WITH AUXILIARY HYDRAULICS ASSY(9108-5126)USE AUXILIARY HYDRAULICS FIELD KIT (9138-5019) FOR SERVIC

522D-524DMATERIAL HANDLER13-12Item Part No. Qty. Description Of Part9138-5019 1 AUX HYDRAULICS FIELD KIT,(3 section boom, include all items)9134-5010

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9108-3262 1 DUAL P.O. CHECK VALVE ASSY(includes all items)9104-4002 Ref SEAL KIT(includ

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9 1 O-RING10 9112-4084 1 PISTON11 1 O-RING12 1 BACK-UP RING13 9112-4085 1 CYLINDER HEAD

522D-524DMATERIAL HANDLER13-15MPC 4008-MBCOPTIONAL EQUIPMENT(9134-5003) Cab Enclosure Installation Starting Serial No. 0277001Original Issue 1-98Revis

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLER13-15Item Part No. Qty. Description Of Part9134-5003 1 CAB ENCLOSURE INSTALLATION,(includes all items on pages 13-15 and13-16

522D-524DMATERIAL HANDLER13-16KG* All cab enclosure pages re-formatted and combined to alleviate confusion. One cab enclosurekit will work for all &

522D-524DMATERIAL HANDLER13-16KG* All cab enclosure pages re-formatted and combined to alleviate confusion. One cab enclosurekit will work for all &

522D-524DMATERIAL HANDLER13-17JMOPTIONAL EQUIPMENT(9114-3267) Cab Enclosure KitStarting Serial No. 0277001Original Issue 1-98Revised 6-27-07

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9114-3267 1 CAB ENCLOSURE KIT (includes allitems on pages 13-17 thru 13-19)1 Ref L.H.

522D-524DMATERIAL HANDLERDOOR HOLD OPEN ASSYWINDOW LATCH ASSYSTRIKER BOLT ASSYSEE ILLUSTRATION & NOTES ONNEXT PAGE FOR LATCH DETAILSSEE STANDARD M

522D-524DMATERIAL HANDLER13-18OPTIONAL EQUIPMENT(9114-3267) Cab Enclosure KitStarting Serial No. 0277001Original Issue 1-98Revised 7-13-01DSItem Part

522D-524DMATERIAL HANDLEROPTIONAL EQUIPMENT(9114-3267) Cab Enclosure Kit - GlassStarting Serial No. 0277001Original Issue 5-98KG13-19Item Part No. Qty

522D-524DMATERIAL HANDLER13-20OPTIONAL EQUIPMENT(9108-5127) Auxiliary Hydraulics & L.H. Sway Assy3 SECTION BOOM ONLYOriginal Issue 5-98Revised 8-3

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part24 8856-1109 2 FLAT WASHER, 3/825 9020-7463 8 CUSHION CLAMP26 8471-8280 2 HOSE ASSY27 9

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLERJH13-21OPTIONAL EQUIPMENT(9108-5128) Auxiliary Hydraulics Assembly w/Electrics3 SECTION BOOM ONLYOriginal Issue 5-98

522D-524DMATERIAL HANDLERJH13-21OPTIONAL EQUIPMENT(9108-5128) Auxiliary Hydraulics Assembly w/Electrics3 SECTION BOOM ONLYOriginal Issue 5-98Item Part

522D-524DMATERIAL HANDLERJH13-22OPTIONAL EQUIPMENT(9108-5125) Auxiliary Hydraulics Assembly w/Electrics2 SECTION BOOM ONLYOriginal Issue 5-98

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9108-5125 Ref AUXILIARY ELECTRICS ASSEMBLY(includes all items)1 7738-3470 2 SWITCH BOOT

522D-524DMATERIAL HANDLER13-23OPTIONAL EQUIPMENT(9138-5004) Work Light PackageOriginal Issue 5-98Revised 9-28-00PCN 000221-SVC* Revised illustration

522D-524DMATERIAL HANDLER863087RELAY85WORK LT SWRELAY GRDRELAY-30CAB WALLTO R.H.FRONT WORK LIGHT (ON CAB)TO L.H.FRONT WORK LIGHT (ON CAB)TO FRONT WORK

522DMATERIAL HANDLER13-24OPTIONAL EQUIPMENT(9138-5005) Foam Tire2 Section Boom OnlyOriginal Issue 5-98JHItem Part No. Qty. Description Of Part9138-500

524DMATERIAL HANDLER13-25OPTIONAL EQUIPMENT(9138-5006) Foam Tire3 Section Boom Option OnlyOriginal Issue 5-98JHItem Part No. Qty. Description Of Part9

