JLG 510AJ Parts Manual

Download

Page 1

Illustrated Parts Manual

Model

510AJ

S/N 1300000100

TO PRESENT

PRIOR TO

S/N E300001114

3121182

August 30, 2013

Page 2

Page 3

REVISION LOG

MODULE ON MACHINES

“WITHOUT UGM”

(UNIVERSAL

GROUND MODULE)

MODULE ON MACHINES

“WITH UGM” (UNIVERSAL

GROUND MODULE)

GROUND MODULE MODULE IDENTIFICATION

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 are also built to the same specs as Romanian Built Machines S/N E300001114 to Present - Use Parts Manual p/n 3121294.

NOTE:

REVISION LOG:

August 29, 2003 - Revised Manual (Edited to B/M 0010578 Revision 39)

November 20, 2003 - Revised Manual (Edited to B/M 0010578 Revision 45)

March 17, 2004 - Revised Manual (Edited to B/M 0010578 Revision 46)

September 30, 2004 - Revised Manual (Edited to B/M 0010578 Revision 58)

December 15, 2004 - Revised Manual (Edited to B/M 0010578 Revision 60)

October 15, 2005 - Revised Manual (Edited to B/M 0010578 Revision 75)

April 7, 2006 - Revised Manual (Edited to B/M 0010578 Revision 84)

August 15, 2006 - Revised Manual (Edited to B/M 0010578 Revision 93)

March 1, 2007 - Revised Manual (Edited to 0010578 Revision 109)

July 31, 2007 - Revised Manual (Edited to 0010578 Revision 119)

November 30, 2007 - Revised Manual (Edited to 0010578 Revision 121)

April 15, 2008 - Revised Manual (Edited to B/M 0010578 Revision 121 & B/M 0010717 Revision 1)

March 30, 2009 - Revised Manual (Edited to B/M 0010717 Revision 5)

October 30, 2009 - Revised Manual (Edited to B/M 0010717 Revision 5)

3121182 510AJ A

Page 4

REVISION LOG

September 1, 2010 - Revised Manual (Edited to B/M 0010717 Revision 19)

April 4, 2011 - Revised Manual (Edited to B/M 0010717 Revision 22)

July 8, 2011 - Revised Manual (Edited to B/M 0010717 Revision 23)

October 18, 2011 - Revised Manual (Edited to 0010717 Revision 25)

December 12, 2011 - Revised Manual (Edited to 0010717 Revision 27)

March 30, 2012 - Revised Manual (Edited to 0010717 Revision B)

July 23, 2012 - Revised Manual (Edited to 0010717 Revision C)

November 6, 2012 - Revised Manual (Edited to 0010717 Revision C)

March 25, 2013 - Revised Manual (Edited to 0010717 Revision C)

May 17, 2013 - Revised Manual (Edited to 0010717 Revision C)

August 30, 2013 - Revised Manual (Edited to 0010717 Revision C)

B 510AJ 3121182

Page 5

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 INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 DRIVE HUB/BRAKE ASSEMBLY (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4 DRIVE HUB/BRAKE ASSEMBLY (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-5 DRIVE HUB ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-6 DRIVE HUB ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-7 DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO

S/N 1300002249) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1-8 DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO

S/N E300001114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-9 DRIVE VALVES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

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

2-1 CONTROL VALVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

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

2-4 SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT FOR BELGIUM BUILT

MACHINES PRIOR TO S/N 1300006701) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT FOR BELGIUM BUILT

MACHINES PRIOR TO S/N 1300006701 & ORIGINAL EQUIPMENT FOR BELGIUM BUILT MACHINES S/N 1300006701 TO PRESENT & ROMANIAN

BUILT MACHINES S/N E300000100 TO S/N E300001114) . . . . . . . . . . . . . . . . . . 2-12

2-6 SWING BEARING & ROTATION BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-7 CATERPILLAR ENGINE INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-8 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM)

(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-9 DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO

S/N 1300000981) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-10 DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO

S/N E300001114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2-11 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . . . 2-46

2-12 PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN)

(WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

2-13 PERKINS ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN)

(WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2-14 PERKINS ENGINE INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

2-15 2500W GENERATOR INSTALLATION - PERKINS MACHINES (OPTIONAL) . . . . . . . . 2-78

2-16 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

2-17 AUXILIARY PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

2-18 TANK INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

2-19 GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . . 2-94

2-20 GROUND CONTROL BOX ASSEMBLY (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

2-21 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . 2-102

2-22 HOODS INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N 1300006659). 2-106 2-23 HOODS INSTALLATION (BELGIUM BUILT MACHINES S/N 1300006659 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO

S/N E300001114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

3121182 510AJ i

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-3 CONTROLLER ASSEMBLY (LIFT AND SWING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-4 CONTROLLER ASSEMBLY (DRIVE & STEER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-5 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

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

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES PRIOR

TO S/N 1300003223). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 AXLE LOCKOUT CYLINDER ASSEMBLY (BELGIUM BUILT MACHINES

S/N 1300003223 TO PRESENT & ROMANIAN BUILT MACHINES

S/N E300000100 TO S/N E300001114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LEVEL (PLATFORM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 LIFT (JIB) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

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

5-6 LIFT (TOWER BOOM) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-8 STEER CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-9 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

