JLG 510AJ Parts Manual

Illustrated Parts Manual

Model

510AJ

S/N E300001114

TO PRESENT

3121294

August 30, 2013

REVISION LOG

NOTE: The 510AJ may be manufactured by JLG Industries in the countries of Belgium or Romania. Refer to the Serial Number Tag to determine the country of manufacture. The country of manufacture may be determined by the Serial Number. Boom Lifts manufactured in Belgium will have a prefix of 13 (i.e. 13XXXXXXXX) and Boom Lifts manufactured in Romania will have a prefix of E3 (i.e. E3XXXXXXXX).

NOTE: Is the Parts Manual you are viewing correct for the machine that you are ordering parts for? See Below:

Belgium Built Machines - All Machines - Use Parts Manual p/n 3121182 Romanian Built Machines Prior to S/N E300001114 - Use Parts Manual P/N 3121182 Romanian Built Machines S/N E300001114 to Present - Use Parts Manual P/N 3121294

NOTE: Machines with S/N E300001068 is also built to the same specs as Romanian Built Machines S/N E300001114 to Present - Use Parts Manual p/n 3121294.

March 25, 2013 - Original Issue (Edited to 1001142991 Revision A)

May 17, 2013 - Original Issue (Edited to 1001142991 Revision B)

August 30, 2013 - Original Issue (Edited to 1001142991 Revision B)

3121294 510AJ A

REVISION LOG

B 510AJ 3121294

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 TIRE AND WHEEL DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 DRIVE HUB/BRAKE ASSEMBLY (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4 DRIVE HUB ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 DRIVE VALVES AND FRAME SHIELDS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-18

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 MAIN CONTROL VALVE AND ALARM INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 MAIN CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-5 SWING BEARING & ROTATION BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-6 CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-7 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-8 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-9 AUXILIARY PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2-10 TANK INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2-11 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2-12 LIGHT INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

2-13 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 TOWER/MID BOOMS AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAIN BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-4 ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-5 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS. . . . . . . . . . . . . . . . . . 3-16

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM CONSOLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 CONTROLLER ASSEMBLY (LIFT AND SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LIFT (JIB) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 LIFT (MAIN BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 LIFT (TOWER BOOM) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-8 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

3121294 510AJ i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 DRIVE HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 DECAL INSTALLATION - ANSI EXPORT SPEC (ENGLISH LANGUAGE) . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION - ANSI EXPORT SPECS (OTHER LANGUAGES) . . . . . . . . . . 8-6

8-3 DECALS INSTALLATION - AUSTRALIAN & CE SPECS . . . . . . . . . . . . . . . . . . . . . . . . 8-10

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . . . 9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii 510AJ 3121294

SECTION 1

FRAME

3121294 510AJ 1-1

SECTION 1 FRAME

113

101 104

109

110 101

107

103

102

101

112

106

108

111

105

218

216

220

201 206

213

203

207

215

201

204

207

217

202

209

215

201

204

212

201 205

214

210

218

212

208

218A

201 211

216

FIGURE 1-1.AXLE AND STEERING INSTALLATION

1-2 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001139087 Ref. OSCILLATING AXLE INSTALLATION D

101 0100011 A/R Compound, Locking 102 0100019 A/R Primer, Locking 103 0641814 8 Bolt 1/2in-13NC x 1-3/4in 104 0642012 1 Bolt 5/8in-11NC x 1-1/2in 105 0791506 4 Screw, 5/16in-18NC x 3/4in 106 0961950 2 Bushing 107 1684465 2 Lockout Cylinder Assembly (See Section 5 for Breakdown): 108 3422592 1 Pin, Axle Pivot 109 3841258 1 Keeper, Pin 110 4641265 1 Lockout Valve Assembly 111 4740229 1 Thrustwasher 112 4891800 8 Flatwasher, 1/2in Hardened 113 1001098130 1 Axle 114 4071101 1 Shim

1001139935 Ref. STEERING INSTALLATION C

201 0100011 A/R Compound, Locking 202 0440271 2 Thrustwasher 203 0440291 2 Bushing 204 0641606 16 Bolt 3/8in-16NC x 3/4in 205 0681607 2 Bolt 3/8in-16NC x 7/8in 206 0681820 4 Bolt 1/2in-13NC x 2-1/2in (Grade 8) 207 3020029 A/R Grease, Bearing (Not Shown) 208 3312008 2 Nut, Flanged 5/8in-11NC 209 3780182 2 O-Ring 210 3841520 2 Keeper 211 3900255 2 Screw, Shoulder 212 4740086 4 Thrustwasher 213 4891800 4 Flatwasher 1/2in Hardened 214 1001116867 2 Pin 215 1001139141 2 Kingpin 216 1001139645 2 Spindle 217 1001139476 2 Bearing 218 1001139892 2 Tie-Rod