522D-524DMATERIAL HANDLER13-26OPTIONAL EQUIPMENT(9133-5023) Ether Start Field KitOriginal Issue 5-98Revised 12-22-98PCN980640 - JHVALVE &COIL ASSY

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part13-27OPTIONAL EQUIPMENTFOR SERVICE ONLYOriginal Issue 2-98Revised 8-13-04DS* Removed al

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLER13-28JHOPTIONAL EQUIPMENT(9133-5026) Rear Axle Advantage KitFOR SERVICE ONLYOriginal Issue 3-991121421531659617818919102011U

522D-524DMATERIAL HANDLER13-28JHOPTIONAL EQUIPMENT(9133-5026) Rear Axle Advantage KitFOR SERVICE ONLYOriginal Issue 3-9936 8867-1001 6 LUBE FITTING,

522DMATERIAL HANDLER13-29OPTIONAL EQUIPMENT(9139-5004) Low Profile Machine Package 522DOriginal Issue 6-99Revised 8-30-02Item Part No. Qty. Descriptio

524DMATERIAL HANDLER13-30OPTIONAL EQUIPMENT(9138-5010) Low Profile Machine Package 524DOriginal Issue 6-99Revised 8-30-02TTItem Part No. Qty. Descript

522D-524DMATERIAL HANDLER1243367891711121314151618910105Item Part No. Qty. Description Of Part9138-3015 1 SWAY CYLINDER ASSY (includesall items)9108-4

522D-524DMATERIAL HANDLER13-32LKOPTIONAL EQUIPMENT(9045-3050) Truss Boom WinchStarting Serial No. 0277001Original Issue 7-01Revised 7-3-06

522D-524DMATERIAL HANDLER13-32ER 49169 - LKOPTIONAL EQUIPMENT(9045-3050) Truss Boom WinchStarting Serial No. 0277001Original Issue 7-01Revised 7-03-06

522D-524DMATERIAL HANDLER13-33SVCOPTIONAL EQUIPMENT(9020-7879) Winch MotorStarting Serial No.0277001Original Issue 7-01Item Part No. Qty. Description

522D-524DMATERIAL HANDLER13-34SVCOPTIONAL EQUIPMENT(9060-2706) Crossover ValveStarting Serial No. 0277001Original Issue 7-01Item Part No. Qty. Descrip

522D-524DMATERIAL HANDLER49130-3041ACBABCYELLOWREDBLACKATTAC H TOSPL ACC2IN DASHHARNESS10567817242728~232526PSITILTCYLINDER3500CHARGE PRESSURE12 VOLT

PART NUMBER PAGEPART NUMBER PAGE PART NUMBER PAGEINDEX522D-524DMATERIAL HANDLE

522D-524DMATERIAL HANDLER1314111521152120SWAY1221314 12 18 1915211621BA.TILTHOISTCROWDItem Part No. Qty. Description Of Part9138-5013 1 ADJUSTABLE

524DMATERIAL HANDLER33841338567314385672122242526272829303333836373435AA15163268910441268910111718192023394041424312MBC13-36OPTIONAL EQUIPMENT(9138-50

524DMATERIAL HANDLER13-36OPTIONAL EQUIPMENT(9138-5025) Stabilizer Option3 SECTION BOOM ONLYOriginal Issue 1-03STABILIZER WIRINGItem Part No. Qty. Desc

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part13 9104-4033 1 PISTON14 1 O-RING15 1 O-RING16 1 BACK-UP RING17 9114-4034 1 CYLINDER HEAD18 1

JLG Worldwide LocationsJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free: (877) 554-5438F

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522D-524DMATERIAL HANDLER2-1CHASSIS & ATTACHING PARTSFrame Shrouding & TrimStarting Serial No. 0277001Original Issue 1-98Revised 03-13-06JD* C

INTRODUCTIONTable of Contents Starting Serial No. 0277001Original Issue 1-98Revised 8-16-99JJ1-1SECTION 1 — INTRODUCTIONTable of Contents...