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

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR

TO S/N 1300000353). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES

S/N 1300000353 TO S/N 1300003223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 AXLE LOCKOUT HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES

S/N 1300003223 TO PRESENT & ROMANIAN BUILT MACHINES

S/N E300000100 TO S/N E300001114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES PRIOR TO

S/N 1300003476) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-5 DRIVE HYDRAULIC DIAGRAM (BELGIUM BUILT MACHINES S/N 1300003476 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO

S/N E300001114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-6 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-7 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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

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

7-2 ELECTRICAL SCHEMATIC (WITHOUT UGM) (SEE FIGURE 7-1 FOR USAGE) . . . . . . 7-4

7-3 ELECTRICAL SCHEMATIC (WITHOUT UGM) (SEE FIGURE 7-1 FOR USAGE) . . . . . . 7-8

7-4 ELECTRICAL SCHEMATIC (WITHOUT UGM) (SEE FIGURE 7-1 FOR USAGE) . . . . . . 7-14

7-5 ELECTRICAL SCHEMATIC (WITH UGM) (SEE FIGURE 7-1 FOR USAGE) . . . . . . . . . . 7-20

ii 510AJ 3121182

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

7-6 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . . . 7-26

7-7 HARNESS COMPONENTS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . 7-42

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

8-1 DECALS INSTALLATION - ANSI SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECALS INSTALLATION - ANSI EXPORT SPECS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-3 DECALS INSTALLATION - CE & AUSTRALIAN SPECS. . . . . . . . . . . . . . . . . . . . . . . . . 8-12

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

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

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

3121182 510AJ iii

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 510AJ 3121182

Page 9

SECTION 1

FRAME

3121182 510AJ 1-1

Page 10

SECTION 1 FRAME

112

119

106

114

108

121

116

107

122

110

123A

109

105

120

216

213

205

223

205

202

204

215

217

208

210

207

211

214

207

214

121A

115

104

113

117

103

118

111

BELGIUM BUILT MACHINES

PRIOR TO S/N

1300000353

BELGIUM BUILT MACHINES

S/N 1300000353 TO PRESENT &

ROMANIAN BUILT MACHINES S/N E300000100 TO PRESENT

203

201

212

209

214

206

222

123B

125

101

126

117

124

201

250

201

101

GENUINE PARTS

FIGURE 1-1.AXLE AND STEERING INSTALLATION

1-2 510AJ 3121182

Page 11

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. OSCILLATING AXLE INSTALLATIONS 0272424 Ref. Belgium Built Machines Prior to S/N 1300000353 E 0273497 Ref. Belgium Built Machines S/N 1300000353 to S/N 1300003223 C 0274753 Ref. Belgium Built Machines S/N 1300003223 to Present A 0274753 Ref. Romanian Built Machines S/N E300000100 to S/N E300001114 A

101 0100011 A/R Compound, Locking

0100019 A/R Compound, Locking

102 0100038 A/R Primer, Locking #7471 103 0641416 4 Bolt 1/4in-20NC x 2in (Belgium Built Machines Prior to

S/N 1300000353)

104 0641607 2 Bolt 3/8in-16NC x 3/4in (Belgium Built Machines Prior to

S/N 1300003223)

105 0641810 2 Bolt 1/2in-13NC x 1-1/4in (Belgium Built Machines Prior to

S/N 1300000353) 106 0642012 1 Bolt 5/8in-11NC x 1-1/2in 107 0682248 2 Bolt 3/4in-10NC x 6in (Belgium Built Machines Prior to

S/N 1300003223) 108 0961950 2 Bushing 109 1100134 1 Cam, Lockout (Belgium Built Machines Prior to

S/N 1300000353) 110 3272201 2 Nut 3/4in-10NC (Belgium Built Machines Prior to

S/N 1300003223) 111 3311405 4 Locknut 1/4in-20NC (Belgium Built Machines Prior to

S/N 1300000353) 112 3422592 1 Pin, Axle Pivot 113 3422520 2 Pin (Belgium Built Machines Prior to S/N 1300003223) 114 3841258 1 Keeper, Pin 115 3841520 2 Keeper, Pin (Belgium Built Machines Prior to S/N 1300003223) 116 4567462 2 Tube, Mounting (Belgium Built Machines Prior to

S/N 1300003223) 117 1 Lockout Valve Assembly Options:

4640871 Valve used on Belgium Built Machines Prior to

S/N 1300000353 7012693 1 Seal Kit - 4640871 Valve 7002840 1 Anti-Rotation Pin Removal Tool 4641265 Valve used on Belgium Built Machines S/N 1300000353 to

Present 4641265 Valve used on Romanian Built Machines S/N E300000100 to

S/N E300001114

118 4711400 4 Flatwasher 1/4in Thin (Belgium Built Machines Prior to

S/N 1300000353) 119 4740158 1 Thrustwasher 120 4752000 4 Flatwasher 5/8in Regular (Belgium Built Machines Prior to

S/N 1300000353)

3121182 510AJ 1-3

Page 12

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

121 1 Axle Weldment Options:

Note: If kingpin holes in the axle measure 1.503in diameter or larger in any direction, axle weldment must be replaced. Note: See Kit Item 250 & additional notes at end of parts list before ordering parts.

