JLG 510AJ Parts Manual

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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

SECTION 2 TURNTABLE

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001138771 Ref. PROPORTIONAL VALVE ASSEMBLY C

1 7012975 1 Cartridge, Check

7012540 1 Seal Kit - 7012975 Cartridge

2 70003787 2 Cartridge

7010543 2 Seal Kit - 70003787 Cartridge

3 70002972 1 Cartridge, Flow Regulator

7010543 1 Seal Kit - 70002972 Cartridge

4 7017440 3 Cartridge, Load Shuttle

7017441 3 Seal Kit - 7017440 Cartridge

5 10837580 2 Cartridge, Load Shuttle

7010543 2 Seal Kit - 10837580 Cartridge

6 7021611 1 Cartridge (Proportional Dump)

7012518 1 Seal Kit - 7021611 Cartridge

7 7023971 1 Cartridge, Relief (Telescope)

7012998 1 Seal Kit - 7023971 Cartridge

8 7021613 1 Cartridge, Relief (Lower Lift)

7012998 1 Seal Kit - 7021613 Cartridge

9 7017422 1 Cartridge, Relief (Steer)

7012998 1 Seal Kit - 7017422 Cartridge

10 7017421 1 Cartridge, Relief (Upper Lift)

7012998 1 Seal Kit - 7017421 Cartridge

11 7017423 1 Cartridge, Relief (Swing)

7012998 1 Seal Kit - 7017423 Cartridge

12 7023922 1 Cartridge without Coil (Upper Lift)

7017402 1 Seal Kit - 7023922 Cartridge

13 7023914 1 Cartridge without Coil (Swing)

7017402 1 Seal Kit - 7023914 Cartridge

14 7017410 1 Cartridge without Coil (Proportional Dump)

7012967 1 Seal Kit - 7017410 Cartridge

15 7017433 1 Cartridge without Coil (Steer)

7017402 1 Seal Kit - 7017433 Cartridge

16 7017454 2 Cartridge without Coil (Lower Lift & Telescope)

7012903 2 Seal Kit - 7017454 Cartridge 17 70002386 7 Coil 18 70003788 4 Coil 19 70003789 1 Coil 20 Not Used 21 See Note 2 Orifice (Note: Not Available for Purchase) 22 7017406 5 Plug 23 7024844 1 Plug 24 See Note 3 Plug (Note: Not Available for Purchase) 25 See Note 2 Plug (Note: Not Available for Purchase)

3121294 510AJ 2-5

SECTION 2 TURNTABLE

113

112

101

103

102

105

108

109

115

110

106

111

107

114

116

112

101

104

4 1

FIGURE 2-3.TURNTABLE AND SWING DRIVE INSTALLATIONS

2-6 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. SWING DRIVE INSTALLATIONS

0273358 Ref. Perfection Gear Dohi Version D

Ref. Perfection Gear Jing Wei Version A

1 0100019 A/R Compound, Locking 2 1 Swing Bearing and Rotation Box Assembly Options (See Figure

2-5 for Breakdown):

0440272 Perfection Gear Dohi Version

1001153016 Perfection Gear Jing Wei Version 3 3931832 2 Bolt 1/2in-13NC x 2in 4 0682040 18 Bolt 5/8in-11NC x 5in (Grade 8) 5 0682048 24 Bolt 5/8in-11NC x 6in (Grade 8) 6 2160001 2 Fitting, Grease 7 1001104850 1 Swing Motor Assembly (See Figure 2-4 for Breakdown) 8 4740171 2 Flatwasher 1/2in Special 9 4892000 42 Flatwasher 5/8in Hardened

1001102695 Ref. DRIVE ORIENTATION INSTALLATION D

101 0100011 A/R Compound, Locking 102 0641406 1 Bolt 1/4in-20NC x 3/4in 103 0641606 2 Bolt 3/8in-16NC x 3/4in 104 88261039 2 Screw 3/8in-16NC x 2in 105 1320041 1 Clamp 106 3311005 2 Locknut #10 107 3311405 1 Locknut 1/4in-20NC 108 3931010 2 Screw #10-24 x 5/8in 109 4360517 1 Switch, Proximity 110 4711000 2 Flatwasher #10 Regular 111 4711400 1 Flatwasher 1/4in Thin 112 4711600 4 Flatwasher 3/8in Thin 113 Use 1001145163 2 Spacer (was p/n 7116691 & 1001114757) 114 1001102526 1 Cam 115 1001102527 1 Bracket, Switch 116 4740120 2 Flatwasher, Special

3121294 510AJ 2-7

SECTION 2 TURNTABLE

12 12A

44857

FIGURE 2-4.SWING MOTOR ASSEMBLY

2-8 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001104850 Ref. SWING MOTOR ASSEMBLY A

1 See Note 5 Bolt (Note: Not Available for Purchase) 2 7004035 1 Cover, End 3 7023318 1 Seal, Commutator 4 7004036 5 O-Ring 5 Use 7024453 1 Commutator 6 7024453 1 Commutator & Ring Assembly (Includes Items 5) 7 7024379 1 Manifold 8 70002206 1 Rotor Set 9 7024380 1 Plate, Wear

10 70002207 1 Link, Drive 11 Not Used 12 70000088 1 Shaft, Coupling

12A 70000089 1 Key

13 7024381 1 Bushing, Inner 14 7004043 1 Thrustwasher 15 7004044 1 Bearing, Thrust 16 7004049 1 Seal, Inner Shaft 17 7004045 1 Ring, Backup 18 See Note 1 Housing (Note: Not Available - Purchase Complete Motor) 19 7024390 1 Bearing 20 7004047 1 Seal, Outer Shaft

21 to 24 Not Used

25 7024389 1 Seal Kit (Includes Items 3, 4, 16, 17 & 20)

3121294 510AJ 2-9

SECTION 2 TURNTABLE

105

142

130

102

103

125

110

134

109

114

112

115

139

102

103

127

128

129

144

106

120 121

122

132

143

135

126

140 141

136 137 138

123

118

124

117 119

113

133

108

104

101

131

150

151

GENUINE PARTS

FIGURE 2-5.SWING BEARING & ROTATION BOX ASSEMBLY

2-10 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-5. SWING BEARING & ROTATION BOX ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. SWING BEARING & ROTATION BOX ASSEMBLIES

0440272 Ref. Perfection Gear Dohi Version E

1001153016 Ref. Perfection Gear Jing Wei Version B

101 4891500 2 Flatwasher 5/16in Hardened 102 7026042 2 Cup, Bearing 103 7026043 2 Cone, Bearing 104 0681610 8 Bolt 3/8in-16NC x 1-1/4in (Grade 8) 105 0641808 2 Bolt 1/2in-13NC x 1in 106 0641810 2 Bolt 1/2in-13NC x 1-1/4in 107 0641520 2 Bolt 5/16in-18NC x 2-1/2in 108 See Note 1 Plug 1/8in (Note: Not Available - Purchase Locally) 109See Note 1Plug (Note: Not Available - Purchase Locally) 110 Use 7026060 1 Seal, Oil 111 Not Used 112See Note 2Cap (Note: Not Available - Purchase Complete Assembly) 113 See Note 1 Fitting, Grease (Note: Not Available - Purchase Locally) 114 7026044 1 Bushing, Reducer 115 7027358 1 Fitting, Grease 116 Not Used 117 7026045 1 Cup, Bearing 118 7026046 1 Ring, Grease 119 7026047 1 Cone, Bearing 120 7026048 1 Cup, Bearing 121 7026049 1 Cone, Bearing 122 7026050 1 Worm-Gear 123 7026051 1 Pinion, Output 124 7026052 1 Spacer, Washer 125See Note 1Housing (Note: Not Available - Purchase Complete Assem-

bly)

126 7026053 1 Cover, Gear 127 Use 7026059 A/R Shim, Brown (.010in) 128 Use 7026059 A/R Shim, Clear (.0075in) 129 Use 7026059 A/R Shim, Blue (.005in) 130 Use 7026059 A/R Shim, Yellow (.020in) 131 1 Bearing, Turntable Options:

Use 1001104627 Perfection Gear Dohi Version (Bearing Kit, Turntable p/n

1001104627 includes bearing & hardware to mount bearing/ rotation box assembly to machine) (was p/n 70000042)

70004158 Perfection Gear Jing Wei Version 132 Use 7026060 1 O-Ring 133 7026055 1 Cap, Gear 134 7027354 1 Cap, Worm 135 70000681 8 Screw #6-32 x 3/8in 136 Use 7026059 A/R Shim, Natural (.0075) 137 Use 7026059 A/R Shim, Blue (.005) 138 Use 7026059 A/R Shim, Green (.003) 139 7026057 1 Worm, Ground 140 Use 7026059 A/R Shim, Blue (.005)

3121294 510AJ 2-11

SECTION 2 TURNTABLE

FIGURE 2-5. SWING BEARING & ROTATION BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

141 Use 7026059 A/R Shim, Yellow (.020) 142 7027356 1 Adapter, Motor 143 Use 7026060 1 Seal, Face 144 Use 7026059 A/R Shim, Green (.003)

145 to 149 Not Used

150 7026060 1 Seal Kit (Includes Items 110, 132 & 143) 151 7026059 1 Shim Kit (Includes Items 127-130, 136-138, 140-141 & 144)

2-12 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-5. SWING BEARING & ROTATION BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-13

SECTION 2 TURNTABLE

031

128

291563931796098339855

38593237353

3161069

110

141

791

37013744

13370

132547

823363457137436

111

131

133

134

101

109

140

143

105

138

145

146

104

127

137

138

28138

814

160

132

142

130

129

139

107

139

116

FIGURE 2-6.CATERPILLAR ENGINE INSTALLATION

2-14 510AJ 3121294

SECTION 2 TURNTABLE

136

112

144

106

114

124

121

112

117

125

103

113

128

138

112

103

138

122

119

124

TO WATER

SEPARATER

TO FUEL

TANK

VENT

LINE

FUEL

RETURN

TO FUEL

PUMP

120

102

112

STARTER

BATTERY

AUX.PWR.