522D-524DMATERIAL HANDLERCHASSIS & ATTACHING PARTSFrame Shrouding & TrimStarting Serial No. 0277001Original Issue 1-98Revised 03-13-062-1JDIte

522D-524DMATERIAL HANDLERCHASSIS & ATTACHING PARTS(9114-3261) Open Cab Starting Serial No. 0277001Original Issue 1-982-2JHItem Part No. Qty. Descr

522D-524DMATERIAL HANDLER1121521631759618819920102111UPPERLOWER1582023122426272829303119ENLARGED VIEW1342571422KNUCKLE LAYOUT FOR BORINGOUT HOLES FOR

522D-524DMATERIAL HANDLER2-3NOTE #1: Cylinder base end must be free to rotate. Shim steer cylinder baseend as required to maintain a total max. gap

522D-524DMATERIAL HANDLER 2-4CHASSIS & ATTACHING PARTSFront Axle MountingStarting Serial No. 0277001Original Issue 1-98Revised 2-2-06Item Part No.

522D-524DMATERIAL HANDLER 3-1JHItem Part No. Qty. Description Of Part1 9108-6101 1 FIRST BOOM SECTION2 9108-1148 1 PIN3 8820-1107 1 HEX HD CAPSCREW, 5

522D-524DMATERIAL HANDLERBOOM2 Section Boom (std.)Second Boom SectionStarting Serial No. 0277001Original Issue 1-98Item Part No. Qty. Description Of

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9108-5049 Ref QUICK SWITCH OPTION ( includes 9108-5091 plus items 9,10, &11)9108-50

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part Item9108-5033 Ref CARRIAGE ASSY, (includes items 1thru 14)1 9108-6116 1 CARRIAGE2 9108

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9045-5051 1 48" CARRIAGE ASSY, (Includes allitems)1 9045-6009 1 48" CARRIAGE

KG1-2SECTION 6 — DRIVE TRAINFront Axle Assembly ...

522D-524DMATERIAL HANDLER4-3Item Part No. Qty. Description Of Part1 9045-5049 1 60" BUCKET (3/4 yard capacity)Item Part No. Qty. Description Of P

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9130-5016 Ref 66" SLOPE PILER CARRIAGE,(includes all items)1 9130-6030 1 CARRIAGE

522D-524DMATERIAL HANDLER4-5NOTE: FORKS RATED LESS THAN THE ATTACHMENT OR MACHINE’S CAPACITY DECREASE CAPACITY OF THEATTACHMENT OR MACHINE TO THAT OF

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part22 9140-3414 1 MALE TIP COUPLER, (S/N 2005283-01& After)23 9104-3126 1 DUST CAP24 9

522D-524DMATERIAL HANDLER4-7ATTACHMENTS(9055-5024) Personnel Platform AssemblyStarting Serial No. 0277706Original Issue 5-01Revised 10-25-022425262723

522D-524DMATERIAL HANDLER4-7ATTACHMENTS(9055-5024) Personnel Platform AssemblyStarting Serial No. 0277706Original Issue 5-01Revised 10-25-02ECN 020507

522D-524DMATERIAL HANDLER4-8ATTACHMENTS(9055-3036) Crane HookStarting Serial No. 0277701Original Issue 12-04DSItem Part No. Qty. Description Of Part I

524DMATERIAL HANDLER5-1ENGINE & ATTACHING PARTS(9108-5130) Engine Left Side View Starting Serial No. 0277001 thru 0277085Original Issue 1-98Revise

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9108-5130 Ref ENGINE ASSY (includes items onpage 5-1 except items10, 22, 23 & 52thru 55

524DMATERIAL HANDLER5-1ENGINE & ATTACHING PARTS(9108-5130) Engine Left Side View Starting Serial No. 0277086 thru 0277119Original Issue 8-99Revise

1-3SECTION 10 — HYDRAULIC COMPONENTS (continued)Crowd Cylinder ...

524DMATERIAL HANDLER5-1ENGINE & ATTACHING PARTS(9108-5130) Engine Left Side View Starting Serial No. 0277086 thru 0277119Original Issue 8-99Revise

524DMATERIAL HANDLER5-1ENGINE & ATTACHING PARTS(9138-5003) EPA Engine Left Side View Starting Serial No. 0277120 thru 0277338Original Issue 9-98Re

524DMATERIAL HANDLER5-1Item Part No. Qty. Description Of Part9138-5003 Ref ENGINE ASSY, (includes all items onpage 5-1 except items 55 thru 61, andall

524DMATERIAL HANDLERAK5-1ENGINE & ATTACHING PARTS(9138-5020) EPA Engine Left Side View Starting Serial No. 0277339Original Issue 7-012404191415515

524DMATERIAL HANDLERAK5-1Item Part No. Qty. Description Of Part9138-5020 Ref ENGINE ASSY, (includes all items onpage 5-1 except items 59 thru 65 andal