4846660 1 Belgium Built Machines Prior to S/N 1300003223 0280203 1 Belgium Built Machines S/N 1300003223 to Present 0280203 1 Romanian Built Machines S/N E300000100 to

S/N E300001114

121A 0561511 2 Steer Cylinder Mounting Block Assembly

122 4892200 4 Flatwasher 3/4in Hardened (Belgium Built Machines Prior to

S/N 1300003223)

123 2 Lockout Cylinder Assembly Options (See Section 5 for

Breakdown): 123A 1684243 Belgium Built Machines Prior to S/N 1300003223 123B 1684465 Belgium Built Machines S/N 1300003223 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114

124 0791506 4 Screw 5/16in-18NC x 3/4in (Belgium Built Machines

S/N 1300000353 to Present)

125 0641814 8 Bolt 1/2in-13NC x 1-3/4in (Belgium Built Machines

S/N 1300003223 to Present)

126 4891800 8 Flatwasher 1/2in Hardened (Belgium Built Machines

S/N 1300003223 to Present & Romanian Built Machines

S/N E300000100 to S/N E300001114)

0272428 Ref. STEERING INSTALLATION F

201 0100011 A/R Compound, Locking 202 A/R Thrustwasher Options:

0440161 Belgium Built Machines Prior to S/N 1300000441(Top &

Bottom Kingpin Location) (Note: See Kit Item 250 & additional

notes at end of parts list before ordering parts)

4740537 Belgium Built Machines S/N 1300000441 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114

(.0625)(Top Kingpin Location)

4740538 Belgium Built Machines S/N 1300000441 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114

(.125)(Top Kingpin Location)

4740539 Belgium Built Machines S/N 1300000441 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114

(.188)(Top Kingpin Location)

4740540 Belgium Built Machines S/N 1300000441 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114

(.250)(Top Kingpin Location)

0440271 Belgium Built Machines S/N 1300000441 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114

(Bottom Kingpin Location)

203 0641606 16 Bolt 3/8in-16NC x 3/4in 204 0641824 4 Bolt 1/2in-13NC x 3in

1-4 510AJ 3121182

Page 13

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

205 2 Bushing / Bearing Options:

0961951 Belgium Built Machines Prior to S/N 1300000441

(Top & Bottom Kingpin Location) (Note: See Kit Item 250 &

additional notes at end of parts list before ordering parts)

Belgium Built Machines S/N 1300000441 to Present & Romanian Built Machines S/N E300000100 to S/N E300001114

Options: 0440291 (Top Kingpin Location) 0440274 (Bottom Kingpin Location)

206 0962140 2 Bearing, Garmax 207 3312008 4 Nut 5/8in-11NC 208 3322201 2 Nut 3/4in-16NC 209 4 Kingpin Options:

3422716 Belgium Built Machines Prior to S/N 1300000441

(2 Bolt Mounting) (Note: See Kit Item 250 & additional notes

at end of parts list before ordering parts)

3423081 Belgium Built Machines S/N 1300000441 to Present

(4 Bolt Mounting) 3423081 Romanian Built Machines S/N E300000100 to S/N E300001114

210 2 Rod-End with Grease Fitting

3841367 Belgium Built Machines Prior to S/N 130005313 3841517 Belgium Built Machines S/N 130005313 to Present 3841517 Romanian Built Machines S/N E300000100 to S/N E300001114

211 3900109 4 Screw, Shoulder 212 1 Spindle (Left Side) Options:

4130391 Belgium Built Machines Prior to S/N 1300000441 4130408 Belgium Built Machines S/N 1300000441 to Present 4130408 Romanian Built Machines S/N E300000100 to S/N E300001114

213 1 Spindle (Right Side) Options:

4130392 Belgium Built Machines Prior to S/N 1300000441 4130407 Belgium Built Machines S/N 1300000441 to Present 4130407 Romanian Built Machines S/N E300000100 to S/N E300001114

214 4740086 4 Thrustwasher 215 4751800 4 Flatwasher 1/2in Regular 216 4846666 2 Tie-Rod 217 1684246 1 Steer Cylinder Assembly (See Section 5 for Breakdown)

218 to 221 Not Used

222 3780182 2 O-Ring (Belgium Built Machines S/N 1300003223 to Present &

Romanian Built Machines S/N E300000100 to S/N E300001114)

223 3020029 A/R Grease, Bearing

224 to 249 Not Used

— — — — — — — — — —

3121182 510AJ 1-5

Page 14

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

250 2902400 1 Kingpin & Bushings Update Kit for Belgium Built Machines Built

Prior to S/N 1300000441 (Includes Newer “Belgium Built Machines S/N 1300000441 to Present” Design Items 202, 205, 210 & 222). Refer to Field Service Bulletin AWP-04-11.

Ref. Note: Newer bushings will fit in “Belgium Built Machines

Prior to S/N 1300000441” axles however if kingpin holes measure 1.503in diameter or larger in any direction, axle weldment must be replaced before installation of kit.

Ref. Note: Spindles require drilling & tapping for 8 additional

kingpin mtg bolts. Newer design kingpins require 4 mtg bolts each.

Ref. Note: All Romanian Built Machines have the newer design

axle.