PUMP

GRD.

94C

94A

94D

94B

AUX.

PWR.

RELAY

83477

57513

86214

308

315

314

313

317

138

128

32532

306

331

326

329

3121294 510AJ 2-15

SECTION 2 TURNTABLE

FIGURE 2-6. CATERPILLAR ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001141999 Ref. CATERPILLAR ENGINE ASSEMBLY A

1 0080181 1 Adaptor, Pump Mounting Plate 2 0080201 1 Elbow, Rubber 3 0100011 A/R Compound, Locking 4 0340041 2 Band, Air Cleaner Mounting 5 0340046 2 Band, Muffler Mounting 6 0630569 9 Bolt M14 x 30mm 7 0641406 8 Bolt 1/4in-20NC x 3/4in 8 0641408 3 Bolt 1/4inin-20NC x 1in

9 0641410 2 Bolt 1/4in-20NC x 1-1/4in 10 0641506 8 Bolt 5/16in-18NC x 3/4in 11 0641507 6 Bolt 5/16in-18NC x 7/8in 12 0641609 5 Bolt 3/8in-16NC x 1-1/8in 13 0641610 39 Bolt 3/8in-16NC x 1-1/4in 14 0641611 2 Bolt 3/8in-16NC x 1-3/8in 15 0641614 2 Bolt 3/8in-16NC x 1-3/4in 16 0641812 2 Bolt 1/2in-13NC x 1-1/2in 17 0641820 4 Bolt 1/2in-13NC x 2-1/2in 18 0741610 2 Screw, Countersunk 3/8in-16NC x 1-1/4in 19 0760815 4 Bolt M8 x 35mm 20 0962172 1 Bushing, Flanged 21 1320012 4 Clamp 22 1320016 4 Clamp 23 1320022 3 Clamp 24 1320058 1 Clamp 25 1320223 5 Clamp 26 1320318 2 P-Clamp 27 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner 28 1580011 1 Container, Coolant Overflow 29 1660255 1 Coupling, Pump 30 1703162 2 Decal - Caution Fan 31 2151212 2 Fitting, 45° 32 2220376 1 Fitting, Straight 33 2220383 2 Fitting, Tee 34 2220567 1 Fitting, 90° 35 2220578 1 Fitting, 90° 36 2220603 2 Fitting, Straight 37 2220947 1 Fitting, Straight 38 2221026 1 Fitting, Tee 39 2221041 1 Fitting, Tee 40 2720058 2.5ft/0.8m Hose 41 2720271 42 2720615 43 3200378 4 Mount, Motor

1.25ft/0.38m

1.5ft/0.46m

Hose Hose

2-16 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-6. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

44 1 Muffler Options:

3220113 Standard Spark Arresting Muffler

70001017 1 Clamp

1001107116 Optional Catalytic Muffler (Not Available on Arctic Machines)

70002705 1 Clamp

70002706 1 Plug, Brass 45 3311405 11 Locknut 1/4in-20NC 46 3311505 6 Locknut 5/16in-18NC 47 3311605 22 Locknut 3/8in-16NC 48 3311805 4 Locknut 1/2in-13NC 49 3340399 2 Pad, Wear 50 3573937 1 Plate, Radiator Support 51 3577130 1 Plate, Engine Mounting (Front) 52 3571032 1 Plate, Baffle 53 3571033 1 Plate, Air 54 3577135 2 Plate, Engine Mounting (Rear) 55 3600318 1 Gear Pump Assembly (Note: Seal Kit is only serviceable part

available)

7023929 1 Seal Kit - 3600318 Pump 56 3600385 1 Piston Pump Assembly (See Figure 2-8 for Breakdown) 57 3600423 1 Auxiliary Pump Assembly (See Figure 2-9 for Breakdown) 58 3740067 1 Relay 59 3790152 1 O-Ring 60 3931620 2 Capscrew, Socket Head 3/8in-16NC x 1-1/4in 61 3960438 62 4031711 4 Bolt M6 x 35mm 63 4070497 4 Shim (11Ga) 64 4070498 2 Shim (16Ga) 65 4100025 66 4568743 1 Pipe, Exhaust 67 4569176 1 Tube, Air Intake 68 4711400 12 Flatwasher, 1/4in Thin 69 4711500 8 Flatwasher 5/16in Thin 70 4711600 26 Flatwasher 3/8in Thin 71 4740274 4 Washer, Snubbing 72 4751400 12 Flatwasher 1/4in Regular 73 4751500 12 Flatwasher 5/16in Regular 74 4751600 42 Flatwasher 3/8in Regular 75 4751800 13 Flatwasher 1/2in Regular 76 4791400 2 Starwasher 1/4in 77 4846821 1 Mount, Motor/Generator 78 4891500 4 Flatwasher 5/16in Hardened 79 4891600 2 Flatwasher 3/8in Hardened 80 8405006 1 Clamp, Gear 81 85941018 1 P-Clamp 82 88662037 1 Fitting, Straight 83 1001097588 1 Clip, Tube 84 1001098525 1 Plate, Muffler Support 85 1001100577 1 Hose, Radiator (Top) 86 1001100818 1 Hose, Radiator (Bottom)

28in/71cm

1.6ft/0.49mm

Seal, Self Gripping

Sleeve, Fiberglass

3121294 510AJ 2-17

SECTION 2 TURNTABLE

FIGURE 2-6. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

87 1001100825 2 Tie-Strap 88 1001100837 1 Bracket, Bottle 89 1001101201 1 Spacer, Fan 90 1001101408 1 Fan 91 1001101681 1 Elbow, Rubber 92 1001101950 1 Tube, Air Intake 93 1001102706 1 Radiator

7027412 1 Cap, Radiator

70004091 1 Shroud, Radiator

94 1001102860 1 Battery Cable Kit A 94A 7027025 1 Cable - Battery to Auxiliary Relay 94B 7027026 1 Cable - Battery & Auxiliary Pump to Ground 94C 7027023 1 Cable - Auxiliary Relay to Starter 94D 7027024 1 Cable - Auxiliary Relay to Auxiliary Pump

95 1001106426 1 Caterpillar Engine Assembly

96 1001106790 1 Tray, Engine

97 1001106793 1 Support, Radiator

98 1001141913 2 Valve, Check

99 to 100 Not Used

1001141998 Ref. CATERPILLAR ENGINE INSTALLATION A

101 0100011 A/R Compound, Locking 102 0100020 A/R Sealant 103 0641406 3 Bolt 1/4in-20NC x 3/4in 104 0641408 5 Bolt 1/4in-20NC x 1in 105 0641418 2 Bolt 1/4in-20NC x 2-1/4in 106 0641420 1 Bolt 1/4in-20NC x 2-1/2in 107 0641512 2 Bolt 5/16n-18NC x 1-1/2in 108 0641608 3 Bolt 3/8in-16NC x 1in 109 0641612 2 Bolt 3/8in-16NC x 1-1/2in 110 0642010 1 Bolt 5/8in-11NC x 1-1/4in 111 0902443 1 Bracket, Hood Latch Mount 112 1320022 7 Clamp, Fuel Line 113 1320223 A/R Clamp, J Clip 1/2in 114 1320318 2 Clamp 115 1701505 1 Decal, Diesel (Not Shown) 116 1787217 1 Clamp, Battery Hold-down 117 2180536 1 Fitting, Barbed 118 2220250 1 Fitting, Reducer 119 2220273 1 Fitting, Reducer 120 2220313 1 Fitting, 90° Barbed 121 2220459 1 Fitting, 90° 122 2220794 1 Fitting, Straight Barbed 123 2300004 124 2720058 10ft/3.0m Hose 125 2720271 8ft/2.4m Hose 126 2750532 7ft/2.1m Hose 127 3020016

2.7 Gal/10.2L

2.5 Gal/9.5L

Coolant, Anti-Freeze Not Shown)

Oil, Motor 15W-40 (Not Shown)

2-18 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-6. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

128 3311405 11 Locknut 1/4in-20NC 129 3311505 2 Locknut 5/16in-18NC 130 3312005 1 Locknut 5/8in-11NC 131 3340399 1 Pad, Wear 132 3900254 1 Screw, Shoulder 133 4070497 2 Shim (11Ga) 134 4070498 1 Shim (16Ga) 135 Not Used 136 4711400 3 Flatwasher 1/4in Thin 137 4740362 5 Washer, Fender 138 4751400 15 Flatwasher 1/4in Regular 139 4751400 4 Flatwasher 5/16in Regular 140 4751600 5 Flatwasher 3/8in Regular 141 4752000 1 Flatwasher 5/8in Regular 142 4752200 2 Flatwasher 3/4in Regular 143 8008750 1 Battery 144 1001100857 1 Separator, Fuel-Water

70002377 1 Filter 70002378 1 Seal, O-Ring

145 1001139079 1 Valve Assembly

7012974 2 Cartridge without Coil 7010543 2 Seal Kit - 7012974 Cartridge

70002386 2 Coil

146 1001140674 1 Panel, Rubber

147 to 159 Not Used

160 1 Decal - Warning Explosion/Fire Options :

1704972 ANSI Spec 1706098 Australian & CE Specs 1706059 Brazilian Spec 1706060 Chinese Spec 1706064 CSA Spec 1706062 Japanese Spec 1706061 Korean Spec 1706063 Spanish Language

1001106426 Ref. CATERPILLAR ENGINE COMPONENTS C

301 7026848 1 Valve, Breather

7026846 1 Gauze, Breather Valve 302 7026847 4 Seal, Valve Cover Nut 303 7026849 1 Gasket, Air Intake 304 7026850 1 Seal, Valve Cover 305 7026852 1 Flywheel with Starter Gear Set