218A 1001139943 2 Bushing for 1001139892 Tie-Rod (1 Per Tie-Rod)

219 Not Used 220 1001143434 1 Steer Cylinder Assembly (See Section 5 for Breakdown)

3121294 510AJ 1-3

SECTION 1 FRAME

202

203

201

204

115

114

127

102 108

128

120

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

1-4 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0275854 Ref. WHEEL DRIVE INSTALLATION C

101 0100011 A/R Compound, Locking 102 0100019 A/R Compound, Locking

103 to 106 Not Used

107 0681810 4 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Front Axle) 108 0682014 12 Bolt 5/8in-11NC x 1-3/4in (Grade 8)

109 to 110 Not Used

111 2780267 2 Drive Hub/Brake Assembly (Rear) (See Figure 1-3 For

Breakdown)

112 2780268 2 Drive Hub/Brake Assembly (Front - Not Shown) (See Figure

1-4 For Breakdown) 113 Not Used 114 3160348 4 Drive Motor Assembly (See Figure 1-5 for Breakdown) 115 3300106 36 Lugnut 116 Not Used 117 3311801 4 Nut 1/2in-13NC (Rear Axle)

118 to 119 Not Used

120 3960526 4 Gasket

121 to 126 Not Used

127 4891800 8 Flatwasher 1/2in Hardened 128 4892000 24 Flatwasher 5/8in Hardened

Ref. TIRE AND WHEEL INSTALLATIONS 0270091 Ref. 12 x 16.5 Pneumatic (Available on ANSI Export Specs Only) C 0270092 Ref. 12 x 16.5 Foam-Filled (Available on All Specs) C 0270653 Ref. 12 x 16.5 Foam-Filled Non-Marking (Available on All Specs) B 0271995 Ref. 14 x 17.5 Pneumatic (Available on ANSI Export Specs Only) B 0271998 Ref. 14 x 17.5 Foam-Filled (Available on All Specs) B 0258031 Ref. 33/1550 x 16.5 Foam-Filled (Available on All Specs) B

Use 1001148863 2 12 x 16.5 Pneumatic Right Side (was p/n 0270074) B/B Use 1001148864 2 12 x 16.5 Pneumatic Left Side (was p/n 0270075) B/B Use 1001148865 2 12 x 16.5 Foam-Filled Right Side (See Note) (was p/n 0270076) C/C Use 1001148869 2 12 x 16.5 Foam-Filled Right Side (Non-Marking) (See Note)

(was p/n 0270654) Use 1001148866 2 12 x 16.5 Foam-Filled Left Side (See Note) (was p/n 0270077) C/C Use 1001148870 2 12 x 16.5 Foam-Filled Left Side (Non-Marking) (See Note)

(was p/n 0270655) Use 1001148873 2 14 x 17.5 Pneumatic Right Side (was p/n 0271993) B/B Use 1001148874 2 14 x 17.5 Pneumatic Left Side (was p/n 0271994) B/B Use 1001148875 2 14 x 17.5 Foam-Filled Right Side (See Note) (was p/n 0271997) B/B Use 1001148876 2 14 x 17.5 Foam-Filled Left Side (See Note) (was p/n 0271996) B/B

0258011 2 33/1550 x 16.5 Foam-Filled Right Side D 0258012 2 33/1550 x 16.5 Foam-Filled Left Side D

C/C

3121294 510AJ 1-5

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: Assemblies may require ballast/foam filling to

manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

201 1702740 1 Decal - 90PSI (Pneumatic Tires Only) 202 1 Tire Options:

4520216 12 x 16.5 NHS 4520240 12 x 16.5 Non-Marking 4520259 14 x 17.5 NHS 4520217 33/1550 x 16.5 NHS

203 1 Valve Stem Options (Pneumatic Only):

1 4640113 Pneumatic Tires Only

8786514 33/1550 x 16.5 Foam-Filled Tire & Wheel Assy Only 4641122 1 Foam Filled Only

