Jlg 510AJ Parts Manual Bedienungsanleitung

Illustrated Parts ManualModel510AJS/N 1300000100 TO PRESENT & PRIOR TO S/N E300001114 3121182August 30, 2013

1-2 510AJ 3121182SECTION 1 FRAMEFIGURE 1-1.AXLE AND STEERING INSTALLATION 112119106114108108121116107122122110123A1091051202162132052232232052

2-54 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-12. PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM)ITEM # PART NUMBER QT

3121182 510AJ 2-55SECTION 2 TURNTABLE36 A/R Hose, Radiator (Top) Options:Prior to S/N 1300006427 (1 piece):1001102308 1 Hose, Radiator (Top) (was p/n

2-56 510AJ 3121182SECTION 2 TURNTABLE68 4751500 12 Flatwasher 5/16in Regular69 4751600 42 Flatwasher 3/8in Regular70 4751800 11 Flatwasher 1/2in Regul

3121182 510AJ 2-57SECTION 2 TURNTABLE109 Use 1001099926 1 Sensor Kit, Speed (Includes 1001097556 Speed Sensor and Items 94, 98 & 99)110 100109758

2-58 510AJ 3121182SECTION 2 TURNTABLE226 4641317 1 Valve Assembly226A A/R Cartridge & Coil Components:7012941 1 Cartridge without Coil 7010543 1 S

3121182 510AJ 2-59SECTION 2 TURNTABLE404 70001396 1 Pump, Water (Includes p/n 70001397 Only)70001397 1 Gasket, Water Pump to Plate70001398 1 Gasket, P

2-60 510AJ 3121182SECTION 2 TURNTABLE431 1 Gasket, Cylinder Head Options (Not Shown):0.4mm70003034 1001095205 EnginesSee Note 1001102270 Engines (Note

3121182 510AJ 2-61SECTION 2 TURNTABLEFIGURE 2-12. PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM) (CONTINUED)ITEM # PA

2-62 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-13.PERKINS ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN) (WITHOUT UGM) 45167369462129683528769

3121182 510AJ 2-63SECTION 2 TURNTABLE 622838104105116110466969183019010730630430730932411131632990308303302310311TO WATERSEPARATERTO FUELTANK VENTL

3121182 510AJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. OSCILLATING AXLE INSTALLATIONS

2-64 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-13. PERKINS ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN) (WITHOUT UGM)ITEM # PART NUMBER QTY. D

3121182 510AJ 2-65SECTION 2 TURNTABLE39B 7016837 1 Cable - Battery & Auxiliary Pump to Ground39C 7016834 1 Cable - Starter Relay to Starter39D 701

2-66 510AJ 3121182SECTION 2 TURNTABLE79 4922737 1 Harness, Engine Grounding80 4711400 12 Flatwasher, 1/4in Thin81 1001130038 1 Tube, Air Cleaner82 360

3121182 510AJ 2-67SECTION 2 TURNTABLE116 1001099926 1 Sensor Kit, Speed2820018 6in/15cm Heat Shrink1001097556 1 Speed Sensor4460464 3 Pin, Male446053

2-68 510AJ 3121182SECTION 2 TURNTABLE231 3311505 3 Locknut 5/16in-18NC232 Not Used233 4751500 1 Flatwasher 5/16in Regular234 2300004 2.7 Gal Coolant,

3121182 510AJ 2-69SECTION 2 TURNTABLE70001411 1 Seal, O-Ring312 70001412 1 Flywheel70001413 1 Ring, Starter313 70001414 1 Starter70001415 1 Solenoid,

2-70 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-14.PERKINS ENGINE INSTALLATION (WITH UGM) 24324524420923540161662626239611417624030871653547537670146

3121182 510AJ 2-71SECTION 2 TURNTABLE 231231212239206214223225220212216224213212203233221218223TO WATERSEPARATERTO FUELTANK VENTLINEFUELRETURNTO FU

2-72 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-14. PERKINS ENGINE INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: For Module

3121182 510AJ 2-73SECTION 2 TURNTABLE38 3311405 11 Locknut 1/4in-20NC 39 3311505 6 Locknut 5/16in-18NC40 3311605 22 Locknut 3/8in-16NC41 3311805 4 Loc

1-4 510AJ 3121182SECTION 1 FRAME121 1 Axle Weldment Options:Note: If kingpin holes in the axle measure 1.503in diameter or larger in any direction, ax

2-74 510AJ 3121182SECTION 2 TURNTABLE86 2151212 2 Fitting, 45°87 2170316 1 Fitting, Tee88 2170808 2 Fitting, Tee89 to 90 Not Used91 2221084 1 Fitting,

3121182 510AJ 2-75SECTION 2 TURNTABLE227 3312005 1 Locknut 5/8in-11NC228 3340399 1 Pad, Wear229 3900254 1 Screw, Shoulder230 4641317 1 Valve Assembly7

2-76 510AJ 3121182SECTION 2 TURNTABLE308 70002438 1 Dipstick70002439 1 Tube, Dipstick70002440 3 O-Ring309 70002441 1 Valve, Oil Drain310 70001404 1 Ca

3121182 510AJ 2-77SECTION 2 TURNTABLEFIGURE 2-14. PERKINS ENGINE INSTALLATION (WITH UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-78 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-15.2500W GENERATOR INSTALLATION - PERKINS MACHINES (OPTIONAL)

3121182 510AJ 2-79SECTION 2 TURNTABLEFIGURE 2-15. 2500W GENERATOR INSTALLATION - PERKINS MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.R

2-80 510AJ 3121182SECTION 2 TURNTABLE9A cont’d 7020193 1 Cord, Power9B 7019680 1 110V/60Hz Control Box 70000127 1 220V/50Hz Control BoxCircuit Breaker

3121182 510AJ 2-81SECTION 2 TURNTABLERef. PLATFORM COMPONENTSRef. Note: For Module (with/without UGM) Identification, refer to Revision Log page A.Ref

2-82 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-16.PISTON PUMP ASSEMBLY 6564636162565758596066555251532654677071272831323435138284838586873680373

3121182 510AJ 2-83SECTION 2 TURNTABLEFIGURE 2-16. PISTON PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. PISTON PUMP ASSEMBLIES3600296 Ref.

