Jlg 510AJ Parts Manual Bedienungsanleitung

Illustrated Parts ManualModel510AJS/N E300001114 TO PRESENT 3121294August 30, 2013

1-4 510AJ 3121294SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION 202203201204115114101117127102108128120

4-6 510AJ 3121294SECTION 4 PLATFORMFIGURE 4-2.PLATFORM CONSOLE ASSEMBLY 1019102344225363837142225134103105391332A331718301302472628222419493247

3121294 510AJ 4-7SECTION 4 PLATFORMFIGURE 4-2. PLATFORM CONSOLE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001139202 Ref. PLATFORM CONSOLE ASSE

4-8 510AJ 3121294SECTION 4 PLATFORM41 Not Used42 4751000 2 Flatwasher #10 Regular43 4751400 8 Flatwasher 1/4in Regular44 1001139135 1 Harness, Upper V

3121294 510AJ 4-9SECTION 4 PLATFORMFIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-10 510AJ 3121294SECTION 4 PLATFORMFIGURE 4-3.CONTROLLER ASSEMBLY (LIFT AND SWING) 912181175641023

3121294 510AJ 4-11SECTION 4 PLATFORMFIGURE 4-3. CONTROLLER ASSEMBLY (LIFT AND SWING)ITEM # PART NUMBER QTY. DESCRIPTION REV.1001129555 Ref. CONTROLLE

4-12 510AJ 3121294SECTION 4 PLATFORMFIGURE 4-4.CONTROLLER ASSEMBLY (DRIVE & STEER) 1143285791081081071091021021031031041041101051066101

3121294 510AJ 4-13SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (DRIVE & STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.1001118416 Ref. CONTRO

4-14 510AJ 3121294SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 5-1SECTION 5CYLINDER

3121294 510AJ 1-5SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0275854 Ref. WHEEL DRIVE INSTALL

5-2 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY 1349856572 15

3121294 510AJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684465 Ref AXLE LOCKOUT CYLINDE

5-4 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY 88214910121718121352014152922883528

3121294 510AJ 5-5SECTION 5 CYLINDERFIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001094789 Ref. LEVEL

5-6 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-3. LIFT (JIB) CYLINDER ASSEMBLY 9922431181920621222311111147282914151617883527

3121294 510AJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LIFT (JIB) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684242 Ref. JIB LIFT CYLINDER ASS

5-8 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-4. LIFT (MAIN BOOM) CYLINDER ASSEMBLY 666610971112142526128212219202324292735

3121294 510AJ 5-9SECTION 5 CYLINDERFIGURE 5-4. LIFT (MAIN BOOM) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684244 Ref. MAIN LIFT CYLIN

5-10 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-5. LIFT (TOWER BOOM) CYLINDER ASSEMBLY 6666121671514101012191718820212430262311 35

3121294 510AJ 5-11SECTION 5 CYLINDERFIGURE 5-5. LIFT (TOWER BOOM) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684239 Ref TOWER LIFT CYL

1-6 510AJ 3121294SECTION 1 FRAMERef. Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on a machi

5-12 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-6. MASTER CYLINDER ASSEMBLY 18888199410251213151814232125

3121294 510AJ 5-13SECTION 5 CYLINDERFIGURE 5-6. MASTER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684241 Ref MASTER CYLINDER ASSEMBLY

5-14 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-7. STEER CYLINDER ASSEMBLY 345678911212211103456789

3121294 510AJ 5-15SECTION 5 CYLINDERFIGURE 5-7. STEER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001143434 Ref. STEER CYLINDER ASSEMBL

5-16 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY 185A176258920213426141916272328530

3121294 510AJ 5-17SECTION 5 CYLINDERFIGURE 5-8. TELESCOPE CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684235 Ref. TELESCOPE CYLINDER AS

5-18 510AJ 3121294SECTION 5 CYLINDERFIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 6-1SECTION 6HYDRAULIC