7026853 1 Gear, Rim

7026851 1 Seal, Rear Main (Not Shown) 306 Use 70001403 1 Filter, Oil (was p/n 7026855) 307 7026860 1 Cap, Oil Fill

7026856 1 Seal, Oil Fill Cap

3121294 510AJ 2-19

SECTION 2 TURNTABLE

FIGURE 2-6. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

308 7026858 1 Valve, Relief

7026857 1 Seal

309 7026864 1 Pump, Water

7026863 1 Gasket, Water Pump (Fits Between Pump and Pump Rear Plate) 7026865 1 Gasket, Water Pump (Fits Between Pump Rear Plate and Engine

Block)

310 7026867 1 Thermostat

7026866 1 Gasket (Fits Between Regulator & Engine Block)

7026868 1 Gasket (Fits Between Regulator & Hose Adapter) 311 7026869 1 Gasket, Exhaust 312 7026870 1 Gasket, Exhaust Manifold 313 70003758 1 Filter Assembly

70003791 1 Element, Fuel Filter (was p/n 7026871)

7026872 1 Gasket, Fuel Filter Element 314 7026873 1 Pump, Fuel Transfer

7026874 1 Seal 315 7026875 4 Injector, Fuel 316 Not Used 317 70003541 1 Actuator 318 70003768 1 Alternator 319 7026878 4 Glowplug 320 70003759 1 Switch, Oil Pressure

70003760 1 Adapter, Oil Pressure Switch 321 70003769 1 Starter 322 7026854 1 Seal, Front Main (Not Shown) 323 7026859 1 Gasket, Oil Pan (Not Shown) 324 7026862 1 Gasket, Valve Bracket (Not Shown - Located Between Valve

Bracket & Cylinder Head) 325 70003761 1 Belt 326 70003762 1 Sensor, Speed

70003766 1 Sensor, Speed 327 70003765 1 Sensor, Temperature (Not Shown) 328 70003763 1 Dipstick

70003764 1 Tube, Dipstick 329 4641272 1 Valve, Oil Drain

7026861 1 Seal, Oil Drain Valve 330 70003767 1 Harness, Engine (Not Shown) 331 70003770 1 ECM

2-20 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-6. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-21

SECTION 2 TURNTABLE

301

307

303

304

302

254

405

202

227

234

267

223

209

254

241

214

255

652395320

531

8262

6422022225921

621325424

209

237

217

237

241

242

252

254

211

209

241

254

214

255

260A

260B

244

211

222

212

202

227

204

253

239

234

251

240

207

262

269

248

208

254

241

263

254

241

208

254

332727184OR2

0220221

462502082

57233

224

226268245

268

2231225

201

415

416

414

410

413

421

404

FIGURE 2-7.DEUTZ ENGINE INSTALLATION

2-22 510AJ 3121294

SECTION 2 TURNTABLE

FUEL

INJECTOR PUMP

VENT

LINE

FUEL

RETURN

223

0222183123022

820

215

202

261

208

221

241

261

256

103

221

238

253

20220925425

424720220

STARTER

ITEM #235 BATTERY CABLE KIT

AUX. POWER

RELAY

BATT.

GRD.

AUX. PWR.

PUMP

235B

235A

235D

235C

235A

235B

GLOW PLUG

258

219

START

RELAY

249

206

239

2535

408

417

405420418

41241

411

402

409

408A

3121294 510AJ 2-23

SECTION 2 TURNTABLE

FIGURE 2-7. DEUTZ ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001141527 Ref. DEUTZ ENGINE INSTALLATION B

1 0100011 A/R Compound, Locking 2 0100020 A/R Sealant, Pipe 3 0641410 4 Bolt 1/4in-20NC x 1-1/4in 4 0641418 2 Bolt 1/4in-20NC x 2-1/4in 5 0641512 2 Bolt 5/16in-18NC x 1-1/2in 6 0641612 2 Bolt 3/8in-16NC x 1-1/2in 7 0642010 1 Bolt 5/8in-11NC x 1-1/4in 8 0902443 1 Bracket, Hood Latch Mount

9 1320022 5 Clamp, Fuel Line 10 1701505 1 Decal, Diesel Fuel (Not Shown) 11 1787217 1 Clamp, Battery Hold-down 12 2180348 1 Fitting, Barbed 13 2200222 1 Plug, Pipe (Not Shown - Located on Bottom of Fuel Tank) 14 2220313 1 Fitting, 90° Barbed 15 2221176 1 Fitting, 90° 16 2750058 17 2750532 18 3311405 6 Locknut 1/4in-20NC 19 3311505 2 Locknut 5/16in-18NC 20 3312005 1 Locknut 5/8in-11NC 21 3340399 1 Pad, Wear 22 3900254 1 Screw, Shoulder 23 4070497 2 Shim (11 Gauge) 24 4070498 1 Shim (16 Gauge) 25 4240099 1 Wire, Tie (Not Shown - Located on Vent Line) 26 4711400 8 Flatwasher 1/4in Thin 27 4751400 4 Flatwasher 1/4in Regular 28 4751500 4 Flatwasher 5/16in Regular 29 4751600 2 Flatwasher 3/8in Regular 30 4752000 1 Flatwasher 5/8in Regular 31 4752200 2 Flatwasher 3/4in Regular 32 8008750 1 Battery 33 1001139079 1 Valve Assembly

7012974 2 Cartridge without Coil 7010543 2 Seal Kit - 7012974 Cartridge

70002386 2 Coil

33 to 50 Not Used

51 1 Decal - Warning Explosion/Fire Options:

1704972 ANSI Spec 1706098 Australian & CE Specs 1706059 Brazilian Spec 1706060 Chinese Spec 1706064 CSA Spec 1706062 Japanese Spec 1706061 Korean Spec 1706063 Spanish Language

52 to 200 Not Used

15ft/4.6m

7ft/2.2m

Hose Hose

2-24 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-7. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001141527 Ref. ENGINE ASSEMBLY B

201 0080231 1 Adapter, Fan Spacer 202 0100011 A/R Compound, Locking 203 Not Used 204 0641406 2 Bolt 1/4in-20NC x 3/4in 205 0641409 2 Bolt, 1/4in-20NC x 1-1/8in 206 0641410 6 Bolt, 1/4in-20NC x 1-1/4in 207 0641510 3 Bolt, 5/16in-10NC x 1-1/4in 208 0641608 11 Bolt 3/8in-16NC x 1in 209 0641610 16 Bolt 3/8in-16NC x 1-1/4in 210 0641812 2 Bolt 1/2in-13NC x 1-1/2in 211 0641820 4 Bolt 1/2in-13NC x 2-1/2in 212 0700816 4 Bolt M8 x 40mm 213 0701014 4 Bolt M10 x 30mm 214 0711414 4 Bolt M10 x 35mm 215 0741610 2 Screw, Countersunk 3/8in-16NC x 1-1/4in 216 0771012 4 Bolt M10 x 25mm 217 0902740 1 Bracket, Engine Mounting (Left) 218 0962172 1 Bushing, Flanged 219 1060904 1 Cable, Jumper 220 1320016 2 Clamp 221 1320223 3 Clamp, J Clip 222 1703162 2 Decal, Fan Blade 223 2060025 1 Fan 224 2151212 2 Fitting, 45° 225 2220376 1 Fitting, Straight 226 2220383 2 Fitting, Tee 227 2220451 2 Fitting, Straight 228 2220567 1 Fitting, 90° 229 2220578 1 Fitting, 90° 230 2220603 2 Fitting, Straight 231 2220947 2 Fitting, Straight 232 2221026 2 Fitting, Tee 233 2221041 1 Fitting, Tee 234 2720467 2 Hose, Oil Cooler

235 2902060 1 Battery Cable Kit C 235A Use 7027041 1 Cable (Battery - to Ground) (was p/n 7016837) 235B 7027050 1 Cable (Battery + to Relays) 235C 7016820 1 Cable (Auxilliary Relay to Starter) 235D 7016834 1 Cable (Auxilliary Relay to Auxilliary Pump)

236 3020016

237 3200406 4 Mount, Rubber

238 3311401 1 Nut 1/4in-20NC

239 3311405 10 Locknut 1/4in-20NC

240 3311505 3 Locknut 5/16in-18NC

241 3311605 21 Locknut 3/8in-16NC

242 3311805 4 Locknut 1/2in-13NC

243 3570801 1 Bracket, Engine Mounting (Rear)

2.5gal/9.46Li

Motor Oil (Not Shown)

3121294 510AJ 2-25

SECTION 2 TURNTABLE

FIGURE 2-7. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

244 3573937 1 Support, Radiator 245 3600318 1 Gear Pump Assembly (Note: Seal Kit is only serviceable part

available)

7023929 1 Seal Kit - 3600318 Pump 246 3600385 1 Piston Pump Assembly (See Figure 2-8 for Breakdown) 247 3600423 1 Auxiliary Pump Assembly (See Figure 2-9 for Breakdown): 248 1001150998 1 Radiator 249 3740067 3 Relay (Auxiliary Power) 250 3790152 1 O-Ring 251 3960407 1 Gasket, Air Intake 252 4740274 4 Washer, Snubbing 253 4751400 21 Flatwasher 1/4in Regular 254 4751600 44 Flatwasher 3/8in Regular 255 4812200 4 Flatwasher, M4 256 4846683 1 Tray, Engine Mounting 257 4891600 2 Flatwasher, 3/8in Hardened 258 4923451 1 Harness, Glow Plugs 259 1001144476 1 Engine, Deutz 260 1 Bracket, Motor Mount Options:

260A 1001138135 Bracket without Generator Mounting Capabilities 260B 4846567 Bracket with Generator Mounting Capabilities