1001149953 1 Cap, Valve Stem (Foam Filled Only)

204 1 Rim, Wheel Options:

Use 1001147274 16.5 x 9.75 (Use with 12 x 16.5 Tires) (was p/n 4860213)

4860179 16.5 x 12 (Use with 33/1550 x 16.5 Tires)

Use 1001146397 17.5 x 10.5 (Use with 14 x 17.5 Tires) (was p/n 4860198)

1-6 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 1-7

SECTION 1 FRAME

105

121

102

119

122

123

104

151

150

152 153 154

103

101

109

107

108

114 113

116

115

118

117

120

1A1B1C

1N1G1E1F1H

163B3F3C3D

3A3E3G

106

111

110

112

GENUINE PARTS

FIGURE 1-3.DRIVE HUB/BRAKE ASSEMBLY (REAR)

1-8 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780267 Ref. DRIVE HUB/BRAKE ASSEMBLY D

1 See Note 1 Spindle/Housing Assembly (Note: Not Available - Individual

Components)

1A 7017059 1 Spindle 1B 7001998 1 Seal 1C 7010429 1 Cone, Bearing (Includes Item 1D) 1D 7010429 1 Cup, Bearing (Includes Item 1C) 1E 7000257 1 Cup, Bearing 1F 7000258 1 Cone, Bearing 1G 7007601 1 Housing/Ring Gear 1H 7000232 1 Thrustwasher

1I 7000229 1 Ring, Retaining

1J Not Used

1K Not Used

1L Not Used 1M Not Used 1N 7007640 9 Stud, Wheel

2 7000246 1 Gear, Internal

3 7024712 1 Carrier Assembly 3A Use 7024712 1 Carrier 3B Use 7024712 6 Ring, Retaining 3C Use 7024712 A/R Bearing, Needle 3D Use 7024712 3 Thrustwasher 3E Use 7024712 3 Shaft, Planet 3F Use 7024712 3 Gear, Planet 3G Use 7024712 3 Rollpin

4 7000248 1 Ring Gear

5 7000230 1 O-Ring 5A 7017070 1 O-Ring

6 Use 70001349 1 Cover Assembly (was p/n 7017090) 6A Use 70001349 1 Spacer, Thrust (was p/n 7017097) 6B Use 70001349 1 Plate, Cover (was p/n 7017091) 6C Use 70001349 1 O-Ring (was p/n 7017095) 6D Use 70001349 1 Rod, Disconnect (was p/n 7017092) 6E Use 70001349 1 Cap, Disengage (was p/n 7017093) 6F Use 70001349 2 Bolt (was p/n 0641404) 6G 7017094 1 Plug, Pipe 6H Not Used

6I See Note 4 Rivet (Note: Not Available - Purchase Locally)

6J See Note 1 Plate, ID (Note: Not Available for Purchase)

7 1 Input Shaft Assembly 7A 7024714 1 Shaft 7B 7000261 1 Ring, Retaining 7C 7000262 1 Spring 7D 7000263 2 Spacer, Thrust

8 7024713 1 Gear, Sun

9 to 10 Not Used

11 7000253 1 Thrustwasher

3121294 510AJ 1-9

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

12 7017067 12 Bolt 13 7017080 4 Pin, Dowell 14 7000206 1 Coupling 15 7024715 1 Spacer, Input 16 7024716 1 Spacer, Input 17 7024182 1 Brake Assembly (See Items 101-154 for Breakdown)

18 to 26 Not Used

27 7024705 1 O-Ring 28 7024717 2 Rod, Threaded 29 7024718 2 Nut 1/2in-13NC 30 7000731 1 Gasket

7024182 Ref. BRAKE ASSEMBLY

101 7024189 1 Shaft 102 Use 7024182 1 Housing 103 Use 7024193 2 Plate, Friction 104 Use 7024193 1 Plate, Pressure 105 7000731 1 Gasket 106 Use 7024193 2 Plate, Outer 107 See Note 1 Gasket (Note: Use Item 150, 153 or 154.) 108 7024191 1 Cylinder 109 7024192 1 Piston 110 See Note 1 Bearing, Ball (Note: Use Item 154) 111 See Note 1 Ring, Retaining (Note: Use Item 154) 112 See Note 1 Seal, Shaft (Note: Use Item 154) 113 See Note 6 Capscrew (Note: Not Available - Purchase Locally) 114 See Note 6 Lockwasher (Note: Not Available - Purchase Locally) 115 Use 7024194 1 O-Ring 116 Use 7024194 1 Ring, Back-up 117 Use 7024194 1 O-Ring 118 Use 7024194 1 Ring, Back-up 119 7024190 2 Pin, Dowel 120 See Note 1 Plug (Note: Not Available - Purchase Locally) 121 See Note 2 Plug (Note: Not Available - Purchase Locally) 122 Use 7024196 10 Spring Kit (Natural) 123 Use 7024196 2 Spring Kit (Blue)