6-2 510AJ 3121294SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM SHUTTLEVALVEPTALOCK-OUT VALVEX46BAL2M5M2M1XPVVP9410913113141487

3121294 510AJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.1001140559 Ref. AXLE LOCKOUT HY

3121294 510AJ 1-7SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-4 510AJ 3121294SECTION 6 HYDRAULICFIGURE 6-2.DRIVE HYDRAULIC DIAGRAM XCASE DRAINFORWARDREVERSE2-SPEED - BRAKE VALVE DRIVE PUMPFILTER I

3121294 510AJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.1001138578 Ref DRIVE HYDRAULIC DIAGRAM

6-6 510AJ 3121294SECTION 6 HYDRAULIC48 2220596 2 Fitting, 45° 49 2220373 2 Fitting, StraightFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM (CONTINUED)ITEM # PAR

3121294 510AJ 6-7SECTION 6 HYDRAULICFIGURE 6-2. DRIVE HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-8 510AJ 3121294SECTION 6 HYDRAULICFIGURE 6-3.STANDARD HYDRAULIC DIAGRAM 427252822112651429161343132915711433563163536123010391238815994011414

3121294 510AJ 6-9SECTION 6 HYDRAULICFIGURE 6-3. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. STANDARD HYDRAULIC DIAGRAM1001

6-10 510AJ 3121294SECTION 6 HYDRAULIC49 1001138306 1 Hose50 1001138307 1 Hose51 1001141595 1 Hose52 1001138309 1 Hose53 1705091 1 Decal, Hose Tags (No

3121294 510AJ 6-11SECTION 6 HYDRAULICFIGURE 6-3. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-12 510AJ 3121294SECTION 6 HYDRAULICFIGURE 6-4. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Diagrams with asterisk

3121294 510AJ 7-1SECTION 7ELECTRICAL

1-8 510AJ 3121294SECTION 1 FRAMEFIGURE 1-3.DRIVE HUB/BRAKE ASSEMBLY (REAR) 10512110211912212310415115015215315410310310110910710828291141131161

7-2 510AJ 3121294SECTION 7 ELECTRICALFIGURE 7-1. ELECTRICAL DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Diagrams are available

3121294 510AJ 7-3SECTION 7 ELECTRICALITEM # PART NUMBER QTY. DESCRIPTION REV.

7-4 510AJ 3121294SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION 340339J5J6J7J2J2J1J8J3J1J82543303293023023023022B542A54DIAGNOSTICANAL

3121294 510AJ 7-5SECTION 7 ELECTRICALSTROBELIGHT339340418706A417713E713G340265266256257706D713G706A339339A339A707707A7500WGENERATORRELAYS7500WSKYPOWER

7-6 510AJ 3121294SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. HARNESS COMPONENTS INSTA

3121294 510AJ 7-7SECTION 7 ELECTRICAL103 4460875 1 Connector - 35 Position (Gray)4460871 26 Socket, Female104 4460873 1 Connector - 35 Position (Black

7-8 510AJ 3121294SECTION 7 ELECTRICAL265 to 267 Not Required268 to 270 Not UsedRef. GROUND CONTROL BOX COMPONENTS301 Not Used302 0100048 A/R Grease, D

3121294 510AJ 7-9SECTION 7 ELECTRICAL341J 4460761 1 Connector, Female - 4 Position 4460227 4 Pin, Male341K 4460536 1 Connector, Female - 3 Position 44

7-10 510AJ 3121294SECTION 7 ELECTRICAL433 4461052 1 Connector - 25 Position (Deutz Engine Machines Only)4461005 5 Terminal 18-20 Gauge (Deutz Engine M

3121294 510AJ 7-11SECTION 7 ELECTRICAL601B 1 Cable, Battery Options (Battery – & Auxiliary Pump to Ground) (Black): Use 7027041 Deutz Engine Machi