3121182 510AJ 1-5SECTION 1 FRAME205 2 Bushing / Bearing Options: 0961951 Belgium Built Machines Prior to S/N 1300000441(Top & Bottom Kingpin Locat

2-84 510AJ 3121182SECTION 2 TURNTABLE34 7021251 1 Screw35 7022342 1 Bracket, Lifting36 7022342 1 Key37 7022341 1 Ring, Retaining38 7021258 1 Gerotor39

3121182 510AJ 2-85SECTION 2 TURNTABLE75 1 Spring7021291 (3600296 Pump Only)7022347 (3600385 Pump Only)76 1 Poppet7021292 (3600296 Pump Only)7024804 (3

2-86 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-17. AUXILIARY PUMP ASSEMBLY

3121182 510AJ 2-87SECTION 2 TURNTABLEFIGURE 2-17. AUXILIARY PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. AUXILIARY PUMP ASSEMBLIESRef. U

2-88 510AJ 3121182SECTION 2 TURNTABLE122 See Note 1 Label (Note: Not Available for Purchase)123 7000974 1 Gasket124 Use 70000978 1 Housing, Gear125 Us

3121182 510AJ 2-89SECTION 2 TURNTABLEFIGURE 2-17. AUXILIARY PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-90 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-18.TANK INSTALLATIONS 6121423211322141168241142010115991617A102052052032022072082062041918212112

3121182 510AJ 2-91SECTION 2 TURNTABLEFIGURE 2-18. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.0272491 Ref. TANK INSTALLATIONS F1 010001

2-92 510AJ 3121182SECTION 2 TURNTABLE205 cont’d Belgium Built Machines S/N 1300006742 to Present & Romanian Built Machines S/N E300000100 to S/N E

3121182 510AJ 2-93SECTION 2 TURNTABLEFIGURE 2-18. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-6 510AJ 3121182SECTION 1 FRAME250 2902400 1 Kingpin & Bushings Update Kit for Belgium Built Machines Built Prior to S/N 1300000441 (Includes New

2-94 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-19.GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)

3121182 510AJ 2-95SECTION 2 TURNTABLEFIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built

2-96 510AJ 3121182SECTION 2 TURNTABLE22 4360470 1 Switch, Key22A 2860030 1 Key 23 4360475 1 Switch, Emergency Stop 23A 7020175 1 Cap, Mushroom Head 23

3121182 510AJ 2-97SECTION 2 TURNTABLEFIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-98 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-20.GROUND CONTROL BOX ASSEMBLY (WITH UGM) 4342464537374416293028321814152832152019816161443737466

3121182 510AJ 2-99SECTION 2 TURNTABLEFIGURE 2-20. GROUND CONTROL BOX ASSEMBLY (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built Ma

2-100 510AJ 3121182SECTION 2 TURNTABLE25 1 Switch, Key Options:4360470 All Specs Except Australian Specs4360470 Australian Specs Belgium Built Machine

3121182 510AJ 2-101SECTION 2 TURNTABLEFIGURE 2-20. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-102 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-21.ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) 31333035343248454647441162415672341411101

3121182 510AJ 2-103SECTION 2 TURNTABLEFIGURE 2-21. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)ITEM # PART NUMBER QTY. DESCRIPTION REV.0271073

3121182 510AJ 1-7SECTION 1 FRAME’FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-104 510AJ 3121182SECTION 2 TURNTABLE37 4240032 12 Tie-Strap (Not Shown)38 4460234 12 Mount, Tie-Strap (Not Shown)39 1 Switch Options (Not Shown - Lo

3121182 510AJ 2-105SECTION 2 TURNTABLEFIGURE 2-21. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-106 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-22.HOODS INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N 1300006659)

3121182 510AJ 2-107SECTION 2 TURNTABLEFIGURE 2-22. HOODS INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N 1300006659)ITEM # PART NUMBER QTY. DESCRIP

2-108 510AJ 3121182SECTION 2 TURNTABLE19 3380445 1 Panel, Rubber20 3573024 1 Plate, Hinge Mounting21 3900232 3 Capscrew, Button Head 3/8in-16NC 1-1/4i

3121182 510AJ 2-109SECTION 2 TURNTABLEFIGURE 2-22. HOODS INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N 1300006659) (CONTINUED)ITEM # PART NUMBER

2-110 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-23.HOODS INSTALLATION (BELGIUM BUILT MACHINES S/N 1300006659 TO PRESENT & ROMANIAN BUILT MACHINES S

3121182 510AJ 2-111SECTION 2 TURNTABLEFIGURE 2-23. HOODS INSTALLATION (BELGIUM BUILT MACHINES S/N 1300006659 TO PRESENT & ROMANIAN BUILT MACHINES

2-112 510AJ 3121182SECTION 2 TURNTABLE16 3311505 2 Nut 5/16in - 18NC17 3311601 5 Nut 3/8in-16NC18 3311605 10 Locknut 3/8in-16NC19 1 Panel, Rubber Opti

3121182 510AJ 2-113SECTION 2 TURNTABLE45 A/R Insulation, Heat Shield Options:Not Required Caterpillar/Perkins Engine Machines Belgium Built Machines S

1-8 510AJ 3121182SECTION 1 FRAMEFIGURE 1-2.TIRE AND WHEEL DRIVE INSTALLATIONS

2-114 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-23. HOODS INSTALLATION (BELGIUM BUILT MACHINES S/N 1300006659 TO PRESENT & ROMANIAN BUILT MACHINES

3121182 510AJ 3-1SECTION 3BOOM

3-2 510AJ 3121182SECTION 3 BOOMFIGURE 3-1.TOWER/MID BOOMS AND CYLINDERS INSTALLATION

3121182 510AJ 3-3SECTION 3 BOOMFIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built Machi

3-4 510AJ 3121182SECTION 3 BOOM110 0961950 20 Bearing, Garmax111 Not Used112 3311605 6 Locknut 3/8in-16NC113 3312005 2 Locknut 5/8in-11NC114 3422568 6

3121182 510AJ 3-5SECTION 3 BOOM210C 1 Connector, Strain Relief Options:4460428 Belgium Built Machines Prior to S/N S/N 13000001334460968 Belgium Built

3-6 510AJ 3121182SECTION 3 BOOMFIGURE 3-2.MAIN BOOM INSTALLATION 12222322312613210110810510113310613211812412213310810111611711913310912311224

3121182 510AJ 3-7SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built Machines use S/Ns 13xxxxx