261 1001138238 2 Pad, Wear 262 1001139819 1 Adapter, Air Intake 263 1001140334 1 Hose, Air Intake 264 1001141693 1 Air Cleaner Assembly

70003783 1 Element, Air Cleaner 265 1001141694 1 Clamp, Air Cleaner 266 Not Used 267 See Note 1 Pipe, Exhaust (Note: See Item 420 for component options) 268 1001141913 2 Fitting, Check Valve 269 1001142230 1 Plate, Radiator Mount

0256847 Ref. PUMP COUPLING INSTALLATION 2

301 1660234 1 Coupling, Hayes 302 0080163 1 Plate, Pump Adapter 303 0700810 63 Bolt M8 x 20mm 304 4831900 6 Lockwasher M8

305 to 306 Not Used

307 3020021 A/R Grease, Coupling

1001144476 Ref. ENGINE COMPONENTS C

401 7020026 1 Dipstick (Not Shown)

70001002 1 Tube, Dipstick (Not Shown) 402 70003475 1 Thermostat

7020460 1 Spring, Compression

2-26 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-7. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

403 A/R Seal & Gasket Options (Not Shown)

70002718 1 Seal, Rear Main Crankshaft

7020430 1 Gasket, Valve Cover

1 Gasket, Cylinder Head Options: 70003479 Gasket (1 Notch) 70003480 Gasket (2 Notches) 70003481 Gasket (3 Notches) 70001871 3 Gasket, Intake Manifold (Not Shown)

7020471 3 Gasket, Exhaust (Not Shown)

404 70000264 1 Flywheel

7024579 1 Ring, Gear 405 7020465 2 Cap, Filler 406 70000800 1 Repair Kit for Timing Belt Tensioner (Not Shown) 407 70001850 1 Pump, Oil Lube (Not Shown)

7020468 1 Seal Between Oil Pump & Engine Block (Not Shown) 408 7016331 1 Filter, Oil

70003472 1 Bracket, Oil Filter

408A 7027236 1 Sensor, Oil Temperature (Located in Rear Of Filter Mount)

409 3 Pump, Injector Options:

70000912 Series A Injector 70000913 Series B Injector 70000914 Series C Injector 70000915 Series D Injector 70003464 3 O-Ring, Injector Pump

410 70003478 3 Injector, Fuel

70003136 3 O-Ring, Injector Pump 70000345 3 Plug, Glow

411 1 Filter, Fuel Options:

7020023 Standard

70003463 RME Resistant (Note: Use with European Bio-Diesel Fuels) 70001423 1 Bracket, Fuel Filter

412 70000916 1 Pump Fuel Supply

70001435 Repair Kit - Pump 70000917 1 O-Seal Between Fuel Pump & Engine Block (Not Shown) 70000918 1 Seal Between Fuel Pump & Hand Pump (Not Shown) 70000919 Pump, Hand

413 7027795 1 Module, EMR2

7027796 1 Cable, Interconnection (Not Shown)

70004059 1 Plug, Analyzer (Not Shown) 70004060 1 Plug, Connector (Not Shown)

70001872 1 Harness, Engine (Not Shown) 414 70004102 1 V-Belt 415 70004056 1 Alternator

70001868 1 Regulator, Voltage (Not Shown)

70001866 1 Gasket Set for Regulator

70004103 1 Cable, Alternator Interconnection (Not Shown) 416 70004057 1 Starter

70004058 1 Relay, Starter

70004062 1 Cable, Starter Interconnection (Not Shown)

3121294 510AJ 2-27

SECTION 2 TURNTABLE

FIGURE 2-7. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

417 7024565 1 Tacho-Generator

70003932 1 Sleeve, Spacer 418 7027791 1 Sensor, Temperature 419 7027790 1 Sensor, Oil Pressure 420 7027792 1 Actuator, Throttle 421 7020455 1 Muffler

70001844 Clamp

2-28 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-7. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-29

SECTION 2 TURNTABLE

656463

625657585960665552

515326

54677071313234

828483

858687

368037

3840414239

10C

10A

10C

10B

29 30

8181184329

77 51

50 26

70 68

104

FIGURE 2-8.PISTON PUMP ASSEMBLY

2-30 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-8. PISTON PUMP ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600385 Ref. PISTON PUMP ASSEMBLY A

1 7021240 1 Shaft Assembly (Includes Items 2-4) 2 7021237 1 Shaft 3 7021238 1 Ring, Retaining 4 7021239 1 Bearing, Roller 5 Use 7021280 1 O-Ring 6 7021242 1 Seal, Lip 7 7021243 1 Carrier, Seal Shaft

8 to 9 Not Used

10 7024855 2 Solenoid Assembly 10A 7024856 2 Coil (1 Per Assy) 10B 7024857 2 Nut (1 Per Assy)

10C 7024858 2 Seal Kit - 7024855 Cartridge (1 Per Assy)

11 to 12 Not Used

13 7022377 2 Orifice

14 7022378 1 Housing Assembly (Includes Items 15-20)

15 7021249 1 Bearing, Needle

16 to 17 Not Used

18 7001485 2 Plug

19 7022380 1 Plug (Includes Item 20)

20 7022381 1 O-Ring

21 7021248 1 Side Cover Assembly (Includes Item 22)

22 Use 7021280 1 Gasket

23 7021255 4 Screw

24 7021251 2 Screw

25 7021250 1 Pin

26 Use 7021280 2 Gasket

27 to 28 Not Used

29 7007419 2 Plug Assembly

30 Use 7021280 2 O-Ring

31 7007470 2 Plug Assembly

32 Use 7021280 2 O-Ring

33 7021257 1 Ring, Retaining

34 7021251 1 Screw

35 7022342 1 Bracket, Lifting

36 7022342 1 Key

37 7022341 1 Ring, Retaining

38 7021258 1 Gerotor

39 7021260 1 Gerotor Cover Assembly

40 7021259 1 Bearing, Journal

41 Not Used

42 Use 7021280 1 O-Ring

43 See Note 1 Pin (Note: Not Available for Purchase)

44 Not Used

45 7024800 1 Spring

46 7021265 2 Bypass Valve Assembly (Includes Items 47-49)

47 Use 7021280 2 O-Ring

48 Use 7021280 2 Ring, Back Up

3121294 510AJ 2-31

SECTION 2 TURNTABLE

FIGURE 2-8. PISTON PUMP ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

49 Use 7021280 2 O-Ring 50 7022382 1 Cover, Servo 51 7021255 10 Screw 52 7007470 1 Plug Assembly 53 Use 7021280 1 O-Ring 54 7021268 1 Cover, Servo 55 7021269 1 Cylinder Block Assembly (Includes Items 56-65) 56 7021270 1 Cylinder Block 57 7021271 1 Washer 58 7021272 1 Spring 59 7021273 1 Washer 60 7021274 1 Ring, Retaining 61 7021275 3 Pin, Slipper Hold Down 62 7021276 1 Retainer, Hold Down Pin 63 7021277 1 Guide, Slipper Retainer 64 7021278 1 Retainer, Slipper 65 7021279 9 Piston Assembly 66 7021281 1 Plate, Valve 67 7022385 1 Servo Piston Assembly (Includes Items 68-70) 68 Use 7021280 2 O-Ring 69 Use 7021280 2 Ring, Bearing 70 Use 7021280 2 Ring, Piston 71 7007412 1 Servo Piston Ring Kit (Includes Items 68 & 70 Only) 72 7022346 1 Plug Assembly 73 Use 7021280 1 O-Ring 74 7021290 1 Nut 75 7022347 1 Spring 76 7024804 1 Poppet 77 Use 7021280 1 Nut, Seal 78 7022386 1 Swashplate 79 7022387 1 Slider, Block 80 7021294 1 Coupling 81 7001481 2 Pin 82 70002257 1 Gasket 83 7021296 7 Screw 84 7021297 1 Cover, Charge Pump 85 7021298 1 Seal 86 7021299 1 Plate, Cover 87 7007289 2 Screw 88 7007470 1 Plug (Not Shown) 89 7021256 1 O-Ring (Not Shown)

90 to 94 Not Used

95 7021280 Seal Kit (Includes Items 5-6,22,26,30,32,42,47-49,53,68-70,73,

77,82 & 89)

2-32 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-8. PISTON PUMP ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-33

SECTION 2 TURNTABLE

1415151617

19 20

102425

GENUINE PARTS

FIGURE 2-9. AUXILIARY PUMP ASSEMBLY

2-34 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-9. AUXILIARY PUMP ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600423 Ref. AUXILIARY PUMP ASSEMBLY A

1 7011067 1 Motor & Adapter 2 See Note 2 Setscrew (Note: Not Available - Purchase Locally) 3 7011044 1 Gasket, Mounting 4 7011016 1 Coupling 5 70000969 1 Seal, Shaft 6 Use 70000978 1 Stator 7 See Note 2 Cap Assembly (Note: Use Item 30 or 31.) 8 Use 70000978 2 Spring

9 Use 70000978 2 Ball 10 Use 70000978 2 Seat 11 70000976 6 Bearing, Needle 12 Use 70000978 4 Washer 13 Use 70000978 4 Screw 14 70000970 4 Ring, Retaining 15 70000971 4 Gear 16 70000972 1 Shaft, Idler 17 Use 70000978 4 Pin, Drive 18 Use 70000978 4 Pin, Dowel 19 70000973 1 Gasket 20 See Note 1 O-Ring (Note: Use Item 30 or 31.) 21 Use 70000978 1 Housing, Gear 22 See Note 1 Label (Note: Not Available for Purchase) 23 7000974 1 Gasket 24 Use 70000978 1 Housing, Gear 25 Use 70000978 1 Plug 26 Use 70000978 8 Screw 27 70000975 1 Shaft, Drive

28 to 29 Not Used

30 70000977 1 Seal Kit (Includes Items 3, 5, 20 & Qty 2 O-Rings for Item 7) 31 70000978 1 Replacement Pump Kit (Includes Items 3-21 & 23-27)