3121294 510AJ 1-9SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR)ITEM # PART NUMBER QTY. DESCRIPTION REV.2780267 Ref. DRIVE HUB/BRAKE ASSEM

7-12 510AJ 3121294SECTION 7 ELECTRICAL610 4360436 A/R Fuel Level Sensor Harness (Includes Sensor Only - Order Plug & Pins Separately)610A 4460320

3121294 510AJ 7-13SECTION 7 ELECTRICAL701A Cont’dSee Note 0275683/0275684/1001101915/1001101916 Installations (Note: Was p/n 0861782 which is no longe

7-14 510AJ 3121294SECTION 7 ELECTRICAL701G Cont’d 4460957 1 Block, Terminal701H 2 Connector, Strain Relief Options:4460633 M20 Diameter1001097150 M25

3121294 510AJ 7-15SECTION 7 ELECTRICALUse 1001100343 220V with CEE 7 Post Ground (70mm x 70mm Box) (Includes Items 701A-701C, 701L & 701N) (027568

7-16 510AJ 3121294SECTION 7 ELECTRICAL703 A/R 2500W Generator Electrical Components1001112588 110V/60Hz A1001112743 110V/50Hz & 220V/50Hz B703A 49

3121294 510AJ 7-17SECTION 7 ELECTRICAL706 Ref. 7500W Generator Electrical Diagram Components1001112586 Ref. Caterpillar/Deutz Engine Machines A706A 1

7-18 510AJ 3121294SECTION 7 ELECTRICAL804 4460510 1 Extractor, Pin (Yellow 12-14 Gauge) (For Removal of Pin/Socket from Connectors)805 7002828 1 Strip

3121294 510AJ 8-1SECTION 8DECALS

8-2 510AJ 3121294SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION - ANSI EXPORT SPEC (ENGLISH LANGUAGE) 618244173A3614173C261034272632645HYDRAUL

3121294 510AJ 8-3SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION - ANSI EXPORT SPEC (ENGLISH LANGUAGE)ITEM # PART NUMBER QTY. DESCRIPTION REV.10011430

1-10 510AJ 3121294SECTION 1 FRAME12 7017067 12 Bolt 13 7017080 4 Pin, Dowell14 7000206 1 Coupling15 7024715 1 Spacer, Input16 7024716 1 Spacer, Input1

8-4 510AJ 3121294SECTION 8 DECALS134 to 172 Not Used173 0272582 Ref. Model Designation Decal Installation 2173A 1704951 2 Decal - 510AJ173B 1705669 4

3121294 510AJ 8-5SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION - ANSI EXPORT SPEC (ENGLISH LANGUAGE) ITEM # PART NUMBER QTY. DESCRIPTION REV.

8-6 510AJ 3121294SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS (OTHER LANGUAGES) 18244173A3614173C261034272632645HYDRAULIC

3121294 510AJ 8-7SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS (OTHER LANGUAGES)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. DEC

8-8 510AJ 3121294SECTION 8 DECALS20 See Note 1 Decal - Bar Code (Note: Not Available for Purchase)21 to 22 Not Used23 1701509 1 Decal - Manual24 17023

3121294 510AJ 8-9SECTION 8 DECALS215B 1702773 1 Decal - JLG (5in)FIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS (OTHER LANGUAGES) ITEM # PART NUM

8-10 510AJ 3121294SECTION 8 DECALSFIGURE 8-3. DECALS INSTALLATION - AUSTRALIAN & CE SPECS 18244173A3614173C26103427263152645HYDRAULICOIL T

3121294 510AJ 8-11SECTION 8 DECALSFIGURE 8-3. DECALS INSTALLATION - AUSTRALIAN & CE SPECSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. DECAL INSTA

8-12 510AJ 3121294SECTION 8 DECALS51 A/R Decal - Emergency Controls Options:1001112551 1 Australian Spec Not Required 0 CE Spec1001142990 Ref. DECAL O

3121294 510AJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 510AJThe following list will service one machine (built to current production per date