3-8 510AJ 3121182SECTION 3 BOOM221 4 Bushing Options:0961947 Belgium Built Machines Prior to S/N 13000068840962292 Belgium Built Machines S/N 13000068

3121182 510AJ 3-9SECTION 3 BOOMFIGURE 3-2. MAIN BOOM INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-9SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. WHEEL DRIVE INSTALLATIONS0

3-10 510AJ 3121182SECTION 3 BOOMFIGURE 3-3.MAIN BOOM ASSEMBLY

3121182 510AJ 3-11SECTION 3 BOOMFIGURE 3-3. MAIN BOOM ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built Machines use S/Ns 13xxxxxxxx

3-12 510AJ 3121182SECTION 3 BOOM149 3572448 2 Plate, Clamp150 3760115 2 Ring, Retaining151 to 152 Not Used153 3900283 4 Screw, Button Head 3/8in-16NC

3121182 510AJ 3-13SECTION 3 BOOMFIGURE 3-3. MAIN BOOM ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-14 510AJ 3121182SECTION 3 BOOMFIGURE 3-4.ROTATOR ASSEMBLY 131311815216111231491A1B10168171825GENUINE PARTS262827272728274

3121182 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 3121182SECTION 3 BOOMFIGURE 3-5.PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS

3121182 510AJ 3-17SECTION 3 BOOMFIGURE 3-5. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium B

3-18 510AJ 3121182SECTION 3 BOOM303 7023915 1 Valve, Relief 7012967 1 Seal Kit - 7023915 Valve304 7017452 1 Valve, Solenoid7017402 1 Seal Kit - 701745

3121182 510AJ 4-1SECTION 4PLATFORM

1-10 510AJ 3121182SECTION 1 FRAME33 to 200 Not UsedRef. TIRE AND WHEEL INSTALLATION OPTIONS0258028 Ref. 12 x 16.5 Pneumatic (ANSI/ANSI Export/CSA/Japa

4-2 510AJ 3121182SECTION 4 PLATFORMFIGURE 4-1.PLATFORM INSTALLATION 58910132012022032042052052053016102104C104B104A1051081051081071031101101061

3121182 510AJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. PLATFORM ASSEMBLY WITH GATERef. All

4-4 510AJ 3121182SECTION 4 PLATFORMRef. PLATFORM ASSEMBLY WITH DROP-BARRef. All Belgium Built Machines & Romanian Built Machines Prior to S/N E300

3121182 510AJ 4-5SECTION 4 PLATFORM104 1 Platform Console Box Assembly Options (Not Shown) (See Figure 4-2 for Breakdown):Without UGM0861512 Deutz Eng

4-6 510AJ 3121182SECTION 4 PLATFORM205 2920140 2 Worklight7016399 2 Bulb, Replacement (1 Per Worklight)206 4240099 10 Tie-Strap (Not Shown)207 2820035

3121182 510AJ 4-7SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-8 510AJ 3121182SECTION 4 PLATFORMFIGURE 4-2.PLATFORM CONSOLE ASSEMBLY 504502503501OPTIONAL GENERATORSWITCH LOCATED ONMOLDED PLATFORM PANEL384

3121182 510AJ 4-9SECTION 4 PLATFORMFIGURE 4-2. PLATFORM CONSOLE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: For Module (with/without U

4-10 510AJ 3121182SECTION 4 PLATFORM15 1 Cover Options:Use 1001110434 Deutz Engines - Belgium Built Machines S/N 1300006000 to S/N 1300006701 (was p/n

3121182 510AJ 4-11SECTION 4 PLATFORM47 4922666 1 Harness, Analyzer Cable (Not Shown - See Section 7 for Breakdown)48 1 Harness, Platform Box (See Sect

3121182 510AJ 1-11SECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-12 510AJ 3121182SECTION 4 PLATFORMRef. LIGHT COMPONENTS (OPTIONAL) Ref. Belgium Built Machines S/N 1300006000 to S/N 1300006701301A 4360336 1 Switch

3121182 510AJ 4-13SECTION 4 PLATFORMFIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-14 510AJ 3121182SECTION 4 PLATFORMFIGURE 4-3.CONTROLLER ASSEMBLY (LIFT AND SWING) 222119185936145876391110121A1C1B102103110104105106107111112

3121182 510AJ 4-15SECTION 4 PLATFORMFIGURE 4-3. CONTROLLER ASSEMBLY (LIFT AND SWING)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Original Equip

4-16 510AJ 3121182SECTION 4 PLATFORM103 7022808 1 Cap, Lift104 70002731 1 Boot105 70002732 4 Screw106 7022815 1 Bezel107 70002733 1 Adapter108 7000273

3121182 510AJ 4-17SECTION 4 PLATFORMFIGURE 4-3. CONTROLLER ASSEMBLY (LIFT AND SWING) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-18 510AJ 3121182SECTION 4 PLATFORMFIGURE 4-4.CONTROLLER ASSEMBLY (DRIVE & STEER) 20820820720920220220320320420421020520610612011817192016

3121182 510AJ 4-19SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (DRIVE & STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Original Eq

4-20 510AJ 3121182SECTION 4 PLATFORM105 70002726 1 Enclosure106 70002727 1 Handle Assembly (See Items 201-210 for Breakdown)107 70002728 1 Screw108 Us

3121182 510AJ 4-21SECTION 4 PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-12 510AJ 3121182SECTION 1 FRAMEFIGURE 1-3.DRIVE HUB/BRAKE ASSEMBLY (REAR)

4-22 510AJ 3121182SECTION 4 PLATFORMFIGURE 4-5.SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)

3121182 510AJ 4-23SECTION 4 PLATFORMFIGURE 4-5. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: No Longer

4-24 510AJ 3121182SECTION 4 PLATFORMFIGURE 4-5. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 5-1SECTION 5CYLINDER

5-2 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-1.AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N 1300003223)

3121182 510AJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N 1300003223)ITEM # PART NUMBER QTY.