1-6 510AJ 3121182

Page 15

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

’

3121182 510AJ 1-7

Page 16

SECTION 1 FRAME

FIGURE 1-2.TIRE AND WHEEL DRIVE INSTALLATIONS

1-8 510AJ 3121182

Page 17

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE INSTALLATIONS 0272320 Ref. Prior to S/N 1300000159 C 0272895 Ref. S/N 1300000159 to S/N 1300003223 G 0275854 Ref. S/N 1300003223 to S/N E300001114 C

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking

3 to 8 Not Used

9 A/R Hardware Options:

0681810 8 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Both Front & Rear Axle)

(Belgium Built Machines Prior to S/N 1300000162)

0681810 4 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Front Axle)

(Belgium Built Machines S/N 1300000162 to Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

3311801 4 Nut 1/2in-13NC (Not Shown) (Rear Axle)

(Belgium Built Machines S/N 1300000162 to Present & Romanian Built Machines S/N E300000100 to

S/N E300001114) 10 0682014 24 Bolt 5/8in-11NC x 1-3/4in (Grade 8) 11 2 Drive Hub/Brake Assembly (Rear) Options:

2780256 Belgium Built Machines Prior to S/N 1300000159 (See Figure

1-3 For Breakdown)

2780267 Belgium Built Machines S/N 1300000159 to Present &

Romanian Built Machines S/N E300000100 to

S/N E300001114 (See Figure 1-4 For Breakdown) 12 2 Drive Hub Assembly (Front) Options:

2780257 Belgium Built Machines Prior to S/N 1300000159 (See Figure

1-5 For Breakdown)

2780268 Belgium Built Machines S/N 1300000159 to Present &

Romanian Built Machines S/N E300000100 to

S/N E300001114 (See Figure 1-6 For Breakdown) 13 4 Drive Motor Assembly Options:

Use 3160348 Belgium Built Machines Prior to S/N 1300002249 (was p/n

3160266 - See Figure 1-7 For Breakdown) (For 3160348

Motor - See Figure 1-8 for Breakdown)

3160348 Belgium Built Machines S/N 1300002249 to Present &

Romanian Built Machines S/N E300000100 to

S/N E300001114 (See Figure 1-8 For Breakdown) 14 3300106 36 Lugnut

15 to 17 Not Used

18 A/R Seal Options:

18A 3790045 2 O-Ring Belgium Built Machines Prior to S/N 1300002638 18B 3960526 4 Gasket Belgium Built Machines S/N 1300002638 to Present

& Romanian Built Machines S/N E300000100 to

S/N E300001114

19 to 26 Not Used

27 4891800 8 Flatwasher 1/2in Hardened 28 4892000 24 Flatwasher 5/8in Hardened

29 to 30 Not Used

31 2300016 A/R Fluid, Hydraulic (Not Shown) 32 3020008 A/R Lubricant, Mobilube HD 80W - 90 (Not Shown)

3121182 510AJ 1-9

Page 18

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

33 to 200 Not Used

Ref. TIRE AND WHEEL INSTALLATION OPTIONS

0258028 Ref. 12 x 16.5 Pneumatic (ANSI/ANSI Export/CSA/Japanese Specs

Only. Not Available on CE/Australian Specs)

0258030 Ref. 12 x 16.5 Foam-Filled (Available on all Specs) A 0270674 Ref. 12 x 16.5 Foam-Filled, Non-Marking (Available on all Specs) B 0258031 Ref. 33/1550 x 16.5 Foam-Filled B 0258831 Ref. 33/16LL x 16.1 Pneumatic (ANSI/ANSI Export/CSA/

Japanese Specs Only. Not Available on CE/Australian Specs) (Requires special counterweighting)

0257740 2 12 x 16.5 Pneumatic Right Side (Not Available on CE/

Australian Specs)

0257746 2 12 x 16.5 Pneumatic Left Side (Not Available on CE/

Australian Specs) 0258009 2 12 x 16.5 Foam-Filled Right Side C 0258010 2 12 x 16.5 Foam-Filled Left Side C 0270675 2 12 x 16.5 Foam-Filled Non-Marking Right Side A 0270676 2 12 x 16.5 Foam-Filled Non-Marking Left Side A 0258011 2 33/1550 x 16.5 Foam-Filled Right Side D 0258012 2 33/1550 x 16.5 Foam-Filled Left Side D 0258830 4 33/16LL x 16.1 Pneumatic (Not Available on CE/

Australian Specs) (Requires special counterweighting)

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

manufacture’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 1 Decal Options (Pneumatic Only):

1702740 1 Decal - 90PSI 1703067 1 Decal - 40PSI

202 1 Tire Options:

4520216 12 x 16.5 NHS (OTR Brand) 4520240 12 x 16.5 Non-Marking (OTR Brand) 4520217 33/1550 x 16.5 NHS (OTR Brand) 4520212 33/16LL x 16.1 (Galaxy Brand)

203 1 Valve Stem Options:, Air (Pneumatic Only)

4640113 All except 33/1550 x 16.5 Foam-Filled Tire & Wheel Assy 8786514 33/1550 x 16.5 Foam-Filled Tire & Wheel Assy Only

204 1 Rim, Wheel Options:

4860178 16.5 x 12 (Use with 12 x 16.5 Tires) 4860179 16.5 x 12 (Use with 33/1550 x 16.5 Tires) 4860193 16.1 x 14 (Use with 33/16LL x 16.1 Tires)