124 to 149 Not Used

150 7024194 1 Seal Kit, Brake (Includes Items 105, 107 & 115-118) 151 Use 7024196 1 Spring Kit, Brake (Includes 12 Natural Colored Springs Item 122)

(was p/n 7024195)

152 7024196 1 Spring Kit, Brake (Includes 12 Natural Colored Springs Item 122 &

2 Blue Colored Springs Item 123) 153 7024193 1 Friction Disc Kit, Brake (Includes Items 103, 104, 106 & 107) 154 7024197 1 Bearing Kit - 7024182 Brake (Includes Items 107 & 110-112)

1-10 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 1-11

SECTION 1 FRAME

1B1C1D1N1G1E1F

7A7D7D7C7B11158163B3F3C3D3C3B33A

6G6J6E6F12

FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT)

1-12 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780268 Ref. DRIVE HUB ASSEMBLY C

1 See Note 1 Spindle/Housing Assembly (Note: Not Available - Individual

Components)

1I 7000229 1 Ring, Retaining

1J to 1M Not Used

1N 7007640 9 Stud, Wheel

2 7000246 1 Gear, Internal

4 7000248 1 Ring Gear

5 7000230 1 O-Ring 5A 7017070 1 O-Ring

6I See Note 4 Rivet (Note: Not Available - Purchase Locally)

6J See Note 1 Plate, ID (Note: Not Available for Purchase)

7 1 Input Shaft Assembly 7A 7024714 1 Shaft 7B 7000261 1 Ring, Retaining 7C 7000262 1 Spring 7D 7000263 2 Spacer, Thrust

8 7024713 1 Gear, Sun

9 to 10 Not Used

11 7000253 1 Thrustwasher 12 7017067 12 Bolt 13 7017080 4 Pin, Dowel 14 7000206 1 Coupling

3121294 510AJ 1-13

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

15 7024715 1 Spacer, Input 16 7024716 1 Spacer, Input

1-14 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 1-15

SECTION 1 FRAME

413401938

303433

313231

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

1-16 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160348 Ref. DRIVE MOTOR ASSEMBLY (4WD) B

1 7022302 2 Bearing, Journal

2 7007446 1 Pin

3 7007438 2 Ring, Retaining

4 7022305 1 Swashplate

5 See Note 2 Pin (Note: Not Available for Purchase)

6 Use 7022328 1 Gasket

7 7023907 1 Cylinder Block Kit (Includes Items 7A & 9-17) 7A Use 7023907 1 Block, Cylinder

8 7023908 1 Plate, Valve

9 7021277 1 Guide, Slipper Retainer

10 7021275 3 Pin, Slipper Hold Down 11 Use 7023907 9 Piston Assembly 12 7021276 1 Retainer, Hold Down Pin 13 7022310 1 Retainer, Slipper 14 7022311 1 Ring, Retaining 15 7022312 1 Spring 16 7024868 1 Washer 17 7022314 1 Retainer, Spring 18 7023910 1 Shaft 19 7007439 1 Ring, Retaining 20 70000797 1 Cap, End - Axial 21 7022368 5 Screw 22 7021249 1 Bearing, Needle 23 2220886 1 Plug (Includes Item 24) 24 Use 7022328 1 O-Ring 25 2220883 1 Plug (Includes Item 26) 26 Use 7022328 1 O-Ring 27 2220888 2 Plug (Includes Item 28) 28 Use 7022328 2 O-Ring 29 7022372 1 Seat, Spring 30 Use 3160348 1 Housing 31 2220883 2 Plug (Items Item 32) 32 Use 7022328 2 O-Ring 33 2220886 1 Plug (Items Item 34) 34 Use 7022328 1 O-Ring 35 Use 7022328 1 O-Ring 36 Use 7022328 1 Ring, Seal 37 7024854 1 Piston, Servo (Includes Items 35 & 36) 38 7007437 1 Bearing 39 7022326 1 Spring 40 Use 7022328 1 Seal, Lip 41 7022371 1 Washer, Support