5-4 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300003223 TO PRESENT & ROMANIAN BUILT M

3121182 510AJ 5-5SECTION 5 CYLINDERFIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300003223 TO PRESENT & ROMANIAN BUILT

5-6 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-3. LEVEL (PLATFORM) CYLINDER ASSEMBLY

3121182 510AJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LEVEL (PLATFORM) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Original Equipmen

3121182 510AJ 1-13SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. USAGE: USED BELGIUM BUILT MA

5-8 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-4.LIFT (JIB) CYLINDER ASSEMBLY

3121182 510AJ 5-9SECTION 5 CYLINDERFIGURE 5-4. LIFT (JIB) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684242 Ref. JIB LIFT CYLINDER ASS

5-10 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-5.LIFT (MAIN BOOM) CYLINDER ASSEMBLY

3121182 510AJ 5-11SECTION 5 CYLINDERFIGURE 5-5. LIFT (MAIN BOOM) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684244 Ref. MAIN LIFT CYLI

5-12 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-6.LIFT (TOWER BOOM) CYLINDER ASSEMBLY

3121182 510AJ 5-13SECTION 5 CYLINDERFIGURE 5-6. LIFT (TOWER BOOM) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684239 Ref TOWER LIFT CYL

5-14 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-7.MASTER CYLINDER ASSEMBLY

3121182 510AJ 5-15SECTION 5 CYLINDERFIGURE 5-7. MASTER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684241 Ref MASTER CYLINDER ASSEMBLY

5-16 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-8.STEER CYLINDER ASSEMBLY

3121182 510AJ 5-17SECTION 5 CYLINDERFIGURE 5-8. STEER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684246 Ref. STEER CYLINDER ASSEMBLY

1-14 510AJ 3121182SECTION 1 FRAME6D 7017092 1 Pin, Dowel6E 7017095 1 O-Ring6F 7024134 1 O-Ring7 7024130 1 Shaft, Input8 7024115 1 Gear, Sun9 7024131 1

5-18 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-9.TELESCOPE CYLINDER ASSEMBLY

3121182 510AJ 5-19SECTION 5 CYLINDERFIGURE 5-9. TELESCOPE CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684235 Ref. TELESCOPE CYLINDER AS

5-20 510AJ 3121182SECTION 5 CYLINDERFIGURE 5-9. TELESCOPE CYLINDER ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510 AJ 6-1SECTION 6HYDRAULIC

6-2 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-1.AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR TO S/N 1300000353) 17168510933224

3121182 510 AJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR TO S/N 1300000353)ITEM # PART NUMBER QT

6-4 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-2.AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300000353 TO S/N 1300003223) 112464

3121182 510 AJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300000353 TO S/N 1300003223)ITEM # PART

6-6 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300003223 TO PRESENT & ROMANIAN BUILT

3121182 510 AJ 6-7SECTION 6 HYDRAULICFIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300003223 TO PRESENT & ROMANIAN BUIL

3121182 510AJ 1-15SECTION 1 FRAMEFIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-8 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-4.DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR TO S/N 1300003476)

3121182 510 AJ 6-9SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR TO S/N 1300003476)ITEM # PART NUMBER QTY. DESC

6-10 510 AJ 3121182SECTION 6 HYDRAULIC39 2753602 1 Hose40 2753603 1 Hose41 2753585 1 Hose42 2753555 1 Hose43 2753597 1 Hose44 2753594 1 Hose45 2753595

3121182 510 AJ 6-11SECTION 6 HYDRAULICFIGURE 6-4. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR TO S/N 1300003476) (CONTINUED)ITEM # PART NUM

6-12 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-5.DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300003476 TO PRESENT & ROMANIAN BUILT MACHIN

3121182 510 AJ 6-13SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300003476 TO PRESENT & ROMANIAN BUILT MACH

6-14 510 AJ 3121182SECTION 6 HYDRAULIC44 2111212 2 Fitting, Straight45 4641281 1 Valve, CheckFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHI

3121182 510 AJ 6-15SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300003476 TO PRESENT & ROMANIAN BUILT MACH

6-16 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-6.STANDARD HYDRAULIC DIAGRAM

3121182 510 AJ 6-17SECTION 6 HYDRAULICFIGURE 6-6. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. STANDARD HYDRAULIC DIAGRAM27

1-16 510AJ 3121182SECTION 1 FRAMEFIGURE 1-4.DRIVE HUB/BRAKE ASSEMBLY (REAR)

6-18 510 AJ 3121182SECTION 6 HYDRAULIC40 2753566 1 Hose41 2753567 2 Hose42 2753568 1 Hose43 2753611 1 Hose44 2753569 2 Hose45 2753570 2 Hose46 2753571

3121182 510 AJ 6-19SECTION 6 HYDRAULICFIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-20 510 AJ 3121182SECTION 6 HYDRAULICFIGURE 6-7. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Diagrams with asterick

3121182 510AJ 7-1SECTION 7ELECTRICAL

7-2 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-1. ELECTRICAL DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: Diagrams with asterisks

3121182 510AJ 7-3SECTION 7 ELECTRICALRef. STANDARD ELECTRICAL DIAGRAMSRef. Note: For Module (with/without UGM) Identification, refer to Revision Log p

7-4 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-2.ELECTRICAL SCHEMATIC (WITHOUT UGM) (SEE FIGURE 7-1 FOR USAGE)

3121182 510AJ 7-5SECTION 7 ELECTRICAL 1870144 GNOTE: FOR GROUND MODULE IDENTIFICATION, REFER TO REVISION LOG PAGE A.

7-6 510AJ 3121182SECTION 7 ELECTRICAL

3121182 510AJ 7-7SECTION 7 ELECTRICAL 1870144 G

3121182 510AJ 1-17SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (REAR)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. USAGE: USED BELGIUM BUILT MA

7-8 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-3.ELECTRICAL SCHEMATIC (WITHOUT UGM) (SEE FIGURE 7-1 FOR USAGE)

3121182 510AJ 7-9SECTION 7 ELECTRICAL 1870191GNOTE: FOR GROUND MODULE IDENTIFICATION, REFER TO REVISION LOG PAGE A.

7-10 510AJ 3121182SECTION 7 ELECTRICAL

3121182 510AJ 7-11SECTION 7 ELECTRICAL 1870191G

7-12 510AJ 3121182SECTION 7 ELECTRICAL

3121182 510AJ 7-13SECTION 7 ELECTRICAL1870191G

7-14 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-4.ELECTRICAL SCHEMATIC (WITHOUT UGM) (SEE FIGURE 7-1 FOR USAGE)

3121182 510AJ 7-15SECTION 7 ELECTRICAL1870215 DNOTE: FOR GROUND MODULE IDENTIFICATION, REFER TO REVISION LOG PAGE A.