3121294 510AJ 1-11SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

9-2 510AJ 3121294SECTION 9 RECOMMENDED SERVICE PARTS STOCKMODEL 510AJThe following list will service one machine (built to current production per date

3121294 510AJ 10-1SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applicable

10-2 510AJ 3121294SECTION 10 SPECIAL OPTIONSRef. Filter KitsRef. Boom HydraulicAir Filter Kit Options:1001109698 Ref. Deutz Engine MachinesRef. Combin

3121294 510AJ 10-3SECTION 10 SPECIAL OPTIONSRef. Platform Mesh Installations (Side Entry Platforms) (ANSI Export Specs Only)0273146 Ref. 30in X 5ft (7

10-4 510AJ 3121294SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applicable t

PagePart Number PagePart Number PagePart NumberPagePart Number3121294 510AJ 11-1SECTION 11 PART NUMBER INDEX0060050 ...3-7, 3-150080163

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 510AJ 3121294SECTION 11 PART NUMBER INDEX1001101915 ... 7-121001101

PagePart Number PagePart Number PagePart NumberPagePart Number3121294 510AJ 11-3SECTION 11 PART NUMBER INDEX1001148902 ... 10-11001148

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 510AJ 3121294SECTION 11 PART NUMBER INDEX2720271 ... 2-16, 2-182720467

PagePart Number PagePart Number PagePart NumberPagePart Number3121294 510AJ 11-5SECTION 11 PART NUMBER INDEX4460428 ...4-7, 7-6446043

1-12 510AJ 3121294SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT) 141A1B1C1D1N1G1E1F1H11277A7D7D7C7B11158163B3F3C3D3C3B33A66B3E3G545A

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 510AJ 3121294SECTION 11 PART NUMBER INDEX7000230 ... 1-9, 1-13700023

PagePart Number PagePart Number PagePart NumberPagePart Number3121294 510AJ 11-7SECTION 11 PART NUMBER INDEX7022372 ... 1-177022

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 510AJ 3121294SECTION 11 PART NUMBER INDEX

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

3121294 510AJ 1-13SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT)ITEM # PART NUMBER QTY. DESCRIPTION REV.2780268 Ref. DRIVE HUB ASSEMBLY C1 See

1-14 510AJ 3121294SECTION 1 FRAME15 7024715 1 Spacer, Input16 7024716 1 Spacer, InputFIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)ITEM # PART NU

3121294 510AJ 1-15SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-16 510AJ 3121294SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLY 34134019383034333231323118161517147522202123242526282711411129107A13862537363

3121294 510AJ 1-17SECTION 1 FRAMEFIGURE 1-5. DRIVE MOTOR ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3160348 Ref. DRIVE MOTOR ASSEMBLY (4WD) B1 7

1-18 510AJ 3121294SECTION 1 FRAMEFIGURE 1-6.DRIVE VALVES AND FRAME SHIELDS INSTALLATION 202202201201203205123123C123C123A123F123E125116123123B1

3121294 510AJ 1-19SECTION 1 FRAMEFIGURE 1-6. DRIVE VALVES AND FRAME SHIELDS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0275854 Ref. DRIVE VA

1-20 510AJ 3121294SECTION 1 FRAMEFIGURE 1-6. DRIVE VALVES AND FRAME SHIELDS INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-1SECTION 2TURNTABLE

2-2 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-1.MAIN CONTROL VALVE AND ALARM INSTALLATIONS 1410121587104101104102103105106106

3121294 510AJ 2-3SECTION 2 TURNTABLEFIGURE 2-1. MAIN CONTROL VALVE AND ALARM INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.1001141804 Ref. VAL

3121294 510AJ AREVISION LOGNOTE: The 510AJ may be manufactured by JLG Industries in the countries of Belgium or Romania. Refer to the SerialNumber Tag

2-4 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY 1317131717186191618424141714172242242222211618171815171517619121712