42 to 49 Not Used

50 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)

3121294 510AJ 1-17

SECTION 1 FRAME

202

201

203

205

123

123C

123A 123F

123E

125

116

123

123B

105

125

123D

10624126

103

118

126

116

206

101

104

124

122

203

206

204

FIGURE 1-6.DRIVE VALVES AND FRAME SHIELDS INSTALLATION

1-18 510AJ 3121294

SECTION 1 FRAME

FIGURE 1-6. DRIVE VALVES AND FRAME SHIELDS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0275854 Ref. DRIVE VALVES INSTALLATIONS C

101 0100011 A/R Compound, Locking 102 Not Used 103 0363012 2 Bar, Clamping 104 0641420 2 Bolt 1/4in-20NC x 2-1/2in 105 0641560 3 Bolt 5/16in-18NC x 7-1/2in 106 0641618 4 Bolt 3/8in-16NC x 2-1/4in

107 to 115 Not Used

116 3311505 A/R Locknut 5/16in-18NC 117 Not Used 118 3340911 4 Rubber, Clamp

119 to 121 Not Used

122 4641155 1 Valve, Junction Manifold B 123 4641510 1 Flow Divider Valve Assembly D

123A 7023917 1 Valve, Cartridge (Flow Divider)

7021625 1 Seal Kit - 7023917 Flow Divider Cartridge

123B 7023934 2 Valve, Cartridge (Flow Divider)

7021655 2 Seal Kit - 7023934 Flow Divider Cartridge

123C 7022397 6 Valve, Cartridge (Check)

7022399 6 Seal Kit - 7022397 Check Cartridge

123D 7021639 2 Valve, Cartridge (Check)

7017496 2 Seal Kit - 7021639 Check Cartridge (was p/n 2900756) 123E 7024881 1 Piston, Pilot 123F 70000781 1 Lockdown Kit

124 4711400 2 Flatwasher 1/4in Thin 125 4751500 6 Flatwasher 5/16in Regular 126 4751600 A/R Flatwasher 3/8in Regular

1001140666 Ref. FRAME SHIELDS INSTALLATION C

201 0100011 A/R Compound, Locking 202 4 Bolt 3/8in-16NC Options:

0641606 Bolt 3/8in-16NC x 3/4in

0641612 Bolt 3/8in-16NC x 1-1/2in

203 4751600 4 Flatwasher 3/8in Regular 204 1001140381 1 Shield, Frame (Rear) 205 1001140404 1 Shield, Frame (Front) 206 3340860 4 Pad, Rubber

3121294 510AJ 1-19

SECTION 1 FRAME

FIGURE 1-6. DRIVE VALVES AND FRAME SHIELDS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-20 510AJ 3121294

SECTION 2

TURNTABLE

3121294 510AJ 2-1

SECTION 2 TURNTABLE

1 4

1 5

104

101 104

102 103

105

106

FIGURE 2-1.MAIN CONTROL VALVE AND ALARM INSTALLATIONS

2-2 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-1. MAIN CONTROL VALVE AND ALARM INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001141804 Ref. VALVES INSTALLATIONS B

1 0100011 A/R Compound, Locking

2 to 3 Not Used

4 0641607 4 Bolt 3/8in-16NC x 7/8in 5 0651405 3 Bolt 1/4in-24NF x 5/8in 6Not Used 7 2120209 1 Pressure Filter Assembly

2120210 Element, Filter

7020020 1 Indicator

70000934 1 O-Ring, Filter Bowl 8 4751400 3 Flatwasher 1/4in Regular 9Not Used

10 4711600 4 Flatwasher 3/8in Thin 11 Not Used 12 1001138771 1 Main Control Valve Assembly (See Figure 2-2 for Breakdown)

1001142264 Ref. ALARM INSTALLATION C

101 0100011 A/R Compound, Locking 102 0100048 A/R Sealant, Silicone 103 0140044 1 Alarm/Harness Assembly 104 0641405 3 Bolt 1/4in-20NC x 5/8in 105 1320136 1 Clamp 106 4711400 3 Flatwasher 1/4in Thin

3121294 510AJ 2-3

SECTION 2 TURNTABLE

13 17

17 18

16 18

14 17

222116

181718

15 17

12 17

171111

24525

FIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

2-4 510AJ 3121294

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