7-16 510AJ 3121182SECTION 7 ELECTRICAL

3121182 510AJ 7-17SECTION 7 ELECTRICAL1870215 D

1-18 510AJ 3121182SECTION 1 FRAME11 7000253 1 Thrustwasher12 7017067 12 Bolt 13 7017080 4 Pin, Dowell14 7000206 1 Coupling15 7024715 1 Spacer, Input16

7-18 510AJ 3121182SECTION 7 ELECTRICAL

3121182 510AJ 7-19SECTION 7 ELECTRICAL1870215 D

7-20 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-5.ELECTRICAL SCHEMATIC (WITH UGM) (SEE FIGURE 7-1 FOR USAGE)

3121182 510AJ 7-21SECTION 7 ELECTRICAL1001108879 - DNOTE: FOR GROUND MODULE IDENTIFICATION, REFER TO REVISION LOG PAGE A.

7-22 510AJ 3121182SECTION 7 ELECTRICAL

3121182 510AJ 7-23SECTION 7 ELECTRICAL1001108879 - D

7-24 510AJ 3121182SECTION 7 ELECTRICAL1001108879 - D

3121182 510AJ 7-25SECTION 7 ELECTRICALBAENGINECONNECTORYEL/RED 2-1-99 (16)WHT/YEL 48-3CDFNRED CAN HIBLK CAN LOBRN/WHT 47-8-1SEESHEET 1ZONE C5J1-11 ON

7-26 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-6. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM)514DRIVEORIENTATIONSWITCH617617A337338J5J6J7J2J2J1J8J3J

3121182 510AJ 7-27SECTION 7 ELECTRICALSTROBELIGHT338337418449706A706D419468466466606454452435434465467606A451450711J713E703B713G337701A701D701B701L701

3121182 510AJ 1-19SECTION 1 FRAMEFIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

7-28 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-6. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: For

3121182 510AJ 7-29SECTION 7 ELECTRICAL104 4460873 1 Connector - 35 Position (Black)4460871 A/R Socket, Female105 4460879 1 Connector, Male 2 Position4

7-30 510AJ 3121182SECTION 7 ELECTRICALRef. GROUND CONTROL BOX COMPONENTS301 to 324 Not Used325 4460426 A/R Connector, Strain Relief3520035 A/R Plug326

3121182 510AJ 7-31SECTION 7 ELECTRICAL337 1 Engine Harness Assembly (See Items 401-469 for Breakdown)4922522 Deutz Engines Belgium Built Machines Prio

7-32 510AJ 3121182SECTION 7 ELECTRICAL434 1 Receptacle, Female - 2 Position Options:4460890 Deutz Engine 4460890 Caterpillar/Perkins Engine (Belgium B

3121182 510AJ 7-33SECTION 7 ELECTRICALRef. GROUND CONTROL BOX WIRING DIAGRAM4933171 Ref. Deutz Engines Belgium Built Machines Prior to S/N 13000009819

7-34 510AJ 3121182SECTION 7 ELECTRICAL605 A/R Deutz EMR2 Engine Harness Components 605A 7027796 1 Deutz Engine Harness605B 4461052 1 Receptacle, Femal

3121182 510AJ 7-35SECTION 7 ELECTRICAL616 4923451 1 Harness, Glow Plugs (Used on p/n 2000338 Engine Only)(Belgium Built Machines S/N 1300001788 to Pre

7-36 510AJ 3121182SECTION 7 ELECTRICAL701A Cont’dSee Note 0275683/0275684/1001101915/1001101916 Installations (Note: Was p/n 0861782 which is no longe

3121182 510AJ 7-37SECTION 7 ELECTRICAL701G 1 Circuit Breaker Box Kit Options (All Installations except 0258303/0258304 Installations): 2902549 Without

1-20 510AJ 3121182SECTION 1 FRAMEFIGURE 1-5.DRIVE HUB ASSEMBLY (FRONT)

7-38 510AJ 3121182SECTION 7 ELECTRICALKIT, PLUG & SOCKET OPTIONS:Ref. Without Generator:See Note Ref. 0258303 Installation (Note: Purchase Individ

3121182 510AJ 7-39SECTION 7 ELECTRICAL702A 1 Plug, Male Options:4460205 110V ANSI & ANSI Export Specs4460233 220V ANSI & ANSI Export SpecsSee

7-40 510AJ 3121182SECTION 7 ELECTRICAL704J See Note 1 Plug, Male - 6 Position (Note: Not Available - Purchase Locally)See Note 6 Socket, Female(Note:

3121182 510AJ 7-41SECTION 7 ELECTRICAL712 4933308 1 Floodlights Harness Components 1/A712A 4460320 2 Plug, Male - 2 Position4460227 4 Pin, Male712B 49

7-42 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-7. HARNESS COMPONENTS INSTALLATION (WITH UGM)337338J5J6J7J2J2J1J8J3J1J8213327326328328328328213B254B254

3121182 510AJ 7-43SECTION 7 ELECTRICALSTROBELIGHT338337418706A419712J713E713G337228233265229232256257706D713G712J706A337338338A338A338B338C338B7087077

7-44 510AJ 3121182SECTION 7 ELECTRICALFIGURE 7-7. HARNESS COMPONENTS INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Note: For Mo

3121182 510AJ 7-45SECTION 7 ELECTRICAL107 4460225 4 Plug, Male - 6 Position4460226 18 Socket, Female108 4460225 1 Plug, Male - 6 Position4460227 5 Pin

7-46 510AJ 3121182SECTION 7 ELECTRICAL326 4460470 1 Nut, Terminal327 4460471 1 Locknut, Terminal328 0100048 A/R Grease, Dielectric329 4460526 1 Connec

3121182 510AJ 7-47SECTION 7 ELECTRICAL338 1001105637 1 Valve Harness Assembly B338A 4460880 12 DIN Connector338B 4460320 2 Connector, Female - 2 Posi

3121182 510AJ 1-21SECTION 1 FRAMEFIGURE 1-5. DRIVE HUB ASSEMBLY (FRONT)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. USAGE: BELGIUM BUILT MACHINES USE

7-48 510AJ 3121182SECTION 7 ELECTRICAL456 2902443 1 Receptacle Kit (Deutz Engine Only)4461071 8 Socket, Female (Gold)4461072 1 Receptacle 8 Position w