3121294 510AJ 2-5SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001138771 Ref. PROPORTIONAL VALVE

2-6 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-3.TURNTABLE AND SWING DRIVE INSTALLATIONS 1131121011031021051081091151101061111071141161121011042

3121294 510AJ 2-7SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. SWING DRIVE INSTA

2-8 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-4.SWING MOTOR ASSEMBLY 25941012 12A13141415161718192041234448576

3121294 510AJ 2-9SECTION 2 TURNTABLEFIGURE 2-4. SWING MOTOR ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1001104850 Ref. SWING MOTOR ASSEMBLY A1 S

2-10 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-5.SWING BEARING & ROTATION BOX ASSEMBLY 105142130102103125110 1341091141121151391021031271281

3121294 510AJ 2-11SECTION 2 TURNTABLEFIGURE 2-5. SWING BEARING & ROTATION BOX ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. SWING BEARING

2-12 510AJ 3121294SECTION 2 TURNTABLE141 Use 7026059 A/R Shim, Yellow (.020) 142 7027356 1 Adapter, Motor 143 Use 7026060 1 Seal, Face144 Use 7026059

3121294 510AJ 2-13SECTION 2 TURNTABLEFIGURE 2-5. SWING BEARING & ROTATION BOX ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

B 510AJ 3121294REVISION LOG

2-14 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-6.CATERPILLAR ENGINE INSTALLATION 9078319955656687445841173734631130510311412813820291218521276781922274

3121294 510AJ 2-15SECTION 2 TURNTABLE 136136112144106114124126121112117125103113128138112103138122119124TO WATERSEPARATERTO FUELTANK VENTLINEFU

2-16 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-6. CATERPILLAR ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001141999 Ref. CATERPILLAR E

3121294 510AJ 2-17SECTION 2 TURNTABLE44 1 Muffler Options:3220113 Standard Spark Arresting Muffler70001017 1 Clamp1001107116 Optional Catalytic Muffle

2-18 510AJ 3121294SECTION 2 TURNTABLE87 1001100825 2 Tie-Strap88 1001100837 1 Bracket, Bottle89 1001101201 1 Spacer, Fan90 1001101408 1 Fan91 10011016

3121294 510AJ 2-19SECTION 2 TURNTABLE128 3311405 11 Locknut 1/4in-20NC129 3311505 2 Locknut 5/16in-18NC130 3312005 1 Locknut 5/8in-11NC131 3340399 1 P

2-20 510AJ 3121294SECTION 2 TURNTABLE308 7026858 1 Valve, Relief 7026857 1 Seal309 7026864 1 Pump, Water7026863 1 Gasket, Water Pump (Fits Between Pum

3121294 510AJ 2-21SECTION 2 TURNTABLEFIGURE 2-6. CATERPILLAR ENGINE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-22 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-7.DEUTZ ENGINE INSTALLATION 3013073033043022544052022022022022272342672232092542412142552652395320531826

3121294 510AJ 2-23SECTION 2 TURNTABLE17159912FUELINJECTOR PUMPVENTLINEFUELRETURN1422292916218232422230222183123022820721520226120822124126125616161032

3121294 510AJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-24 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-7. DEUTZ ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001141527 Ref. DEUTZ ENGINE INSTAL

3121294 510AJ 2-25SECTION 2 TURNTABLE1001141527 Ref. ENGINE ASSEMBLY B201 0080231 1 Adapter, Fan Spacer202 0100011 A/R Compound, Locking203 Not Used20

2-26 510AJ 3121294SECTION 2 TURNTABLE244 3573937 1 Support, Radiator 245 3600318 1 Gear Pump Assembly (Note: Seal Kit is only serviceable part availab

3121294 510AJ 2-27SECTION 2 TURNTABLE403 A/R Seal & Gasket Options (Not Shown)70002718 1 Seal, Rear Main Crankshaft 7020430 1 Gasket, Valve Cover1