1-10 510AJ 3121182

Page 19

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-11

Page 20

SECTION 1 FRAME

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

1-12 510AJ 3121182

Page 21

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. USAGE: USED BELGIUM BUILT MACHINES PRIOR TO

S/N 1300000159

2780256 Ref. DRIVE HUB/BRAKE ASSEMBLY F

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

individual Components)

1A 7024105 1 Spindle

1B 7024113 1 Seal 1C 7007006 2 Cone, Bearing 1D 7024112 2 Cup, Bearing 1E 7024110 1 Housing/Ring Gear 1F 7024109 1 Thrustwasher 1G 7024107 1 Ring, Retaining

1H to 1M Not Used

1N 7024111 9 Stud, Wheel

2 7024106 1 Brake, Input

2A 7024710 1 Kit, Brake Lining (Includes Qty 8 Outer Plates & Qty 7 Inner

Plates) 2B 7024709 1 Kit, Brake O-Ring (Includes Qty 2 O-RIngs & Back-up RIngs) 2C 7024711 1 Kit, Brake Spring (Includes Qty 12 Springs) 2D 7024719 1 Kit, Brake Hardware (Includes End Plate, Spacer & Qty 2 E-

Clips)

3 See Note 1 Carrier Assembly (Note: Not Available - Purchase individual

Components)

3A 7024116 1 Carrier 3B 7024127 6 Thrustwasher 3C 7024123 42 Bearing, Needle 3D Not Used 3E 7024120 3 Shaft, Planet 3F 7024118 3 Gear, Planet

4 See Note 1 Carrier Assembly (Note: Not Available - Purchase individual

Components)

4A 7024117 1 Carrier 4B 7024126 6 Thrustwasher 4C 7024122 45 Bearing, Needle 4D Not Used 4E 7024121 3 Shaft, Planet 4F 7024119 3 Gear, Planet 4G 7001913 3 Rollpin 4H 7024128 1 Thrustwasher

4I 7024124 1 Spring

4J 7024129 1 Thrustwasher

4K 7024125 1 Thrustwasher

5Not Used 6 See Note 1 Cover Assembly (Note: Not Available - Purchase individual

Components)

6A 7024132 1 Plate, Cover 6B 7017093 1 Cap, Disengage 6C 0641404 2 Bolt 1/2in-20NC x 1/2in

3121182 510AJ 1-13

Page 22

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

6D 7017092 1 Pin, Dowel 6E 7017095 1 O-Ring 6F 7024134 1 O-Ring

7 7024130 1 Shaft, Input 8 7024115 1 Gear, Sun

9 7024131 1 Coupling 10 7017097 1 Spacer, Thrust 11 7017094 2 Plug, Pipe 12 7024108 1 Plug, Pressure 13 Not Used 14 7024133 12 Bolt 1/4in-20NC x 7/8in (Grade 8) 15 See Note 1 Plate, ID (Not Shown) (Note: Not Available for Purchase) 16 7017082 1 Plug, O-Ring 17 7024114 1 Gear, Sun

— — — — — — — — — —

100 7024198 1 Seal Kit (Includes Items 1B,1G & 6F)

1-14 510AJ 3121182

Page 23

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-15

Page 24

SECTION 1 FRAME

FIGURE 1-4.DRIVE HUB/BRAKE ASSEMBLY (REAR)

1-16 510AJ 3121182

Page 25

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (REAR)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. USAGE: USED BELGIUM BUILT MACHINES S/N 1300000159 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114

2780267 Ref. DRIVE HUB/BRAKE ASSEMBLY D

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

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

3121182 510AJ 1-17

Page 26

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

11 7000253 1 Thrustwasher 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 101-123 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 I7024193 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 Use 7024197 1 Bearing, Ball 111 Use 7024197 1 Ring, Retaining 112 Use 7024197 1 Seal, Shaft 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

152

153 7024193 1 Friction Disc Kit, Brake (Includes Items 103, 104, 106 & 107) 154 7024197 1 Bearing Kit, Brake (Includes Items 107 & 110-112)

Use 7024196 1 Spring Kit, Brake (Includes 12 Natural Colored Springs Item 122)

(was p/n 7024195)

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

2 Blue Springs Colored Springs Item 123))

1-18 510AJ 3121182

Page 27

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (REAR) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-19

Page 28

SECTION 1 FRAME

FIGURE 1-5.DRIVE HUB ASSEMBLY (FRONT)

1-20 510AJ 3121182

Page 29

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (FRONT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. USAGE: BELGIUM BUILT MACHINES USED PRIOR TO S/N

1300000064

2780257 Ref. DRIVE HUB ASSEMBLY E

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

Individual Components)

1A 7024105 1 Spindle 1B 7024113 1 Seal 1C 7007006 2 Cone, Bearing 1D 7024112 2 Cup, Bearing 1E 7024110 1 Housing/Ring Gear 1F 7024109 1 Thrustwasher 1G 7024107 1 Ring, Retaining

1H to 1M Not Used

1N 7024111 9 Stud, Wheel

2Not Used

3 See Note 1 Carrier Assembly (Note: Not Available - Purchase Individual

Components)