524DMATERIAL HANDLER5-2STARTERALT BATSTRT-SOLPULL-INSTART-CSTARTER SOLENOID TO ENGINEWIRE CONNECTIONSCLT TMP4X4GND-3GND-1GND-2GND-3GND-4GND-5BATALT B

524DMATERIAL HANDLER41 9116-3201 1 TUBE ASSY42 9108-6131 1 TUBE SUPPORT43 8471-9142 1 HOSE ASSY44 Ref TRACTION LOCK VALVE (see page10-20 for details)4

524DMATERIAL HANDLER5-2ENGINE & ATTACHING PARTS(9108-5130) Engine Right Side View Starting Serial No. 0277086 thru 0277119Original Issue 8-99START

524DMATERIAL HANDLER5-2ENGINE & ATTACHING PARTS(9108-5130) Engine Right Side View Starting Serial No. 0277086 thru 0277119Original Issue 8-99GR546

524DMATERIAL HANDLER5-2ENGINE & ATTACHING PARTS(9138-5003) EPA Engine Right Side View Starting Serial No. 0277120 thru 0277338Original Issue 9-98R

1-4JHSECTION 13 — OPTIONAL EQUIPMENT (continued)L.H. Tilt Assembly...

524DMATERIAL HANDLERItem Part No. Qty. Description Of Part30 9002-7187 1 TY-RAP31 8871-1284 1 HEX SOCKET PIPE PLUG, 3/432 9020-5792 1 CUSHION CLAMP33

524DMATERIAL HANDLERENGINE & ATTACHING PARTS(9138-5020) EPA Engine Right Side View Starting Serial No. 0277339Original Issue 7-015-2AKALT BATALT B

524DMATERIAL HANDLERSERVICE NOTES:1. Use Loctite, P/N 1440-3364, on all bolt& fitting threads except pipe threads.2. Use Loctite pipe sealant, P/N

524DMATERIAL HANDLERENGINE & ATTACHING PARTS (9108-5130) Engine Pump Mount & Flywheel Housing Starting Serial No. 0277001 thru 0277085Original

524DMATERIAL HANDLERENGINE & ATTACHING PARTS (9108-5130) Engine Pump Mount & Flywheel Housing Starting Serial No. 0277086 thru 0277119Original

524DMATERIAL HANDLERENGINE & ATTACHING PARTS (9138-5003) EPA Engine Pump Mount & Flywheel Housing Starting Serial No. 0277120 thru 0277338Orig

524DMATERIAL HANDLERVIEW A-AVIEW B-BABBAJD5-3ENGINE & ATTACHING PARTS(9138-5020) Engine Pump Mount & Flywheel Housing Starting Serial No. 0277

522DMATERIAL HANDLER5-4ENGINE & ATTACHING PARTS(9109-5029) Engine Left Side View - 522D Starting Serial No. 0277001 thru 0277085Original Issue 1-9

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part33 9108-3144 1 SUCTION TUBE34 8866-2011 1 CONNECTOR (includes o-ring)8859-1210 1 O-RING35 91

522DMATERIAL HANDLER5-4DSENGINE & ATTACHING PARTS(9109-5029) Engine Left Side View - 522D Starting Serial No. 0277086 thru 0277119Original Issue 8

ACCELERATOR CABLE ...

522DMATERIAL HANDLER5-4DSENGINE & ATTACHING PARTS(9109-5029) Engine Left Side View - 522D Starting Serial No. 0277086 thru 0277119Original Issue 8

522DMATERIAL HANDLER5-4SERVICE NOTES:1). Use Loctite 242, P/N 1440-3364, on all bolt & fitting threads except pipe threads.2). Use L

522DMATERIAL HANDLER5-4Item Part No. Qty. Description Of Part9139-5001 Ref ENGINE ASSY (includes all items onpage 5-4 except items 50 thru 56,all item

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part-9109-5029 Ref ENGINE ASSY(includes all items onpage 5-4 except 45, 46 & 49 thru 53,and

522DMATERIAL HANDLER5-5ENGINE & ATTACHING PARTS(9109-5029) Engine Right Side View - 522D Starting Serial No. 0277086 thru 0277119Original Issue 8-

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part9109-5029 Ref ENGINE ASSY, (includes all items onpage 5-4 except items 45, 46 & 49 thru5

522DMATERIAL HANDLER5-5SERVICE NOTES:1). Use Loctite 242, P/N 1440-3364, on all bolt & fitting threads except pipe threads.2). Use L

522DMATERIAL HANDLERItem Part No. Qty. Description Of Part9139-5001 Ref ENGINE ASSY (includes all items onpage 5-4 except items 50 thru 56,all items o

522DMATERIAL HANDLER5-6ENGINE & ATTACHING PARTS(9109-5029) Engine Pump Mount & Flywheel Housing - 522D Starting Serial No. 0277001 thru 027708

522DMATERIAL HANDLER5-6ENGINE & ATTACHING PARTS(9109-5029) Engine Pump Mount & Flywheel Housing - 522D Starting Serial No. 0277086 thru 027711

DUAL P.O. CHECK VALVE ...