3121182 510AJ 7-49SECTION 7 ELECTRICAL604 70003767 A/R Caterpillar/Perkins Engine Harness Components 604A 70020808 1 Connector 23 Position4460871 16 S

7-50 510AJ 3121182SECTION 7 ELECTRICAL615A 4460224 1 Receptacle, Female - 6 Position4460226 8 Socket, Female616 4923451 1 Harness, Glow Plugs (Deutz E

3121182 510AJ 7-51SECTION 7 ELECTRICAL701A Cont’dSee Note 0275683/0275684/1001101915/1001101916 Installations (Note: Was p/n 0861782 which is no longe

7-52 510AJ 3121182SECTION 7 ELECTRICAL701G 1 Circuit Breaker Box Kit Options (All Installations except 0258303/0258304 Installations): 2902549 Without

3121182 510AJ 7-53SECTION 7 ELECTRICALRef. KIT, PLUG & SOCKET OPTIONS:Ref. Without Generator:See Note 0258303 Installation (Note: Purchase Individ

7-54 510AJ 3121182SECTION 7 ELECTRICAL702B 1 Receptacle, Female Options:4460134 1 110V (ANSI & CSA Specs)4460701 1 220V (ANSI & CSA Specs)See

3121182 510AJ 7-55SECTION 7 ELECTRICAL704G See Note 1 Connector, Strain Relief (Note: Not Available - Purchase Locally)704H 4922925 1 Harness, Generat

7-56 510AJ 3121182SECTION 7 ELECTRICAL711 See Note 1 Soft-Touch System Harness (Note: Not Available for Purchase)711A 1060341 A/R Cable, Electrical -

3121182 510AJ 8-1SECTION 8DECALS

3121182 510AJ AREVISION LOGNOTE: The 510AJ may be manufactured by JLG Industries in the countries of Belgium or Romania. Refer to the SerialNumber Ta

1-22 510AJ 3121182SECTION 1 FRAME10 7017097 1 Spacer, Thrust11 7017094 2 Plug, Pipe12 7024108 1 Plug, Pressure13 Not Used14 7024133 12 Bolt 1/4in-20NC

8-2 510AJ 3121182SECTION 8 DECALSFIGURE 8-1.DECALS INSTALLATION - ANSI SPEC618244101373A361423337373C26103427263152645HYDRAULICOIL TANK REF.1816174393

3121182 510AJ 8-3SECTION 8 DECALSFIGURE 8-1. DECALS INSTALLATION - ANSI SPECITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built Machines use S

8-4 510AJ 3121182SECTION 8 DECALS23 1701509 1 Decal - Manual24 1702300 4 Decal - Tie Down /Lift25 1701500 4 Decal - Tie Down /Lift26 1701529 4 Decal-

3121182 510AJ 8-5SECTION 8 DECALS373 0272582 Ref. Model Designation Decal Installation 2373A 1705487 2 Decal - 510AJ373B 1705669 4 Decal - Max Tire L

8-6 510AJ 3121182SECTION 8 DECALSFIGURE 8-2.DECALS INSTALLATION - ANSI EXPORT SPECS 61824410136142333726103427263152645HYDRAULICOIL TANK REF.181617439

3121182 510AJ 8-7SECTION 8 DECALSFIGURE 8-2. DECALS INSTALLATION - ANSI EXPORT SPECSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built Machin

8-8 510AJ 3121182SECTION 8 DECALS6 A/R Decal - Legend Options:Not Required Brazil/Chinese/Japanese/Korean Spec1703808 CSA/Latin American Spec Belgium

3121182 510AJ 8-9SECTION 8 DECALS13 cont’d Korean Spec1703996 Belgium Built Machines Prior to S/N 13000026011707058 Belgium Built Machines S/N 1300002

8-10 510AJ 3121182SECTION 8 DECALS14 cont’d Latin American Spec1704112 Belgium Built Machines Prior to S/N 13000027751707049 Belgium Built Machines S/

3121182 510AJ 8-11SECTION 8 DECALS37 A/R Decal - LPG GasNot Required 0 Non-Dual Fuel Machines1701543 1 Dual Fuel Machines38 A/R Decal - LP Gas Liquid

3121182 510AJ 1-23SECTION 1 FRAMEFIGURE 1-5. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

8-12 510AJ 3121182SECTION 8 DECALSFIGURE 8-3.DECALS INSTALLATION - CE & AUSTRALIAN SPECS 1851244268102645HYDRAULICOIL TANK REF.181617439173A24173B

3121182 510AJ 8-13SECTION 8 DECALSFIGURE 8-3. DECALS INSTALLATION - CE & AUSTRALIAN SPECSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Bui

8-14 510AJ 3121182SECTION 8 DECALS2 1 Decal - Danger/Warning Options:1705332 Australian Spec 1705410 Dutch Spec1705412 French Spec1705409 German Spec1

3121182 510AJ 8-15SECTION 8 DECALS34 cont’d French Spec1693292 Belgium Built Machines Prior to S/N 13000001781705828 Belgium Built Machines S/N 130000

8-16 510AJ 3121182SECTION 8 DECALSFIGURE 8-3. DECALS INSTALLATION - CE & AUSTRALIAN SPECS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 510AJThe following list will service one machine (built to current production per date

9-2 510AJ 3121182SECTION 9 RECOMMENDED SERVICE PARTS STOCKMODEL 510AJThe following list will service one machine (built to current production per date

3121182 510AJ 10-1SECTION 10 SPECIAL OPTIONSmNote: This list is to accommodate machines ordered with special equipment. Options may not be applicable

10-2 510AJ 3121182SECTION 10 SPECIAL OPTIONSCont’d Ref. Clear Sky (Telematic) Kit (Includes Installation, Decals, User Guide and Manual 3128499) 10011

3121182 510AJ 10-3SECTION 10 SPECIAL OPTIONSRef. Filter KitsRef. Boom HydraulicAir Filter Kit Options:1001109694 Ref. Belgium Built Machines Prior to

1-24 510AJ 3121182SECTION 1 FRAMEFIGURE 1-6.DRIVE HUB ASSEMBLY (FRONT)

10-4 510AJ 3121182SECTION 10 SPECIAL OPTIONSRef. Oil Cooler Installation0275004 Ref. Deutz Engines Belgium Built Machines Prior to S/N 130000415010010