3A 7024116 1 Carrier 3B 7024127 6 Thrustwasher 3C 7024123 42 Bearing, Needle 3D Not Used 3E 7024120 3 Shaft, Planet 3F 7024118 3 Gear, Planet

4 See Note 1 Carrier Assembly (Note: Not Available - Purchase Individual

Components)

4A 7024117 1 Carrier 4B 7024126 6 Thrustwasher 4C 7024122 45 Bearing, Needle 4D Not Used 4E 7024121 3 Shaft, Planet 4F 7024119 3 Gear, Planet 4G 7001913 3 Rollpin 4H 7024128 1 Thrustwasher

4I 7024124 1 Spring

4J 7024129 1 Thrustwasher

4K 7024125 1 Thrustwasher

5Not Used

6 See Note 1 Cover Assembly (Note: Not Available - Purchase Individual

Components)

6A 7024132 1 Plate, Cover 6B 7017093 1 Cap, Disengage 6C 0641404 2 Bolt 1/2in-20NC x 1/2in 6D 7017092 1 Pin, Dowel 6E 7017095 1 O-Ring 6F 7024134 1 O-Ring

7 7024130 1 Shaft, Input

8 7024115 1 Gear, Sun

9 7024131 1 Coupling

3121182 510AJ 1-21

Page 30

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

10 7017097 1 Spacer, Thrust 11 7017094 2 Plug, Pipe 12 7024108 1 Plug, Pressure 13 Not Used 14 7024133 12 Bolt 1/4in-20NC x 7/8in (Grade 8) 15 See Note 1 Plate, ID (Not Shown) (Note: Not Available For Purchase) 16 7017082 1 Plug, O-Ring 17 7024114 1 Gear, Sun

— — — — — — — — — —

100 7024198 1 Seal Kit (Includes Items 1B,1G & 6F)

1-22 510AJ 3121182

Page 31

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-23

Page 32

SECTION 1 FRAME

FIGURE 1-6.DRIVE HUB ASSEMBLY (FRONT)

1-24 510AJ 3121182

Page 33

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. USAGE: USED ON BELGIUM BUILT MACHINES S/N 1300000064

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114

2780268 Ref. DRIVE HUB ASSEMBLY C

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

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

3121182 510AJ 1-25

Page 34

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

11 7000253 1 Thrustwasher 12 7017067 12 Bolt 13 7017080 4 Pin, Dowel 14 7000206 1 Coupling 15 7024715 1 Spacer, Input 16 7024716 1 Spacer, Input

1-26 510AJ 3121182

Page 35

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-27

Page 36

SECTION 1 FRAME

373938

3435363240

FIGURE 1-7.DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N

1300002249)

1-28 510AJ 3121182

Page 37

SECTION 1 FRAME

FIGURE 1-7. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N

1300002249)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160266 Ref. DRIVE MOTOR ASSEMBLY D

Ref. Note: Original Equipment Motor p/n 3160266 uses 4 bolts to

assemble the motor. Service Replacement Motor p/n 3160348 motors use 5 bolts to assemble the motor. Visually identify component before ordering parts. If equipped with 3160348 refer to next illustration.

1 7022302 2 Bearing, Journal

2 Use 7022328 1 O-Ring

3 Use 7022328 1 O-Ring

4 7007446 1 Pin

5 7007438 2 Ring, Retaining

6 7022305 1 Swashplate

7 Use 7022328 1 O-Ring

8 7023907 1 Cylinder Block Kit (Includes Items 10-19)

9 7023908 1 Plate, Valve

10 Use 7023907 1 Block, Cylinder 11 7021277 1 Guide, Slipper Retainer 12 7021275 3 Pin, Slipper Hold Down 13 Use 7023907 9 Piston Assembly 14 7021276 1 Retainer, Hold Down Pin 15 7022310 1 Retainer, Slipper 16 7022311 1 Ring, Retaining 17 7022312 1 Spring 18 7022313 1 Washer 19 7022314 1 Retainer, Spring 20 7023910 1 Shaft 21 7007439 1 Ring, Retaining 22 7022367 1 Cap, End - Axial 23 7022368 4 Screw 24 7021249 1 Bearing, Needle 25 7022321 1 Plug (Includes Item 26) 26 Use 7022328 1 O-Ring 27 7022318 1 Plug (Includes Item 28) 28 Use 7022328 1 O-Ring 29 7007419 2 Plug (Includes Item 30) 30 Use 7022328 2 O-Ring 31 7022372 1 Seat, Spring 32 7022370 1 Housing 33 7022318 2 Plug (Items Item 34) 34 Use 7022328 2 O-Ring 35 7022321 1 Plug (Items Item 36) 36 Use 7022328 1 O-Ring 37 7022323 1 Piston, Servo (Includes Items 38 & 39) 38 Use 7022328 1 O-Ring 39 Use 7022328 1 Ring, Seal 40 7007437 1 Bearing 41 7022326 1 Spring 42 Use 7022328 1 Seal, Lip

3121182 510AJ 1-29

Page 38

SECTION 1 FRAME

FIGURE 1-7. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N

1300002249) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

43 7022371 1 Washer, Support 44 Not Used 45 7022328 1 Seal Kit (Includes Items 2,3,7,26,28,30,34,36,38,39 and 42)