2-28 510AJ 3121294SECTION 2 TURNTABLE417 7024565 1 Tacho-Generator70003932 1 Sleeve, Spacer418 7027791 1 Sensor, Temperature 419 7027790 1 Sensor, Oil

3121294 510AJ 2-29SECTION 2 TURNTABLEFIGURE 2-7. DEUTZ ENGINE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-30 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-8.PISTON PUMP ASSEMBLY 65646361625657585960665552515326546770713132343513828483858687368037384041

3121294 510AJ 2-31SECTION 2 TURNTABLEFIGURE 2-8. PISTON PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600385 Ref. PISTON PUMP ASSEMBLY A1 702

2-32 510AJ 3121294SECTION 2 TURNTABLE49 Use 7021280 2 O-Ring50 7022382 1 Cover, Servo51 7021255 10 Screw52 7007470 1 Plug Assembly53 Use 7021280 1 O-R

3121294 510AJ 2-33SECTION 2 TURNTABLEFIGURE 2-8. PISTON PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

ii 510AJ 3121294FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-34 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-9. AUXILIARY PUMP ASSEMBLY 12234567891012121313111414151516171727111819 2021221815112378910242526

3121294 510AJ 2-35SECTION 2 TURNTABLEFIGURE 2-9. AUXILIARY PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600423 Ref. AUXILIARY PUMP ASSEMBLY

2-36 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-10.TANK INSTALLATIONS 6118181220181911817320113291415A1017410410610310510710216211015118157301302

3121294 510AJ 2-37SECTION 2 TURNTABLEFIGURE 2-10. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.1001144403 Ref. TANK INSTALLATION D1 0100

2-38 510AJ 3121294SECTION 2 TURNTABLE83304172 6 Stud 1/4”-20NC107 83304170 2 Bolt 3/8in-16NC x 1-1/4inUse 4751600 2 Flatwasher 3/8in Regular201 Ref. F

3121294 510AJ 2-39SECTION 2 TURNTABLEFIGURE 2-10. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-40 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-11.GROUND CONTROL BOX ASSEMBLY 434246453737441629302832181415283215201981616144373746612232125

3121294 510AJ 2-41SECTION 2 TURNTABLEFIGURE 2-11. GROUND CONTROL BOX ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. GROUND CONTROL BOX ASSEMBLI

2-42 510AJ 3121294SECTION 2 TURNTABLE37 4751400 12 Flatwasher 1/4in Regular38 Not Used39 1001138588 1 Valve Harness Assembly (Not Shown - See Section

3121294 510AJ 2-43SECTION 2 TURNTABLEFIGURE 2-11. GROUND CONTROL BOX ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 1-1SECTION 1 FRAME

2-44 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-12.LIGHT INSTALLATIONS 313330353432116241567234141110132526262527292928

3121294 510AJ 2-45SECTION 2 TURNTABLEFIGURE 2-12. LIGHT INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.0271073 Ref. STROBE LIGHT INSTALLATION (

2-46 510AJ 3121294SECTION 2 TURNTABLE39 1 Switch Options (Not Shown - Located on Console):4360336 Toggle Switch4360522 Pushbutton Switch40 3790012 A/R

3121294 510AJ 2-47SECTION 2 TURNTABLEFIGURE 2-12. LIGHT INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-48 510AJ 3121294SECTION 2 TURNTABLEFIGURE 2-13.HOODS INSTALLATION 1921523262152326428591828214SEE ENGINEINSTALLATIONSEE ENGINEINSTALLATION27

3121294 510AJ 2-49SECTION 2 TURNTABLEFIGURE 2-13. HOODS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. HOODS INSTALLATION 1001137918 Ref. C

2-50 510AJ 3121294SECTION 2 TURNTABLE31 1 Hood Kit (Engine Side) Options (was p/n 2680438):1001145959 Caterpillar Engine Machines (Includes Items 31A-

