JLG 510AJ Parts Manual

4 (4)

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

REVISION LOG

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

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

510AJ

3121294

SECTION 1

FRAME

3121294

510AJ

1-1

SECTION 1 FRAME

FIGURE 1-1.AXLE AND STEERING INSTALLATION

105

110

101

106

111

114

216

	108	103
		103
106		102
106		101
		101

112

109 101 104

113

218

213

201

206

	212201
220	205
220	210
	214

218A

218

212

208

201

211

107

201

204

215

203

207

216

207

217

202

209 215

201

204

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

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

202	203

201

115

114	204

101

117

127		120

128102

108

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)	C/C
			(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)	C/C
			(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

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

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

150

151	7B
151	7D
152
153	7C
154	7D
GENUINE PARTS	7D
	7

6F				7A
6F
6E		12
6D		12
6D
6C			2
6J	6	6G
6J	6	6		1
6G		6		1
6G		6B
				1H
13				1F
13		13
		13
6A
			1	1E
			1
5A				1G
				1G
4
				1N
5		3G		1D
		3E		1D
		3E
				1C
		3		1B
		3A	1
			1
		3B		1A
16		3C

8	3D
8	3C
	3C
15	3F
	3F	14
		14
11
	3B

111

110

112

121

102

122

123

119

104

103

106

103

106 17

	101
	116
	115
	109
	118
	117
120	107
120
	108
114
113	105
	105
	28
	29

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.

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510AJ

1-11

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT)

6F	3E

6E 12

6	6G	3	1
6J		3A
6J
6G		6
6G		6B	3B
			3B
		16	3C
			3C
		8	3D
13		8	3C
13		13	3C
		13
6A		15	3F
			3F
		11
		7B	3B
		7B
5A		7D
		7C
		7D
		7
4
		7A	1
		7A
5
		2

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)
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 to 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
12	7017067	12	Bolt
13	7017080	4	Pin, Dowel
14	7000206	1	Coupling

3121294

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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

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3121294

SECTION 1 FRAME

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

ITEM #	PART NUMBER	QTY.	DESCRIPTION	REV.

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1-15

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

		28
	24	25
	24	26
		26

20 5

	29
	39	37
5		36
5		35
	6	35
2	6
2

9 12

11 4

31	1
	1
32
	33
	34

18	30

19 3

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)

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1-17

SECTION 1 FRAME

FIGURE 1-6.DRIVE VALVES AND FRAME SHIELDS INSTALLATION

201	205
202

203

206

116 125

123D 123E

123A

123F

123

105

125

123B 123C

123

123C

106

126

103

118

126 116

204

206203

122

124

101

104

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

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1-19

SECTION 1 FRAME

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

ITEM #	PART NUMBER	QTY.	DESCRIPTION	REV.

1-20

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SECTION 2 TURNTABLE

3121294

510AJ

2-1

SECTION 2 TURNTABLE

FIGURE 2-1.MAIN CONTROL VALVE AND ALARM INSTALLATIONS

4 10

106 105

104	102
	103

101 106

104

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
6	Not 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
9	Not 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