JLG 510AJ Parts Manual (3121182) – PDF DOWNLOAD (Eng)

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JLG 510AJ Parts Manual (3121182) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 510AJ Parts Manual (3121182) – PDF DOWNLOAD 

SECTION 1 - FRAME...........................................................................................................................................................................................................................................  9
	FIGURE 1-1. AXLE AND STEERING INSTALLATION.............................................................................................................................................................................................................. 10
	FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS.......................................................................................................................................................................................................... 14
	FIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR)............................................................................................................................................................................................................. 18
	FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (REAR)............................................................................................................................................................................................................. 22
	FIGURE 1-5. DRIVE HUB ASSEMBLY (FRONT).................................................................................................................................................................................................................. 26
	FIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT).................................................................................................................................................................................................................. 30
	FIGURE 1-7. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES) (Prior to SN 1300002249)...................................................................................................................................................................... 34
	FIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (SN 1300002249 to Present, SN E300000100 through E300001114)...................................................................................................... 36
	FIGURE 1-9. DRIVE VALVES INSTALLATIONS.................................................................................................................................................................................................................. 38
SECTION 2 - TURNTABLE....................................................................................................................................................................................................................................... 41
	FIGURE 2-1. CONTROL VALVE INSTALLATION.................................................................................................................................................................................................................. 42
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY................................................................................................................................................................................................................. 44
	FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS..................................................................................................................................................................................................... 46
	FIGURE 2-4. SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT FOR BELGIUM BUILT MACHINES) (Prior to SN 1300006701)............................................................................................................................................... 50
	FIGURE 2-5. SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT FOR BELGIUM BUILT MACHINES AND ORIGINAL EQUIPMENT FOR BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (Prior to SN 1300006701, SN 1300006701 to Present, SN E300000100 through E300001114).... 52
	FIGURE 2-6. SWING BEARING AND ROTATION BOX ASSEMBLY (ORIGINAL EQUIPMENT)................................................................................................................................................................................ 54
	FIGURE 2-7. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT)............................................................................................................................................................................... 58
	FIGURE 2-8. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT)............................................................................................................................................................................... 60
	FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (WITH UGM).................................................................................................................................................................................................. 62
	FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES) (Prior to SN 1300000981)................................................................................................................................................................ 70
	FIGURE 2-11. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (SN 1300000981 to Present, SN E300000100 through E300001114)................................................................................................ 76
	FIGURE 2-12. PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM)............................................................................................................................................................. 84
	FIGURE 2-13. PERKINS ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN) (WITHOUT UGM)................................................................................................................................................................. 92
	FIGURE 2-14. PERKINS ENGINE INSTALLATION (WITH UGM).....................................................................................................................................................................................................100
	FIGURE 2-15. PISTON PUMP ASSEMBLY.......................................................................................................................................................................................................................108
	FIGURE 2-16. AUXILIARY PUMP ASSEMBLY....................................................................................................................................................................................................................112
	FIGURE 2-17. TANK INSTALLATIONS.........................................................................................................................................................................................................................116
	FIGURE 2-18. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)..................................................................................................................................................................................................120
	FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (WITH UGM).....................................................................................................................................................................................................124
	FIGURE 2-20. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)........................................................................................................................................................................................128
	FIGURE 2-21. HOODS INSTALLATION (BELGIUM BUILT MACHINES) (Prior to SN 1300006659).......................................................................................................................................................................132
	FIGURE 2-22. HOODS INSTALLATION (BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (SN 1300006659 to Present, SN E300000100 through E300001114).......................................................................................................136
	FIGURE 2-23. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM) (OPTIONAL)..................................................................................................................................................................140
	FIGURE 2-24. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)...................................................................................................................................................................................144
	FIGURE 2-25. 2500W GENERATOR INSTALLATION - PERKINS MACHINES (OPTIONAL).................................................................................................................................................................................148
	FIGURE 2-26. 7500W GENERATOR INSTALLATION - 50HZ (DEUTZ ENGINE MACHINES WITHOUT UGM)....................................................................................................................................................................152
	FIGURE 2-27. 7500W GENERATOR INSTALLATION - 50HZ (PERKINS ENGINE MACHINES WITHOUT UGM)..................................................................................................................................................................156
	FIGURE 2-28. 7500W GENERATOR INSTALLATION - 50HZ (PERKINS ENGINE MACHINES WITH UGM).....................................................................................................................................................................160
SECTION 3 - BOOM............................................................................................................................................................................................................................................165
	FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION..................................................................................................................................................................................................166
	FIGURE 3-2. MAIN BOOM INSTALLATION......................................................................................................................................................................................................................170
	FIGURE 3-3. MAIN BOOM ASSEMBLY..........................................................................................................................................................................................................................174