3121182 510AJ 10-5SECTION 10 SPECIAL OPTIONSRef. SkyGuard Components1001149560 Ref. SkyGuard Complete Installation Kit (ADE/Non-UGM Equipped Machines)

10-6 510AJ 3121182SECTION 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 Number3121182 510AJ 11-1SECTION 11 PART NUMBER INDEX0010578 ... 8-150010

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 510AJ 3121182SECTION 11 PART NUMBER INDEX0641520 ... 2-150641

PagePart Number PagePart Number PagePart NumberPagePart Number3121182 510AJ 11-3SECTION 11 PART NUMBER INDEX1001103977 ... 6-7100110

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 510AJ 3121182SECTION 11 PART NUMBER INDEX1671013 ... 3-3167

PagePart Number PagePart Number PagePart NumberPagePart Number3121182 510AJ 11-5SECTION 11 PART NUMBER INDEX2170106 ... 6-172170

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 510AJ 3121182SECTION 11 PART NUMBER INDEX3128499 ... 10-1, 10-23160260

PagePart Number PagePart Number PagePart NumberPagePart Number3121182 510AJ 11-7SECTION 11 PART NUMBER INDEX4061046 ... 1-384061

3121182 510AJ 1-25SECTION 1 FRAMEFIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. USAGE: USED ON BELGIUM BUILT MACH

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 510AJ 3121182SECTION 11 PART NUMBER INDEX4461197 ...7-37, 7-52, 7-544461198 .

PagePart Number PagePart Number PagePart NumberPagePart Number3121182 510AJ 11-9SECTION 11 PART NUMBER INDEX70000797 ... 1-3370000

PagePart Number PagePart Number PagePart NumberPagePart Number11-10 510AJ 3121182SECTION 11 PART NUMBER INDEX7011016 ... 2-87701

PagePart Number PagePart Number PagePart NumberPagePart Number3121182 510AJ 11-11SECTION 11 PART NUMBER INDEX7022326 ...1-29, 1-337022328

PagePart Number PagePart Number PagePart NumberPagePart Number11-12 510AJ 3121182SECTION 11 PART NUMBER INDEX7026866 ... 2-24702

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

1-26 510AJ 3121182SECTION 1 FRAME11 7000253 1 Thrustwasher12 7017067 12 Bolt 13 7017080 4 Pin, Dowel14 7000206 1 Coupling15 7024715 1 Spacer, Input16

3121182 510AJ 1-27SECTION 1 FRAMEFIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-28 510AJ 3121182SECTION 1 FRAMEFIGURE 1-7.DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N 1300002249) 25262728293023224242973141373

3121182 510AJ 1-29SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N 1300002249)ITEM # PART NUMBER QTY. DESCRIPTION

1-30 510AJ 3121182SECTION 1 FRAME43 7022371 1 Washer, Support44 Not Used45 7022328 1 Seal Kit (Includes Items 2,3,7,26,28,30,34,36,38,39 and 42)FIGURE

3121182 510AJ 1-31SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N 1300002249) (CONTINUED)ITEM # PART NUMBER QTY.

B 510AJ 3121182REVISION LOGSeptember 1, 2010 - Revised Manual (Edited to B/M 0010717 Revision 19)April 4, 2011 - Revised Manual (Edited to B/M 0010717

1-32 510AJ 3121182SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO PRESENT & ROMANIAN BUILT MACHINES S/N

3121182 510AJ 1-33SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO PRESENT & ROMANIAN BUILT MACHINES S/N

1-34 510AJ 3121182SECTION 1 FRAME42 to 44 Not Used45 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)FIGURE 1-8. DRIVE MOTOR ASSEMBL

3121182 510AJ 1-35SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO PRESENT & ROMANIAN BUILT MACHINES S/N

1-36 510AJ 3121182SECTION 1 FRAMEFIGURE 1-9.DRIVE VALVES INSTALLATIONS

3121182 510AJ 1-37SECTION 1 FRAMEFIGURE 1-9. DRIVE VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. DRIVE VALVES INSTALLATION0272320

1-38 510AJ 3121182SECTION 1 FRAME124 4711400 2 Flatwasher 1/4in Thin125 4751500 8 Flatwasher 5/16in Regular126 4751600 A/R Flatwasher 3/8in RegularRef

3121182 510AJ 2-1SECTION 2TURNTABLE

2-2 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-1.CONTROL VALVE INSTALLATION

3121182 510AJ 2-3SECTION 2 TURNTABLEFIGURE 2-1. CONTROL VALVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. VALVES INSTALLATIONS0271197 Re

3121182 510AJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

3121182 510AJ 2-5SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.4641176 Ref. PROPORTIONAL VALVE AS

2-6 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-3.TURNTABLE AND SWING DRIVE INSTALLATIONS TOREMOTE11011063710510610810910111210210310710411211158

3121182 510AJ 2-7SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. SWING DRIVE INSTA

2-8 510AJ 3121182SECTION 2 TURNTABLE111 3311605 2 Locknut 3/8in-16NC112 4751600 4 Flatwasher 3/8in Regular1001102695 Ref. DRIVE ORIENTATION INSTALLATI

3121182 510AJ 2-9SECTION 2 TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-10 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-4.SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT FOR BELGIUM BUILT MACHINES PRIOR TO S/N 1300006701) 14

3121182 510AJ 2-11SECTION 2 TURNTABLEFIGURE 2-4. SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT FOR BELGIUM BUILT MACHINES PRIOR TO S/N 1300006701)ITEM # P

2-12 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-5.SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT FOR BELGIUM BUILT MACHINES PRIOR TO S/N 1300006701 & ORI

3121182 510AJ 2-13SECTION 2 TURNTABLEFIGURE 2-5. SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT FOR BELGIUM BUILT MACHINES PRIOR TO S/N 1300006701 & O

ii 510AJ 3121182FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 3 - BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-6.SWING BEARING & ROTATION BOX ASSEMBLY 10514213010210312511013410911411211513910210312712812

3121182 510AJ 2-15SECTION 2 TURNTABLEFIGURE 2-6. SWING BEARING & ROTATION BOX ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. SWING BEARING

2-16 510AJ 3121182SECTION 2 TURNTABLE131 1 Bearing, Turntable Options:7026054 0440255 BearingUse 1001104627 0440272 Bearing (Bearing Kit, Turntable p/