3121294 510AJ 2-35

SECTION 2 TURNTABLE

201819

201

15A

104

106

103

105

107

102

101

301

302

FIGURE 2-10.TANK INSTALLATIONS

2-36 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-10. TANK INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001144403 Ref. TANK INSTALLATION D

1 0100011 A/R Compound, Locking

2 0100079 A/R Sealant

3 0641405 2 Bolt 1/4in-20NC x 5/8in

4 0641416 1 Bolt 1/4in-20NC x 2in

5 0641606 3 Bolt 3/8in-16NC x 3/4in

6 0641608 4 Bolt 3/8in-16NC x 1in

7 0902535 1 Bracket, Hood Latch

8 1120532 1 Cap, Protective

9 2820035 10 3311405 1 Locknut 1/4in-20NC 11 3311601 1 Nut 3/8in-16NC 12 4240145 1 Strap, Tank Mount 13 4280295 14 4360436 1 Switch, Fuel Level 15 4400408 1 Tank, Fuel (Includes Standard Non-Locking Cap)

15A 7020056 1 Fitting & Pick-up Tube (Supply Line)

16 4567627 1 Tube, Hood Prop 17 4751400 4 Flatwasher 1/4in Regular 18 4751600 10 Flatwasher 3/8in Regular 19 4761600 4 Lockwasher 3/8in 20 4846665 1 Tray Weldment 21 Use 1001153619 1 Hydraulic Tank Assembly (See Items 101-107 for Breakdown)

2ft/.61m

Insulate, Tubing

Strip, Bumper

(was p/n 1001141821)

Ref. HYDRAULIC TANK ASSEMBLY 1001141821 Ref. Original Equipment C 1001153619 Ref. Service Replacement C

Ref Note: Original Equipment Tank may have been replaced with

Service Replacement Tank p/n 1001153619. Identify p/n stamped on tank before ordering parts.

101 7024446 1 Plug, Magnetic 102 7024439 1 Cover 103 7024444 1 Cap

7024445 1 Strainer 7024443 1 Neck, Fill 7024440 1 Gasket (Cover to Tank)

104 70001959 1 Filter, Return

70001960 1 Element, Filter

7023347 1 Gasket (Filter Flange to Tank) 7023306 Seal (Filter Cap to Filter Housing

105 1 Gauge, Sight Options:

70003865 1001141821 Tank

7024441 1001153619 Tank

106 83304174 6 Nut 1/4in-20NC

83304173 6 Flatwasher 1/4” Regular

3121294 510AJ 2-37

SECTION 2 TURNTABLE

FIGURE 2-10. TANK INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

83304172 6 Stud 1/4”-20NC

107 83304170 2 Bolt 3/8in-16NC x 1-1/4in

Use 4751600 2 Flatwasher 3/8in Regular

201 Ref. FUEL CAP OPTIONS

7016314 Cap, Fuel (Standard) 1120487 Cap, Fuel (Optional)

Ref. ENGINE INSTALLATIONS

301 2200222 1 Plug 302 0100020 A/R Sealant, Pipe

2-38 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-10. TANK INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-39

SECTION 2 TURNTABLE

1 5

19816

25A

26A

26B

15913

FIGURE 2-11.GROUND CONTROL BOX ASSEMBLY

2-40 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-11. GROUND CONTROL BOX ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. GROUND CONTROL BOX ASSEMBLIES 1001138764 Ref. Deutz Engine Machines (ANSI Export & Australian Specs) B 1001138676 Ref. Deutz Engine Machines (CE Specs) B 1001138761 Ref. Caterpillar Engine Machines (CE Specs) B

Ref. Note: Caterpillar Engines not available on ANSI Export &

Australian Specs.

1 0100011 A/R Compound, Locking 2 0100048 A/R Grease, Dielectric 3 0630518 2 Screw, Button Head 4 0630548 5 Bolt 5 0641506 4 Bolt 5/16in-18NC x 3/4in 6 1001105784 1 Box, Fiberglass

6A 7020246 2 Latch

7Not Used 8 1001103667 1 Module, Control (Re-calibration Required When Replaced)

9 1670829 1 Bezel 10 1706712 1 Decal - Ground Control Display 11 1001102598 1 Decal - Faceplate 12 2420172 1 Gauge, Hourmeter 13 2760105 1 Housing, Display Light 14 3300205 4 Nut, Retainer 15 3300408 4 Locknut, Plastic Insert 16 77143013 11 Locknut 1/4in-20NC 17 Not Used 18 3539219 1 Plate, Reinforcement 19 3740049 2 Relay - SPDT 20 3900268 2 Screw #10-24NC x 1/2in 21 3910804 6 Screw #8-32NC x 1/4in 22 4060906 1 Shield, Toggle Switch 23 1 Shim Options:

4070987 Shim (.015in) (S/N E300001114 to S/N E300001302)

1001151393 Shim, Nylon (.068in) (S/N E300001302 to Present) 24 4360328 A/R Switch, Toggle 25 1 Switch, Key Options:

4360469 ANSI Export & Australian Specs 4360470 CE Specs

25A 2860030 1 Key

26 4360475 1 Switch, Emergency Stop

26A 7020175 1 Cap, Mushroom Head 26B 7020176 1 Block, Contact

27 4360476 1 Switch, Contact Block 28 4460426 1 Connector, Strain Relief 29 4460470 1 Nut, Terminal 30 4460471 1 Locknut, Terminal 31 4460488 10 Base, Terminal Mounting 32 4460526 1 Connector, Strain Relief

33 to 35 Not Used

36 4740444 A/R Washer, Special

3121294 510AJ 2-41

SECTION 2 TURNTABLE

FIGURE 2-11. GROUND CONTROL BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

37 4751400 12 Flatwasher 1/4in Regular 38 Not Used 39 1001138588 1 Valve Harness Assembly (Not Shown - See Section 7 for

Breakdown)

40 1001105636 1 Ground Control Box Harness Assembly (Not Shown - See

Section 7 for Breakdown)

41 1 Engine Harness Assembly (Not Shown - See Section 7 for

Breakdown) 1001139084 Caterpillar Engine Machines 1001139085 Deutz Engine Machines

42 4460496 1 Lockwasher 43 4460497 1 Nut 44 4761400 6 Lockwasher 1/4in 45 0641407 1 Bolt 1/4in-20NC x 7/8in 46 1001106736 1 Cap, Dust

2-42 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-11. GROUND CONTROL BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-43

SECTION 2 TURNTABLE

3330353432116

2 3 4

141110

262625

FIGURE 2-12.LIGHT INSTALLATIONS

2-44 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-12. LIGHT INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271073 Ref. STROBE LIGHT INSTALLATION (AMBER) (OPTIONAL) D

1 4060865 1 Guard 2 3911014 2 Screw, Machine #10-24NC x 7/8in 3 4751000 4 Flatwasher #10 Regular 4 3311001 2 Nut #10-24NC 5 2820035 6 4460320 1 Plug, Terminal 7 4460267 2 Pin, Male 8 4240032 1 Tiestrap (Not Shown)

9 4460234 1 Clamp (Not Shown) 10 4220162 1 Spacer, Stop 11 4846698 1 Mounting, Light

12 to 13 Not Used

14 0100011 A/R Compound, Locking 15 0100048 A/R Sealant, Silicone 16 Use 0272529 1 Strobe Light Assembly (was p/n 2920146)

7016319 1 Bulb, Replacement 7016372 1 Lens

17 to 23 Not Used

24 0272529 1 Strobe Light Kit (Includes Items 1-7, 10, 11 & 16)

12ft/31cm

Loom (Not Shown)

Ref. LIGHTS INSTALLATIONS (OPTIONAL)

0271072 Ref. Headlights & Taillights C

1001108204 Ref. Chassis Floodlights (Not Shown) A

25 A/R Light Options:

2920110 2 Headlight (Round Shape) 7016628 2 Bulb, Light (1 Per Light)

2920157 2 Floodlight (Rectangular Shape) 26 0902206 2 Bracket, Mounting 27 0642612 1 Bolt 1in-8NC x 1-1/2in 28 4220162 2 Spacer 29 0100011 A/R Compound, Locking 30 A/R Light Options:

2920113 2 Taillight

2920157 2 Floodlight (Rectangular Shape) 31 3911040 4 Screw, Machine #10-24NC x 2-1/2in (0271072 Installation) 32 3311005 4 Nut #10-24NC (0271072 Installation Only) 33 4751000 4 Flatwasher #10 Regular (0271072 Installation Only) 34 4 Washer Options:

4740362 Headlights & Taillights

4751800 Chassis Floodlights 35 3960461 2 Gasket (0271072 Installation Only) 36 Not Used 37 4240032 12 Tie-Strap (Not Shown) 38 4460234 12 Mount, Tie-Strap (Not Shown)

3121294 510AJ 2-45

SECTION 2 TURNTABLE

FIGURE 2-12. LIGHT INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

39 1 Switch Options (Not Shown - Located on Console):

4360336 Toggle Switch

4360522 Pushbutton Switch 40 3790012 A/R O-Ring (Not Shown - Located on Console) 41 1 Decal, Lights (Not Shown - Located on Console)

2-46 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-12. LIGHT INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 2-47

SECTION 2 TURNTABLE

152326

SEE E

NGINE

INSTAL

LATIONSEE ENGIN

EINSTALLATION

12E

12A

12C

12B

12G

12H

12F

12G

12D

711111241017286182828132431A1

124814132

352

172832

31E

31F

31G

31H

31A

31C

31B

31C

31D

FIGURE 2-13.HOODS INSTALLATION

2-48 510AJ 3121294

SECTION 2 TURNTABLE

FIGURE 2-13. HOODS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. HOODS INSTALLATION 1001137918 Ref. Caterpillar Engine Machines C 1001137922 Ref. Deutz Engine Machines D