	FIGURE 3-4. ROTATOR ASSEMBLY............................................................................................................................................................................................................................178
	FIGURE 3-5. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS...........................................................................................................................................................................................180
SECTION 4 - PLATFORM........................................................................................................................................................................................................................................183
	FIGURE 4-1. PLATFORM INSTALLATION.......................................................................................................................................................................................................................184
	FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY...................................................................................................................................................................................................................188
	FIGURE 4-3. CONTROLLER ASSEMBLY (LIFT AND SWING)........................................................................................................................................................................................................194
	FIGURE 4-4. CONTROLLER ASSEMBLY (DRIVE AND STEER).......................................................................................................................................................................................................198
	FIGURE 4-5. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)...................................................................................................................................................................................................202
	FIGURE 4-6. SKYGLAZIER INSTALLATION - WITHOUT LSS.......................................................................................................................................................................................................204
	FIGURE 4-7. SKYGLAZIER INSTALLATION - WITH LSS..........................................................................................................................................................................................................206
	FIGURE 4-8. SKYWELDER INSTALLATION - 50HZ (Prior to SN 1300001851)......................................................................................................................................................................................208
	FIGURE 4-9. WELDER ASSEMBLY.............................................................................................................................................................................................................................210
SECTION 5 - CYLINDER........................................................................................................................................................................................................................................213
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES) (Prior to SN 1300003223)............................................................................................................................................................214
	FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (SN 1300003223 to Present, SN E300000100 through E300001114)............................................................................................216
	FIGURE 5-3. LEVEL (PLATFORM) CYLINDER ASSEMBLY..........................................................................................................................................................................................................218
	FIGURE 5-4. LIFT (JIB) CYLINDER ASSEMBLY................................................................................................................................................................................................................220
	FIGURE 5-5. LIFT (MAIN BOOM) CYLINDER ASSEMBLY..........................................................................................................................................................................................................222
	FIGURE 5-6. LIFT (TOWER BOOM) CYLINDER ASSEMBLY.........................................................................................................................................................................................................224
	FIGURE 5-7. MASTER CYLINDER ASSEMBLY....................................................................................................................................................................................................................226
	FIGURE 5-8. STEER CYLINDER ASSEMBLY.....................................................................................................................................................................................................................228
	FIGURE 5-9. TELESCOPE CYLINDER ASSEMBLY.................................................................................................................................................................................................................230
SECTION 6 - HYDRAULIC.......................................................................................................................................................................................................................................233
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES) (Prior to SN 1300000353)............................................................................................................................................................234
	FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES) (SN 1300000353 through 1300003222)..................................................................................................................................................236
	FIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (SN 1300003223 to Present, SN E300000100 through E300001114)............................................................................................238
	FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES) (Prior to SN 1300003476)...................................................................................................................................................................240
	FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES AND ROMANIAN BUILT MACHINES) (SN 1300003476 to Present, SN E300000100 through E300001114)...................................................................................................244
	FIGURE 6-6. STANDARD HYDRAULIC DIAGRAM..................................................................................................................................................................................................................246
	FIGURE 6-7. HYDRAULIC DIAGRAM LIST......................................................................................................................................................................................................................250
SECTION 7 - ELECTRICAL......................................................................................................................................................................................................................................251
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.....................................................................................................................................................................................................................252
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM)...............................................................................................................................................................................................254
	FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITH UGM)..................................................................................................................................................................................................268
SECTION 8 - DECALS..........................................................................................................................................................................................................................................281
	FIGURE 8-1. DECALS INSTALLATION - ANSI SPEC.............................................................................................................................................................................................................282
	FIGURE 8-2. DECALS INSTALLATION - ANSI EXPORT SPECS.....................................................................................................................................................................................................286
	FIGURE 8-3. DECALS INSTALLATION - CE AND AUSTRALIAN SPECS...............................................................................................................................................................................................292
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.................................................................................................................................................................................................................297
	FIGURE 9-1. MODEL 510AJ STANDARD PARTS..................................................................................................................................................................................................................298
	FIGURE 9-2. MODEL 510AJ VARIABLE PARTS..................................................................................................................................................................................................................300
SECTION 10 - SPECIAL OPTIONS................................................................................................................................................................................................................................301
	FIGURE 10-1. SPECIAL OPTIONS............................................................................................................................................................................................................................302
PART NUMBER INDEX...........................................................................................................................................................................................................................................307

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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