3121294 510AJ 3-1SECTION 3BOOM

3-2 510AJ 3121294SECTION 3 BOOMFIGURE 3-1.TOWER/MID BOOMS AND CYLINDERS INSTALLATION LIMIT SWITCHLOCATED ON ITEM 119141191101101141141161161061

3121294 510AJ 3-3SECTION 3 BOOMFIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. TOWER BOOMS AND CYL

1-2 510AJ 3121294SECTION 1 FRAMEFIGURE 1-1.AXLE AND STEERING INSTALLATION 113101104109110101107103102101112106106108111114105218216220201206

3-4 510AJ 3121294SECTION 3 BOOM114 3422568 6 Pin115 3422912 2 Pin116 3841258 8 Keeper, Pin 117 4751600 12 Flatwasher 3/8in Regular118 4846905 1 Rest,

3121294 510AJ 3-5SECTION 3 BOOM316 4922770 1 Cable, Electrical - 18/2 (Not Shown - See Section 7)FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATI

3-6 510AJ 3121294SECTION 3 BOOMFIGURE 3-2.MAIN BOOM INSTALLATION 12222322312613210110810510113310613211812412213310810111611711913310912311224

3121294 510AJ 3-7SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. MAIN BOOM AND CYLINDERS INSTALLATION 02

3-8 510AJ 3121294SECTION 3 BOOM231 1001094789 1 Level (Platform Slave) Cylinder Assembly (See Section 5 for Breakdown):232 1684242 1 Jib Lift Cylinder

3121294 510AJ 3-9SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-10 510AJ 3121294SECTION 3 BOOMFIGURE 3-3.MAIN BOOM ASSEMBLY 139140156157157118118157156156140120116166140122122105155160160134134107107158158

3121294 510AJ 3-11SECTION 3 BOOMFIGURE 3-3. MAIN BOOM ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.0801337 Ref. MAIN BOOM ASSEMBLY L101 Not Used1

3-12 510AJ 3121294SECTION 3 BOOM159 4711600 4 Flatwasher 3/8in Thin160 4751400 14 Flatwasher 1/4in Regular161 Not Used162 4846650 1 Tube, Carrier163 t

3121294 510AJ 3-13SECTION 3 BOOMFIGURE 3-3. MAIN BOOM ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.1001139087 Ref. OSCILLATING AXLE IN

3-14 510AJ 3121294SECTION 3 BOOMFIGURE 3-4.ROTATOR ASSEMBLY 131311815216111231491A1B10168171825GENUINE PARTS262827272728274

3121294 510AJ 3-15SECTION 3 BOOMFIGURE 3-4. ROTATOR ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.0060050 Ref. ROTATOR ASSEMBLY F1 See Note1Case/Br

3-16 510AJ 3121294SECTION 3 BOOMFIGURE 3-5.PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS 867924169220620220120120120920321021121320920253

3121294 510AJ 3-17SECTION 3 BOOMFIGURE 3-5. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. PLATFORM

3-18 510AJ 3121294SECTION 3 BOOM310 7017406 2 Plug311 See Note 1 Plug (Note: Not Available for Purchase)312 2221086 3 Fitting, DiagnosticFIGURE 3-5.

3121294 510AJ 4-1SECTION 4PLATFORM

4-2 510AJ 3121294SECTION 4 PLATFORMFIGURE 4-1.PLATFORM INSTALLATION 40740140440440430172042072062032082082052072011425386111109110113106104108

3121294 510AJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. PLATFORM ASSEMBLY WITH GATE100114540

4-4 510AJ 3121294SECTION 4 PLATFORM206 3380434 1 Panel, Decal Mount207 4740362 1 Washer, Fender 1/4in208 4751600 8 Flatwasher 3/8in Regular209 1001139

3121294 510AJ 4-5SECTION 4 PLATFORM515 4711400 2 Flatwasher 1/4in Thin (Used with #413 - Not Shown)FIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)ITEM