1-30 510AJ 3121182

Page 39

SECTION 1 FRAME

FIGURE 1-7. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES PRIOR TO S/N

1300002249) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-31

Page 40

SECTION 1 FRAME

FIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

1-32 510AJ 3121182

Page 41

SECTION 1 FRAME

FIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE MOTOR ASSEMBLY

3160348 Ref. Original Equipment Motor for Belgium Built Machines

S/N 1300002249 to Present & Romanian Built Machines S/N E300000100 to S/N E300001114

3160348 Ref. Service Replacement Motor for p/n 3160266 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

3121182 510AJ 1-33

Page 42

SECTION 1 FRAME

FIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

42 to 44 Not Used

45 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)

1-34 510AJ 3121182

Page 43

SECTION 1 FRAME

FIGURE 1-8. DRIVE MOTOR ASSEMBLY (BELGIUM BUILT MACHINES S/N 1300002249 TO

PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-35

Page 44

SECTION 1 FRAME

FIGURE 1-9.DRIVE VALVES INSTALLATIONS

1-36 510AJ 3121182

Page 45

SECTION 1 FRAME

FIGURE 1-9. DRIVE VALVES INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE VALVES INSTALLATION 0272320 Ref. Belgium Built Machines Prior to S/N 1300000064 C 0272895 Ref. Belgium Built Machines S/N 1300000064 to S/N 1300003223 G 0275854 Ref. Belgium Built Machines S/N 1300003223 to Present C 0275854 Ref. Romanian Built Machines S/N 1300003223 to S/N E300001114 C

101 to 102 Not Used

103 0363012 2 Bar, Clamping 104 0641420 2 Bolt 1/4in-20NC x 2-1/2in 105 0641618 4 Bolt 3/8in-16NC x 2-1/4in 106 0641530 2 Bolt 5/16in-18NC x 3-3/4in (Belgium Built Machines Prior to S/N

1300003223)

0641560 3 Bolt 5/16in-18NC x 7-1/2in (Belgium Built Machines S/N

1300003223 to Present Romanian Built Machines S/N E300000100 to S/N E300001114)

107 0641538 2 Bolt 5/16in-18NC x 4-3/4in (Belgium Built Machines Prior to

S/N 1300003223 Only)

108 to 114 Not Used

115 3311505 A/R Locknut 5/16in-18NC 116 Not Used 117 3340911 4 Rubber, Clamp

118 to 120 Not Used

121 4641208 1 Flow Divider Valve Assembly (Belgium Built Machines Prior to

S/N 1300003223 Only)

121A 7023934 2 Valve, Cartridge (Flow Divider) (4641208 Valve)

7021655 2 Seal Kit - 7023934 Flow Divider Cartridge

121B 7023935 4 Valve, Cartridge (Check) (4641208 Valve)

7023936 4 Seal Kit - 7023935 Check Cartridge

122 1 Flow Divider Valve Assembly Options:

122A 4641207 1 Flow Divider Valve Assembly (Belgium Built Machines Prior to

S/N 1300003223)

122B 7023917 1 Valve, Cartridge (Flow Divider) (Used on 4641207 Valve)

7021625 1 Seal Kit - 7021625 Flow Divider Cartridge

122C 7022397 1 Valve, Cartridge (Check) (4641207 Valve)

7022399 1 Seal Kit - 7022397 Check Cartridge

122D 7010542 2 Valve, Cartridge (Load Shuttle) (4641207 Valve)

7010543 2 Seal Kit - 7010542 Load Shuttle Cartridge

122E 4641510 1 Flow Divider Valve Assembly (Belgium Built Machines

S/N 1300003223 to Present) & Romanian Built Machines S/N E300000100 to S/N E300001114

122F 7023917 1 Valve, Cartridge (Flow Divider) ( 4641510 Valve)

7021625 1 Seal Kit - 7023917 Flow Divider Cartridge

122G 7023934 2 Valve, Cartridge (Flow Divider) (4641510 Valve)

7021655 2 Seal Kit - 7023934 Flow Divider Cartridge

122H 7022397 5 Valve, Cartridge (Check) (4641510 Valve)

7022399 5 Seal Kit - 7022397 Check Cartridge

122J 7021639 2 Valve, Cartridge (Check) (4641510 Valve)

7017496 2 Seal Kit - 7021639 Check Cartridge (was p/n 2900756)

122K 7024881 1 Piston, Pilot (4641510 Valve)

123 4641155 1 Valve, Junction Manifold B

3121182 510AJ 1-37

Page 46

SECTION 1 FRAME

FIGURE 1-9. DRIVE VALVES INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

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

Ref. FRAME SHIELDS INSTALLATION OPTIONS: 0272600 Ref. Belgium Built Machines Prior to S/N 1300000353 B 0273499 Ref. Belgium Built Machines S/N 1300000353 to S/N 1300003223 C 0275858 Ref. Belgium Built Machines S/N 1300003223 to Present A 0275858 Ref. Romanian Built Machines S/N E300000100 to S/N E300001114 A

201 0100011 A/R Compound, Locking 202 0641606 10 Bolt 3/8in-16NC x 3/4in 203 1 Cover (Front) Options:

4061046 Belgium Built Machines Prior to S/N 1300000353 3380504 Belgium Built Machines S/N 1300000353 to S/N 1300003223 3380764 Belgium Built Machines S/N 1300003223 to Present 3380764 Romanian Built Machines S/N E300000100 to