522DMATERIAL HANDLERJD 5-6ENGINE & ATTACHING PARTS(9139-5001) EPA Engine Pump Mount & Flywheel Housing - 522D Starting S

522D-524DMATERIAL HANDLER5-7MPC 3100PCN 980059 - JHENGINE & ATTACHING PARTS(9115-5016) Fuel Tank & LinesStarting Serial No. 0277001Original I

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part17 7714-3006 10 HEX LOCKNUT, 5/16-1818 9108-3573 1 OIL COOLER19 8688-3327 2 HOSE CLAMP2

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part11 9108-3129 1 REDUCING ELBOW12 9114-3353 1 AIR INTAKE TUBE13 2492-1332 1 MUFFLER CLAMP

522D-524DMATERIAL HANDLER4892371651510111716151515151213141918ENGINE & ATTACHING PARTSAir Cleaner Piping Starting Serial No. 0277595 thru currentO

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part9020-5663 1 AIR CLEANER, (includes items 1 thru 5)1 9020-6606 1 COVER W/NUT2 9020-6262

522D-524DMATERIAL HANDLERENGINE & ATTACHING PARTS(9138-3065) 7" Air CleanerStarting Serial No. 0277595 thru currentOriginal Issue 9-005-10 SV

522D-524DMATERIAL HANDLERItem Part No. Qty. Description Of Part1 9108-3560 1 TAIL PIPE2 8368-3175 2 MUFFLER CLAMP (includes items3 & 4)3 2 BRIDGE4

522D-524DMATERIAL HANDLER6-1PCN 980393 - JHDRIVE TRAIN(9108-5110) Front Axle Assembly - 524D(9109-5020) Front Axle Assembly - 522D Starting Serial No.

522D-524DMATERIAL HANDLERDRIVE TRAIN(9112-3119) Front AxleStarting Serial No. 0277001Original Issue 1-98Revised 3-18-98G-Tech Report #MH97-7 KGItem Pa

HORN WIRING ...

522D-524DMATERIAL HANDLER6-3DRIVE TRAINCarrier Assembly Starting Serial No. 0277001Original Issue 1-98Revised 10-24-03Item Part No. Qty. Description O

522D-524DMATERIAL HANDLER6-4DRIVE TRAINBrake Assembly Starting Serial No. 0277001Original Issue 12-97Revised 5-26-05Item Part No. Qty. Description Of

522D-524DMATERIAL HANDLER6-5DRIVE TRAIN(9114-4339) (9114-4337) Left/Right Housing Assembly(9114-4333) (9114-4335) Axle Shaft and Wheel Flange Assembly

524DMATERIAL HANDLERDRIVE TRAIN(9112-3145) Rear Steering Axle Drive Hub - 524DStarting Serial No. 0277001Original Issue 1-98JH6-6Item Part No. Qty.

522DMATERIAL HANDLERDRIVE TRAIN(9109-3006) Rear Steering Axle Non-Drive Hub - 522DStarting Serial No. 0277001Original Issue 1-98JH6-7Item Part No. Qty

522D-524DMATERIAL HANDLERDRIVE TRAINWheels & TiresStarting Serial No. 0277001Original Issue 1-986-8Item Part No. Qty. Description Of Part9112-5002

522D-524DMATERIAL HANDLER7-1CONTROLSTilt & SwayStarting Serial No. 0277001Original Issue 1-98Revised 8-13-99Item Part No. Qty. Description Of Part

522D-524DMATERIAL HANDLER1011145121723131415131415161314156789CONTROLS(9114-3342) Accelerator Pedal Assembly Starting Serial No. 0277001 thru 0277119O

522D-524DMATERIAL HANDLER131412451101197861523CONTROLS(9114-3342) Accelerator Pedal Assembly Starting Serial No. 0277120Original Issue 8-99Revised 1-1

522D-524DMATERIAL HANDLERCONTROLSSteering Column & Attaching Parts Starting Serial No. 0277001Original Issue 1-98Revised 12-8-00Item Part No. Qty.