3121182 510AJ 2-17SECTION 2 TURNTABLEFIGURE 2-6. SWING BEARING & ROTATION BOX ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-18 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-7.CATERPILLAR ENGINE INSTALLATION (WITH UGM) 2432452442092354016166262623961141762407165354753767

3121182 510AJ 2-19SECTION 2 TURNTABLE231231212239206214223225220212216224213212203233221218223TO WATERSEPARATERTO FUELTANK VENTLINEFUELRETURNTO FUELPU

2-20 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. Belgium Built

3121182 510AJ 2-21SECTION 2 TURNTABLE38 3311405 11 Locknut 1/4in-20NC 39 3311505 6 Locknut 5/16in-18NC40 3311605 22 Locknut 3/8in-16NC41 3311805 4 Loc

2-22 510AJ 3121182SECTION 2 TURNTABLE83 2720615 1.5ft/0.46mHose84 1001101408 1 Fan85 8405006 1 Clamp, Gear86 2151212 2 Fitting, 45°87 2170316 1 Fittin

3121182 510AJ 2-23SECTION 2 TURNTABLE224 2720271 8ft/2.4m Hose 225 2750532 7ft/2.1m Hose226 3311405 13 Locknut 1/4in-20NC227 3312005 1 Locknut 5/8in-1

3121182 510AJ iiiTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.7-6 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . . . 7-

2-24 510AJ 3121182SECTION 2 TURNTABLE310 7026867 1 Thermostat7026866 1 Gasket (Fits Between Regulator & Engine Block)7026868 1 Gasket (Fits Betwee

3121182 510AJ 2-25SECTION 2 TURNTABLEFIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-26 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-8.2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM) (OPTIONAL) 103105102101MOUNTED O

3121182 510AJ 2-27SECTION 2 TURNTABLEFIGURE 2-8. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM) (OPTIONAL)ITEM # PART NUMBER QTY. DES

2-28 510AJ 3121182SECTION 2 TURNTABLE9B (cont’d) 4460027 1 Receptacle, Double Twist Lock (110V Box)70000124 1 Receptacle, Double (220V Box)70000125 1

3121182 510AJ 2-29SECTION 2 TURNTABLEFIGURE 2-8. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM) (OPTIONAL) (CONTINUED)ITEM # PART NUM

2-30 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-9.DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N 1300000981)

3121182 510AJ 2-31SECTION 2 TURNTABLEFIGURE 2-9. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N 1300000981)ITEM # PART NUMBER QTY. DE

2-32 510AJ 3121182SECTION 2 TURNTABLE30 1 Battery (Wet)Use 8008750 Prior to S/N 1300000238 (was p/n 0400075)8008750 S/N 1300000238 to S/N 130000098131

3121182 510AJ 2-33SECTION 2 TURNTABLE127 1 Engine, Deutz Options:2000190 Prior to S/N 13000003532000217 S/N 1300000353 to S/N 1300000981128 2060025 1

iv 510AJ 3121182FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS

2-34 510AJ 3121182SECTION 2 TURNTABLE162 4846567 1 Motor Mount Weldment163 4846683 1 Engine Tray Weldment164 4891600 2 Flatwasher 3/8in HardenedRef. E

3121182 510AJ 2-35SECTION 2 TURNTABLE217 7020026 1 Dipstick 7020403 1 Seal, Ring1 Tube, Dipstick Options:70001002 Tube for p/n 2000217See Note Tube fo

2-36 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-10.DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981 TO PRESENT & ROMANIAN BUILT MACH

3121182 510AJ 2-37SECTION 2 TURNTABLE404413406402410407415311710924630133022TO INJECTOR PUMPVENTLINE11112017261918224328TO FUELPUMP111911114201523

2-38 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981 TO PRESENT & ROMANIAN BUILT MA

3121182 510AJ 2-39SECTION 2 TURNTABLE27A Cont’d 7012974 1 Cartridge without Coil (4641108 Valve)7010543 1 Seal Kit - 7012974 Cartridge 7012941 1 Cartr

2-40 510AJ 3121182SECTION 2 TURNTABLE214 4 Bolt M10 x 25mm Options:0701012 Belgium Built Machines S/N 1300000981 to S/N 13000017880771012 Belgium Buil

3121182 510AJ 2-41SECTION 2 TURNTABLE233B Use 7027041 1 Cable (Battery - to Ground) (was p/n 7016837)233C 7016820 1 Cable (Auxilliary Relay to Starter

2-42 510AJ 3121182SECTION 2 TURNTABLE260 1 Bracket, Motor Mount Options:260A 4846567 All Machines with Generator Option4846567 All Belgium Built Machi

3121182 510AJ 2-43SECTION 2 TURNTABLERef. ENGINE COMPONENTS2000273 Ref. Belgium Built Machines S/N 1300000981 to S/N 1300001788 (F3M2011 Tier II)20003

3121182 510AJ 1-1SECTION 1 FRAME

2-44 510AJ 3121182SECTION 2 TURNTABLE422 7027795 1 Module, EMR2423 7027769 2 Connector, Radiator424 70001181 1 Valve (Not Shown - Located behind oil f

3121182 510AJ 2-45SECTION 2 TURNTABLEFIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981 TO PRESENT & ROMANIAN BUILT MA

2-46 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-11.2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

3121182 510AJ 2-47SECTION 2 TURNTABLEFIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref

2-48 510AJ 3121182SECTION 2 TURNTABLE9 cont’d 2460056 220V/50Hz Assembly (Belgium Built Machines S/N 1300000731 to S/N 1300006619)1001100321 220V/50Hz

3121182 510AJ 2-49SECTION 2 TURNTABLE9D 1 Pulley Options:3580276 110V/60Hz3580134 110V/50Hz3580134 220V/50Hz7027887 1 Key, Woodruff10 3290505 1 Locknu

2-50 510AJ 3121182SECTION 2 TURNTABLE1001115411 Ref. 110V/50Hz Generator A1001115412 Ref. 220V/50Hz Generator A101 4360336 1 Switch, Toggle102 4740397

3121182 510AJ 2-51SECTION 2 TURNTABLEFIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-52 510AJ 3121182SECTION 2 TURNTABLEFIGURE 2-12.PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM)

3121182 510AJ 2-53SECTION 2 TURNTABLE STARTERBATTERYAUX.PWR.PUMPAUX.PWR.RELAYGLOWPLUGRELAYSTARTRELAYGRD.+257939C39A39D39E39B62283890104105106107901