1 0100011 A/R Compound, Locking 2 0641408 6 Bolt 1/4in-20NC x 1-1/4in 3 0641606 3 Bolt 3/8in-16NC x 3/4in 4 0641608 13 Bolt 3/8in-16NC x 1in 5 0641610 2 Bolt 3/8in-16NC x 1-1/4in 6 0641614 4 Bolt 3/8in-16NC x 1-3/4in 7 0721004 4 Bolt #10-24NC x 1/2in 8 0721006 4 Bolt #10-24NC x 3/4in

9 0902504 1 Angle, Mounting 10 0940071 1 Bumper 11 0940083 2 Bumper 12 2680439 1 Hood Kit (Tank Side) (Includes Items 12A-12H) N

12A 2940109 1 Latch 12B 0721008 2 Screw, Machine #10-24NC x 1in 12C 4750800 4 Flatwasher #8 Regular 12D 3311005 2 Locknut #10-24NC 12E 2600246 2 Hinge 12F 0721006 4 Screw, Machine #10-24NC x 3/4in 12G 4750800 8 Flatwasher #8 Regular 12H 3311005 4 Locknut #10-24NC

13 3311005 4 Locknut #10-24NC 14 3311401 2 Nut 1/4in-20NC 15 3311405 6 Locknut 1/4in-20NC 16 3311505 2 Nut 5/16in - 18NC 17 3311601 A/R Nut 3/8in-16NC 18 3311605 10 Locknut 3/8in-16NC 19 1 Panel, Rubber Options:

See Note Caterpillar Engine Machines (Note: See Engine Installation

for call out)

3380445 Deutz Engine Machines 20 3573024 1 Plate, Hinge Mounting 21 4160170 1 Spring, Gas 22 1 Hood Mounting Weldment Options:

1001107157 Caterpillar Engine Machines

4341388 Deutz Engine Machines 23 4740362 6 Washer, Fender 24 4750800 12 Flatwasher #8 Regular 25 4751000 8 Flatwasher #10 Regular 26 4751400 6 Flatwasher 1/4in Regular 27 4751500 2 Flatwasher 5/16in Regular 28 4751600 A/R Flatwasher 3/8in Regular 29 4846037 1 Hood Mounting Weldment 30 4846669 1 Hood Mounting Weldment

3121294 510AJ 2-49

SECTION 2 TURNTABLE

FIGURE 2-13. HOODS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

31 1 Hood Kit (Engine Side) Options (was p/n 2680438):

1001145959 Caterpillar Engine Machines (Includes Items 31A-31H &

Current Heat Shields) (Note: Item 34 must be ordered

separately)

1001146954 Deutz Engine Machines (Includes Items 31A-31H, 16, 32, 33,

34 & Current Heat Shields)

Ref. Note: Replacement Decals Must Be Ordered Separately -

See Section 8.

31A 2940109 1 Latch 31B 0721008 2 Screw, Machine #10-24NC x 1in 31C 4751000 4 Flatwasher #10 Regular 31D 3311005 2 Locknut #10-24NC 31E 2600210 1 Hinge

31F 3900232 4 Screw, Button Head 3/8in-16NC x 1-1/4in 31G 4751600 8 Flatwasher 3/8in Regular 31H 3311605 4 Locknut 3/8in-16NC

32 3900232 3 Capscrew, Button Head 3/8in-16NC 1-1/4in 33 4740500 3 Flatwasher, Special 34 4845194 1 Exhaust Tube Weldment

35 to 38 Not Used

39 1001105272 A/R Insulation, Heat Shield (Caterpillar Engine Machines) 40 1001105273 A/R Insulation, Heat Shield (Caterpillar Engine Machines) 41 1001105275 A/R Insulation, Heat Shield (Caterpillar Engine Machines) 42 1001105276 A/R Insulation, Heat Shield (Caterpillar Engine Machines) 43 Not Used 44 1001109495 A/R Insulation, Heat Shield (Caterpillar Engine Machines)

45 to 48 Not Used

49 2820099 3 Foam, Acoustical (Deutz Engine Machines Only) 50 2820100 2 Foam, Acoustical (Deutz Engine Machines Only) 51 1001153313 A/R Insulation, Heat Shield (Deutz Engine Machines) 52 1001153314 A/R Insulation, Heat Shield (Deutz Engine Machines) 53 1001153315 A/R Insulation, Heat Shield (Deutz Engine Machines) 54 1001153316 A/R Insulation, Heat Shield (Deutz Engine Machines) 55 1001153317 A/R Insulation, Heat Shield (Deutz Engine Machines) 56 1001153318 A/R Insulation, Heat Shield (Deutz Engine Machines)

2-50 510AJ 3121294

SECTION 3

BOOM

3121294 510AJ 3-1

SECTION 3 BOOM

LIMIT SWITCH

LOCATED ON ITEM 119

119

110

114

116

106

114

116

105

435

307

314

309

305

301

313

303

208

212

206

BOOM REST

(118)

LOCATED ON

ITEM 122

SHOWN HERE

FOR CLARITY

117

112

118

104

117

112

107

105

101

105

116

115

114

110

113

3420110

110

114

115

116

105

107

113

108

120

122

311

302

306

307

308

118

205

203

LIMIT SWITCH

LOCATED AT BAS E

OF ITEM 120

37825

1034111028

110

109

120

121

123

124

125

204

209

201

202

210B

205

210

210A

201 207

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

3-2 510AJ 3121294

SECTION 3 BOOM

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. TOWER BOOMS AND CYLINDERS INSTALLATION

0272496 Ref. Booms and Cylinders Installation F

1001098639 Ref. Boom Assemblies D

1 0100011 A/R Compound, Locking 2Not Used 3 0641505 4 Bolt 5/16in-18NC x 5/8in 4 0641507 2 Bolt 5/16in-18NC x 7/8inin

5 to 6 Not Used

7 0641806 2 Bolt 1/2in-13NC x 3/4in 8 0641810 3 Bolt 1/2in-13NC x 1-1/4in

9Not Used 10 0642012 2 Bolt 5/8in-11NC x 1-1/2in 11 0642016 2 Bolt 5/8in-11NC x 2in 12 Not Used 13 0940048 1 Bumper 14 1671013 1 Cover 15 1684239 1 Tower Lift Cylinder Assembly (See Section 5 for Breakdown)

16 to 19 Not Used

20 3312005 1 Locknut 5/8in-11NC 21 3340914 1 Pad

22 to 24 Not Used

25 3422664 1 Pin 26 Not Used 27 3422912 1 Pin 28 3422913 1 Pin 29 3423015 3 Pin 30 3572691 1 Plate, Boom Rest

31 to 33 Not Used

34 3841258 4 Keeper, Pin 35 4711500 2 Flatwasher 5/16in Thin 36 4751500 4 Flatwasher 5/16in Regular 37 4751800 3 Flatwasher 1/2in Regular

0272340 Ref. TOWER BOOM ASSEMBLY J

101 0100011 A/R Compound, Locking 102 Not Used 103 0561076 1 Block, Boom Rest 104 0641610 6 Bolt 3/8in-16NC x 1-1/4in 105 0642012 4 Bolt 5/8in-11NC x 1-1/2in 106 0642014 2 Bolt 5/8in-11NC x 1-3/4in 107 0642016 2 Bolt 5/8in-11NC x 2in 108 0801356 1 Boom, Mid 109 0801357 1 Boom, Tower 110 0961950 20 Bearing, Garmax 111 Not Used 112 3311605 6 Locknut 3/8in-16NC 113 3312005 2 Locknut 5/8in-11NC

3121294 510AJ 3-3

SECTION 3 BOOM

FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

114 3422568 6 Pin 115 3422912 2 Pin 116 3841258 8 Keeper, Pin 117 4751600 12 Flatwasher 3/8in Regular 118 4846905 1 Rest, Boom 119 4846697 1 Upright (Upper) 120 3010140 2 Link 121 4846701 1 Link, Timing 122 1001145890 1 Upright (Lower) 123 3340608 1 Pad, Wear 124 0641605 2 Bolt 3/8in-16NC x 3/8in 125 3574066 1 Cover

0272497 Ref. LIMIT SWITCHES INSTALLATION E

201 0100011 A/R Compound, Locking 202 0641406 2 Capscrew, 1/4in-20NC x 3/4in 203 1001096617 1 Cover, Switch 204 1671086 1 Cover, Switch 205 3311005 4 Locknut #10-24NC 206 3931024 2 Capscrew #10-24NC x 1-1/2in 207 3931030 2 Capscrew #10-24NC x 1-7/8in 208 4360548 1 Switch, Limit 209 4751400 2 Flatwasher, 1/4in Regular

210 4922714 1 Cable / Limit Switch (Not Shown) B 210A 1060902 210B 4360548 1 Switch, Limit 210C 4460968 1 Connector, Strain Relief 210D 4460226 2 Socket, Contact (Not Shown)

211 4060803

212 4460968 1 Connector, Strain Relief

8.5ft/2.6m

8.5in/217mm

Cable, Electrical 18/2 (Not Shown - See Section 7)

Shield, Flex Trim (Not Shown)

0272594 Ref. BOOM CABLES AND CLAMPS INSTALLATIONS D

301 0561460 1 Block, Clamp

302 0630498 1 Bolt

303 0641528 3 Bolt 5/16in-18NC x 3-1/2in

304 1060991 1 Cable, Electrical - 12/3 (AC Power Cable) (Not Shown - See

Section 7) 305 1320300 1 Clamp, Hose 306 3300420 1 Nut, Acorn 1/4in-20NC 307 3311605 3 Locknut 3/8in-16NC 308 3860096 1 Roller 309 4061032 2 Shield, Cable 310 4240018 3 Tie-Strap (Not Shown) 311 4460425 2 Connector, Strain Relief 312 4460866 1 Connector, Female - 19 Pin (Not Shown - See Section 7) 313 4711500 3 Flatwasher 5/16in Thin 314 4711600 2 Flatwasher 3/8in Thin 315 4922530 1 Harness, Tower Boom (Not Shown - See Section 7)

