JLG 510AJ Parts Manual (3121294) – PDF DOWNLOAD (ENG)

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JLG 510AJ Parts Manual (3121294) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 510AJ Parts Manual (3121294) – PDF DOWNLOAD

SECTION 1 - FRAME.........................................................................................  9
	FIGURE 1-1. AXLE AND STEERING INSTALLATION............................................................ 10
	FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION......................................................... 12
	FIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR)........................................................... 16
	FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT)................................................................ 20
	FIGURE 1-5. DRIVE MOTOR ASSEMBLY...................................................................... 22
	FIGURE 1-6. DRIVE VALVES AND FRAME SHIELDS INSTALLATION............................................... 24
SECTION 2 - TURNTABLE..................................................................................... 27
	FIGURE 2-1. MAIN CONTROL VALVE AND ALARM INSTALLATIONS................................................ 28
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY............................................................... 30
	FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS................................................... 32
	FIGURE 2-4. SWING MOTOR ASSEMBLY...................................................................... 34
	FIGURE 2-5. SWING BEARING AND ROTATION BOX ASSEMBLY (ORIGINAL EQUIPMENT).............................. 36
	FIGURE 2-6. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT)............................. 38
	FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION........................................................... 40
	FIGURE 2-8. DEUTZ ENGINE INSTALLATION................................................................. 48
	FIGURE 2-9. PISTON PUMP ASSEMBLY...................................................................... 56
	FIGURE 2-10. AUXILIARY PUMP ASSEMBLY.................................................................. 60
	FIGURE 2-11. TANK INSTALLATIONS....................................................................... 62
	FIGURE 2-12. GROUND CONTROL BOX ASSEMBLY (FIBERGLASS BOX)............................................. 66
	FIGURE 2-13. GROUND CONTROL BOX ASSEMBLY (STEEL BOX).................................................. 70
	FIGURE 2-14. LIGHT INSTALLATIONS...................................................................... 74
	FIGURE 2-15. HOODS INSTALLATION....................................................................... 78
	FIGURE 2-16. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)........................... 82
	FIGURE 2-17. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)................................. 86
	FIGURE 2-18. 4000W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (SN E300001114 through E300002603).... 90
	FIGURE 2-19. 4000W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (SN E300002604 to Present)............ 94
	FIGURE 2-20. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (110V-50HZ).................. 98
	FIGURE 2-21. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (220V-50HZ)..................102
SECTION 3 - BOOM..........................................................................................105
	FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION................................................106
	FIGURE 3-2. MAIN BOOM INSTALLATION....................................................................110
	FIGURE 3-3. MAIN BOOM ASSEMBLY........................................................................114
	FIGURE 3-4. ROTATOR ASSEMBLIES........................................................................118
	FIGURE 3-5. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS.........................................120
SECTION 4 - PLATFORM......................................................................................123
	FIGURE 4-1. PLATFORM INSTALLATION (WITHOUT SKYGUARD)..................................................124
	FIGURE 4-2. PLATFORM INSTALLATION (WITH SKYGUARD).....................................................128
	FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (WITHOUT SKYGUARD)..............................................132
	FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (WITH SKYGUARD).................................................136
	FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) (SN E300001114 through E300001831)...................140
	FIGURE 4-6. CONTROLLER ASSEMBLY (LIFT AND SWING) (SN E300001832 to Present)...........................142
	FIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE AND STEER) (SN E300001114 through E300001831)..................146
	FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (SN E300001832 to Present)..........................148
	FIGURE 4-9. CROSS RAIL INSTALLATION...................................................................150
	FIGURE 4-10. SKYGUARD SYSTEM INSTALLATION.............................................................152
	FIGURE 4-11. SKYGLAZIER INSTALLATION - WITH LSS (AUSTRALIAN SPECS)....................................154
	FIGURE 4-12. SKYWELDER INSTALLATION - 50HZ............................................................156
	FIGURE 4-13. WELDER ASSEMBLY..........................................................................158
SECTION 5 - CYLINDER......................................................................................161
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY............................................................162
	FIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY..................................................164
	FIGURE 5-3. LIFT (JIB) CYLINDER ASSEMBLY..............................................................166
	FIGURE 5-4. LIFT (MAIN BOOM) CYLINDER ASSEMBLY........................................................168
	FIGURE 5-5. LIFT (TOWER BOOM) CYLINDER ASSEMBLY.......................................................170
	FIGURE 5-6. MASTER CYLINDER ASSEMBLY..................................................................172
	FIGURE 5-7. STEER CYLINDER ASSEMBLY...................................................................174
	FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY...............................................................176
SECTION 6 - HYDRAULIC.....................................................................................179
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM............................................................180
	FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM...................................................................182
	FIGURE 6-3. STANDARD HYDRAULIC DIAGRAM................................................................186
	FIGURE 6-4. HYDRAULIC DIAGRAM LIST....................................................................190
SECTION 7 - ELECTRICAL....................................................................................191
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST...................................................................192
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION...........................................................194
SECTION 8 - DECALS........................................................................................209
	FIGURE 8-1. DECAL INSTALLATION - ANSI EXPORT SPEC (ENGLISH LANGUAGE)..................................210
	FIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS (OTHER LANGUAGES)..................................212
	FIGURE 8-3. DECALS INSTALLATION - AUSTRALIAN AND CE SPECS.............................................216
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK...............................................................219
	FIGURE 9-1. MODEL 510AJ STANDARD PARTS................................................................220
	FIGURE 9-2. MODEL 510AJ VARIABLE PARTS................................................................222
SECTION 10 - SPECIAL OPTIONS..............................................................................223
	FIGURE 10-1. SPECIAL OPTIONS..........................................................................224
PART NUMBER INDEX.........................................................................................229

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