3-4 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

316 4922770 1 Cable, Electrical - 18/2 (Not Shown - See Section 7)

3121294 510AJ 3-5

SECTION 3 BOOM

122

223

126

132

101 108

105

101

133

106

132

118

124

122

133

108

101

116

117

119

133

109

123

112

246

238

252

215

243

251

212

251

245

231

232

265

263

264

261

237

236

229

209

201

224

221

244

213

214

247

237

222

244

213

214

247

237

242

FIGURE 3-2.MAIN BOOM INSTALLATION

3-6 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-2. MAIN BOOM INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MAIN BOOM AND CYLINDERS INSTALLATION

0272496 Ref. Booms and Cylinders Installation F

1001098639 Ref. Boom Assemblies D

101 0100011 A/R Compound, Locking

102 to 104 Not Used

105 0641608 1 Bolt 3/8in-16NC x 1in 106 0641610 1 Bolt 3/8in-16NC x 1-1/4in 107 Not Used 108 0641810 2 Bolt 1/2in-13NC x 1-1/4in 109 0641812 1 Bolt 1/2in-13NC x 1-1/2in

110 to 111 Not Used

112 0801337 1 Main Boom Assembly (See Figure 3-3 & Items 201-266 for

Breakdown)

113 to 115 Not Used

116 1684241 1 Master Cylinder Assembly (See Section 5 for Breakdown) 117 1684244 1 Upper Lift Cylinder Assembly (See Section 5 for Breakdown) 118 3311605 1 Locknut 3/8in-16NC 119 3311805 1 Locknut 1/2in-13NC

120 to 121 Not Used

122 3422177 2 Pin 123 3422178 1 Pin 124 3422582 1 Pin 125 Not Used 126 3422806 1 Pin

127 to 131 Not Used

132 3841143 2 Keeper, Pin 133 3841203 3 Keeper, Pin

0801337 Ref. JIB INSTALLATION L

201 0060050 1 Rotator Assembly (See Figure 3-4 for Breakdown) 202 0100011 A/R Compound, Locking

203 to 208 Not Used

209 0641518 2 Bolt 516in-18NC x 2-1/4in 210 Not Used 211 0641607 1 Bolt 3/8in-16NC x 7/8in 212 0641610 1 Bolt 3/8in-16NC x 1-1/4in 213 0641616 4 Bolt 3/8in-16NC x 2in 214 0641618 2 Bolt 3/8in-16NC x 2-1/4in 215 0641810 1 Bolt 1/2in-13NC x 1-1/4in

216 to 220 Not Used

221 0962292 4 Bushing 222 0961948 2 Bushing 223 0961950 2 Bushing 224 0961951 2 Bushing

225 to 228 Not Used

229 1671083 2 Cover, Jib Hose 230 Not Used

3121294 510AJ 3-7

SECTION 3 BOOM

FIGURE 3-2. MAIN BOOM INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

231 1001094789 1 Level (Platform Slave) Cylinder Assembly (See Section 5 for

Breakdown): 232 1684242 1 Jib Lift Cylinder Assembly (See Section 5 for Breakdown)

233 to 235 Not Used

236 3311505 2 Locknut 5/16in-18NC 237 3311605 10 Locknut 3/8in-16NC 238 3311805 1 Locknut 1/2in-13NC

239 to 241 Not Used

242 3340943 4 Pad, Rubber 243 3422669 1 Pin 244 3422791 2 Pin 245 3422792 1 Pin 246 3422793 1 Pin 247 3422794 2 Pin

248 to 250 Not Used

251 3841143 2 Keeper, Pin 252 3841203 1 Keeper, Pin

253 to 259 Not Used

260 4751400 6 Flatwasher 1/4in Regular 261 4751500 6 Flatwasher 5/16in Regular 262 Not Used 263 4846688 1 Link, Jib (Upper) 264 4846689 2 Link, Jib (Lower) 265 4846693 1 Pivot, Jib 266 Not Used

3-8 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-2. MAIN BOOM INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 3-9

SECTION 3 BOOM

139

140

156

157

118

157

156

140

120

116

166

140

122

105

155

160

134

107

158

128

123

117

156

140

139

140

157

117

102

103

117

118

130

150

148

150

119

154

137

162

106

141

149

136

125

110

153

170

159

127

FIGURE 3-3.MAIN BOOM ASSEMBLY

3-10 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-3. MAIN BOOM ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0801337 Ref. MAIN BOOM ASSEMBLY L

101 Not Used 102 0100011 A/R Compound, Locking 103 0100081 A/R Adhesive #454 104 Not Used 105 0561515 2 Block, Hose Clamp 106 0630401 2 Bolt, Carriage 5/16in-18NC x 2in 107 0641404 4 Bolt 1/4in-20NC x 1/2in

108 to 109 Not Used

110 0641604 4 Bolt 3/8in-16NC x 1/4in

111 to 115 Not Used

116 0641818 4 Bolt 1/2in-13NC x 2-1/4in 117 0791606 12 Screw 3/8in-16NC x 3/4in 118 0791607 16 Screw 3/8in-16NC x 7/8in 119 0801375 1 Base Weldment 120 0801374 1 Fly Weldment 121 Not Used 122 0961948 2 Bearing 123 0961950 2 Bearing 124 Not Used 125 1180377 1 Powertrack

7026120 A/R Repair Section

7026119 1 Feet, Mounting (Includes 4 Feet & Mounting Hardware) 126 Not Used 127 1671078 1 Shield 128 1671079 1 Cover, Boom End 129 Not Used 130 1684235 1 Telescope Cylinder Assembly (See Section 5 for Breakdown)

131 to 133 Not Used

134 3311402 12 Nut, Jam 1/4in-20NC 135 Not Used 136 3311505 2 Locknut 5/16in-18NC 137 3311605 10 Locknut 3/8in-16NC 138 Not Used 139 3340837 4 Pad, Wear 140 1001148652 10 Pad, Wear 141 3340940 2 Pad, Rubber

142 to 147 Not Used

148 3422996 1 Pin 149 3572448 2 Plate, Clamp 150 3760115 2 Ring, Retaining

151 to 152 Not Used

153 3900283 4 Screw, Button Head 3/8in-16NC x 3/4in 154 3900316 4 Screw, Button Head 3/8in-16NC x 1in 155 3951420 6 Setscrew 1/4in-20NC x 2-1/2in 156 4071056 10 Shim (1mm) 157 4071057 10 Shim (3mm) 158 4711400 3 Flatwasher 1/4in Thin

3121294 510AJ 3-11

SECTION 3 BOOM

FIGURE 3-3. MAIN BOOM ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

159 4711600 4 Flatwasher 3/8in Thin 160 4751400 14 Flatwasher 1/4in Regular 161 Not Used 162 4846650 1 Tube, Carrier

163 to 165 Not Used

166 4891800 4 Flatwasher 1/2in Hardened 167 Not Used 168 3941406 1 Screw, Self Tap 1/4in-20NC x 3/4in (Not Shown) 169 3311501 4 Nut, 5/16-18NC (Not Shown) 170 4891600 4 Flatwasher 3/8in Hardened

0272620 Ref. BOOM CABLES & CLAMPS INSTALLATION C

201 1060992 1 Cable, Electrical - 12/3 (AC Power Cable) (Not Shown - See

Section 7) 202 4460865 1 Plug, Male - 19 Pin (Not Shown - See Section for Location) 203 4922806 1 Harness, Main Boom (Not Shown - See Section 7) 204 4460473 1 Terminal, Cable Clamp Assembly (Not Shown - See Section 7)

3-12 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-3. MAIN BOOM ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121294 510AJ 3-13

SECTION 3 BOOM

152161112314

16817

GENUINE PARTS

272827

FIGURE 3-4.ROTATOR ASSEMBLY

3-14 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-4. ROTATOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0060050 Ref. ROTATOR ASSEMBLY F

1 See Note

1A 0962257 2 Bushing (Top) (Must be ordered separately from Case) 1B 0961947 2 Bushing (Bottom) (Must be ordered separately from Case)

2 7017140 1 Shaft 3 7017139 1 Sleeve, Piston 4 7017148 1 Cap, End

5 to 7 Not Used

8 See Note 3 Bolt 1/4in-20NC (Grade 8) (Note: Not Available for Purchase)

9 Use 7017137 1 Seal, Cap 10 Use 7017137 1 Ring, Back-Up Cap 11 Use 7017137 1 Seal, Rod 12 Use 7017137 1 Seal, Piston 13 Use 7017137 2 Packing, Bearing 14 Use 7017138 1 Bearing, Cap 15 Use 7017138 1 Bearing, Shaft 16 Use 7017138 2 Thrustwasher 17 7017172 1 Counterbalance Valve Assembly

7017192 2 Cartridge (No Seal Kit Available) 18 7017136 2 Bushing 19 70001697 6 Capscrew 1/4in-20NC x 3/8in (Grade 8)

20 to 24 Not Used

25 7017137 1 Seal Kit (Includes Items 9-13) 26 7017138 1 Bearing Kit (Includes Items 14-16) 27 See Note 1 Hardware Kit (Note: Not Available for Purchase) 28 70001697 4 Screw, Countersunk 1/4in-20NC x 3/8in (Grade 8)

Case/Bracket Weldment (Note: Not Available - Purchase

Complete Assembly)

3121294 510AJ 3-15

SECTION 3 BOOM

206

202

201

209

203

210

211

213

209

202

309 310

309

310

113B

304

303

306

305

301

312

311

302

FIGURE 3-5.PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS

3-16 510AJ 3121294

SECTION 3 BOOM

FIGURE 3-5. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PLATFORM SUPPORT INSTALLATION

0272070 Ref. Machines without LSS E

See Note Ref. Machines with LSS (Note: For Replacement Parts, Contact

JLG Customer Service and Request Manual p/n 3124287)

1 0100011 A/R Compound, Locking 2 0641812 8 Bolt 1/2in-13NC x 1-1/2in 3 0642684 1 Bolt 1in-8NC x 10-1/2in 4 0681608 8 Bolt 3/8in-16NC x 1in 5 3300243 1 Locknut 1in-8NC (was p/n 3272605) 6 3311805 8 Locknut 1/2in-13NC 7 4846573 1 Support Weldment 8 4891600 8 Flatwasher 3/8in Hardened 9 4891800 8 Flatwasher 1/2in Hardened

10 4892600 1 Flatwasher 1in Hardened

11 to 200 Not Used

1001141804 Ref. CONTROL VALVE INSTALLATIONS B

201 0100011 A/R Compound, Locking 202 0630467 6 Screw, Button Head 203 0641606 2 Bolt 3/8in-16NC x 3/4in

204 to 205 Not Used

206 1670964 1 Cover

207to 208 Not Used

209 4711500 9 Flatwasher 5/16in Thin 210 4711600 2 Flatwasher 3/8in Thin 211 4846218 1 Plate, Valve Mounting 212 Not Used 210 1001138951 1 Platform Valve Assembly (See Items 301-305 for Breakdown)

1001138951 Ref. PLATFORM VALVE ASSEMBLY (450AJ SERIES II) B

301 7012989 1 Valve, Cartridge

7012953 1 Seal Kit - 7012989 Valve

302 7023984 1 Valve, Cartridge

7012953 1 Seal Kit - 7023984 Valve

303 70003790 1 Valve, Cartridge

7021653 1 Seal Kit - 70003790 Valve

304 7012914 2 Valve, Pressure Control

7012918 2 Seal Kit - 7012914 Valve

305 7023911 1 Valve, Relief

7012967 1 Seal Kit - 7023911 Valve

306 7023912 1 Valve, Relief

7012967 1 Seal Kit - 7023912 Valve

307 7017452 2 Valve, Solenoid

7017402 2 Seal Kit - 7017452 Valve

308 70002386 6 Coil 309 See Note 2 Orifice (Note: Not Available for Purchase)

3121294 510AJ 3-17

SECTION 3 BOOM

FIGURE 3-5. PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

310 7017406 2 Plug 311 See Note 1 Plug (Note: Not Available for Purchase) 312 2221086 3 Fitting, Diagnostic

3-18 510AJ 3121294

SECTION 4

PLATFORM

3121294 510AJ 4-1

SECTION 4 PLATFORM

407

401

404

301

204

207

206

203

208

208 205

207

201

111

109

110

113

106

104 108

101 105 107

112

107

102

103

202

207

204

209B

209C

209D

209A

508

503 504 505 506

508 503

502 501

509

FIGURE 4-1.PLATFORM INSTALLATION

4-2 510AJ 3121294

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PLATFORM ASSEMBLY WITH GATE 1001145407 Ref. 6ft (1.83m) with No Mesh B 1001145409 Ref. 5ft (1.52m) with No Mesh B 1001145411 Ref. 4ft (1.22m) with No Mesh B

Ref. Note: Platform and Mesh must be ordered separately for

Platforms with Mesh. See Section 10 for Mesh Installations.

Ref. Note: Replacement Decals Must Be Ordered Separately - See

Section 8.

1 2080040 16 Fastener, Huck 2 2600281 2 Hinge, Self-Closing 3 2940074 1 Latch 4 3820020 2 Rivet, Pop 5 1001144629 1 Gate Weldment 6 1001152037 1 Cap-Plug 7 See Note 1 Platform Weldment (Note: Not Available - Purchase Platform

Assembly)

8 1001145781 2 Cap-Plug

Ref. PLATFORM ASSEMBLY WITH DROP-BAR 1001145406 Ref. 6ft (1.83m) with No Mesh B 1001145408 Ref. 5ft (1.52m) with No Mesh B 1001145410 Ref. 4ft (1.22m) with No Mesh B

Ref. Note: Platform and Mesh must be ordered separately for

Platforms with Mesh. See Section 10 for Mesh Installations.

Ref. Note: Replacement Decals Must Be Ordered Separately - See

Section 8.

101 0100011 A/R Compound, Locking 102 0641418 2 Bolt 1/4in-20NC x 2-1/4in 103 0961845 2 Bushing 104 3290606 2 Nut M6 105 3300151 2 Nut, Acorn 106 4010618 2 Screw M6 x 50mm 107 4711400 4 Flatwasher 1/4in 108 4811700 2 Flatwasher M6 109 1001138494 1 Bar, Drop 110 1001138514 1 Rail (Top) 111 1001140429 1 Decal - Drop-Bar 112 See Note 1 Platform Weldment (Note: Note Available - Purchase

Platform Assembly)

113 1001145781 2 Cap-Plug

1001143630 Ref. CONSOLE BOX & FOOTSWITCH INSTALLATION A

201 0641406 2 Bolt 1/4in-20NC x 3/4in 202 0641408 3 Bolt 1/4in-20NC x 1in 203 0641610 4 Bolt 3/8in-16NC x 1-1/4in 204 3311405 5 Locknut 1/4in-20NC 205 3311605 4 Locknut 3/8in-16NC

3121294 510AJ 4-3

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

206 3380434 1 Panel, Decal Mount 207 4740362 1 Washer, Fender 1/4in 208 4751600 8 Flatwasher 3/8in Regular 209 1001139202 1 Platform Console Box Assembly (Not Shown) (See Figure 4-2 for

Breakdown)

209A 1001117174 1 Footswitch Assembly (Includes Footswitch & Items 209B-209E) B

70002902 1 Block, Contact 70002903 1 Gasket 70002905 1 Cover

70002904 1 Bolt Kit - Cover 209B 1060918 7.5ft/2.3m Cable, Electrical - 18/3 209C 4460071 1 Connector, Strain Relief 209D 4460464 1 Pin, Male (Not Shown) 209E 4460226 2 Socket, Female (Not Shown)

Ref. TRAY INSTALLATIONS (OPTIONAL)

301 1580012 1 Tray, Storage (Center)

0274862 Ref. WORKLIGHTS INSTALLATIONS (OPTIONAL) B

401 2080040 4 Fastener, Huck

402 to 403 Not Used

404 2920140 2 Worklight Assembly (Includes Nut & Flatwasher)

7016399 2 Bulb, Replacement (1 Per Worklight)

405 to 406 Not Used

407 3536089 2 Plate, Mounting

408 to 412 Not Used

413 4460426 1 Connector, Strain Relief (Not Shown - Located at Console Box):

414 to 416 Not Used

417 2820035 9 Loom, Vinyl (Not Shown) 418 4240099 10 Tie-Strap (Not Shown)

0272921 Ref. FLOODLIGHTS INSTALLATION (OPTIONAL) A

501 0641518 2 Bolt 5/16in-18NC x 2-1/4in 502 2560173 2 Handle, Star Knob 503 2920157 2 Floodlight

7024452 2 Bulb, Replacement (1 Per Light) 504 3250585 1 Nameplate - Lights On 505 4060802 1 Guard, Switch 506 4360336 1 Switch, Toggle 507 4420037 A/R Tape, Insulation (Not Shown) 508 4751800 2 Flatwasher 1/2in Regular 509 4846561 1 Mount, Light 510 Not Used 511 0641406 Bolt 1/4in-20NC x 3/4in (Used with #413 - Not Shown) 512 1060663 72ft/22m Cable, Electrical 12/3 (Not Shown) 513 1320222 1 J-Clip (Not Shown) 514 3311405 1 Locknut 1/4in-20NC (Used with #413 - Not Shown)

4-4 510AJ 3121294

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

515 4711400 2 Flatwasher 1/4in Thin (Used with #413 - Not Shown)

3121294 510AJ 4-5

SECTION 4 PLATFORM

101

102

42 25

363837

513

103

105

32A

301

302

201

601

401

106

104

FIGURE 4-2.PLATFORM CONSOLE ASSEMBLY

4-6 510AJ 3121294

JLG 510AJ Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1.AXLE AND STEERING INSTALLATION

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

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

FIGURE 1-4. DRIVE HUB ASSEMBLY (FRONT)

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

FIGURE 1-6.DRIVE VALVES AND FRAME SHIELDS INSTALLATION

FIGURE 2-1.MAIN CONTROL VALVE AND ALARM INSTALLATIONS

FIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

FIGURE 2-3.TURNTABLE AND SWING DRIVE INSTALLATIONS

FIGURE 2-4.SWING MOTOR ASSEMBLY

FIGURE 2-5.SWING BEARING & ROTATION BOX ASSEMBLY

FIGURE 2-6.CATERPILLAR ENGINE INSTALLATION

FIGURE 2-7.DEUTZ ENGINE INSTALLATION

FIGURE 2-8.PISTON PUMP ASSEMBLY

FIGURE 2-9. AUXILIARY PUMP ASSEMBLY

FIGURE 2-10.TANK INSTALLATIONS

FIGURE 2-11.GROUND CONTROL BOX ASSEMBLY

FIGURE 2-12.LIGHT INSTALLATIONS

FIGURE 2-13.HOODS INSTALLATION

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

FIGURE 3-2.MAIN BOOM INSTALLATION

FIGURE 3-3.MAIN BOOM ASSEMBLY

FIGURE 3-4.ROTATOR ASSEMBLY

FIGURE 3-5.PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS

FIGURE 4-1.PLATFORM INSTALLATION

FIGURE 4-2.PLATFORM CONSOLE ASSEMBLY