S/N E300001114 204 4061047 1 Shield (Rear) 205 4751600 10 Flatwasher 3/8in Regular

1-38 510AJ 3121182

Page 47

SECTION 2

TURNTABLE

3121182 510AJ 2-1

Page 48

SECTION 2 TURNTABLE

FIGURE 2-1.CONTROL VALVE INSTALLATION

2-2 510AJ 3121182

Page 49

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. VALVES INSTALLATIONS 0271197 Ref. Belgium Built Machines Prior to S/N 1300001243 F 0274616 Ref. Belgium Built Machines S/N 1300001243 to Present A 0274616 Ref. Romanian Built Machines S/N E300000100 to S/N E300001114 A

1 0100011 A/R Compound, Locking 2 0140001 1 Horn 3Not Used 4 0641404 1 Bolt 1/4in-20NC x 1/2in 5 0651405 4 Bolt 1/4in-24NF x 5/8in 6Not Used 7 0641607 4 Bolt 3/8in-16NC x 7/8in 8Not Used 9 1 Pressure Filter Assembly Options:

2120163 Belgium Built Machines Prior to S/N 1300001243 2120150 1 Element, Filter 7020020 1 Indicator 7023206 1 O-Ring, Filter 7023207 1 Ring, Back-up 2120209 Belgium Built Machines S/N 1300001243 to Present &

Romanian Built Machines S/N E300000100 to

S/N E300001114 2120210 1 Element, Filter 7020020 1 Indicator

70000934 1 O-Ring, Filter Bowl 10 Not Used 11 4641176 1 Main Control Valve Assembly (See Figure 2-2 for Breakdown)

12 to 13 Not Used

14 4711600 10 Flatwasher 3/8in Thin 15 4751400 1 Flatwasher 1/4in Regular

16 to 19 Not Used

20 4711400 4 Flatwasher 1/4in Thin 21 4791400 1 Starwasher 1/4in

3121182 510AJ 2-3

Page 50

SECTION 2 TURNTABLE

FIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

2-4 510AJ 3121182

Page 51

SECTION 2 TURNTABLE

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641176 Ref. PROPORTIONAL VALVE ASSEMBLY E

1 7012975 1 Cartridge, Check

7012540 1 Seal Kit - 7012975 Cartridge

2 7017482 2 Cartridge

70003649 2 Seal Kit - 7017482 Cartridge (was p/n 7012518)

3 7023970 1 Cartridge, Flow Regulator

7012953 1 Seal Kit - 7023970 Cartridge

4 7017440 3 Cartridge, Load Shuttle

7017441 3 Seal Kit - 7017440 Cartridge

5 7010542 2 Cartridge, Load Shuttle

7010543 2 Seal Kit - 7010542 Cartridge

6 7021611 1 Cartridge (Proportional Dump)

7012518 1 Seal Kit - 7021611 Cartridge

7 7023913 2 Cartridge, Relief (Telescope & Lower Lift)

7012998 2 Seal Kit - 7023913 Cartridge

8 7017422 1 Cartridge, Relief (Steer)

7012998 1 Seal Kit - 7017422 Cartridge

9 7017421 1 Cartridge, Relief (Upper Lift)

7012998 1 Seal Kit - 7017421 Cartridge

10 7017428 1 Cartridge, Relief (Swing)

7012998 1 Seal Kit - 7017428 Cartridge

11 7023922 1 Cartridge without Coil (Upper Lift)

7017402 1 Seal Kit - 7023922 Cartridge

12 7023914 1 Cartridge without Coil (Swing)

7017402 1 Seal Kit - 7023914 Cartridge

13 7017410 1 Cartridge without Coil (Main Dump)

7012967 1 Seal Kit - 7017410 Cartridge

14 7017433 1 Cartridge without Coil (Steer)

7017402 1 Seal Kit - 7017433 Cartridge

15 7017454 2 Cartridge without Coil (Lower Lift & Telescope)

7012903 2 Seal Kit - 7017454 Cartridge 16 7012944 7 Coil 17 7012943 4 Coil 18 7017451 1 Coil

3121182 510AJ 2-5

Page 52

SECTION 2 TURNTABLE

REMOTE

110

105

106

108

109

101

112

102

103

107

104

112

111

5 8

201

204

212

213

212

201

203

202

205

208

209

215

210

206

211

207

214

216

FIGURE 2-3.TURNTABLE AND SWING DRIVE INSTALLATIONS

2-6 510AJ 3121182

Page 53

SECTION 2 TURNTABLE

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. SWING DRIVE INSTALLATION OPTIONS: 0272167 Ref. Belgium Built Machines Prior to S/N 1300000353 D 0273358 Ref. Belgium Built Machines S/N 1300000353 to Present 0273358 Ref. Romanian Built Machines S/N E300000100 to S/N E300001114 D

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

2-6 for Breakdown): 0440255 Belgium Built Machines Prior to S/N 1300000353 0440272 Belgium Built Machines S/N 1300000353 to Present 0440272 Romanian Built Machines S/N E300000100 to

S/N E300001114

3 2 Bolt 1/2in-13NC Options:

0641818 2-1/4in Length (Belgium Built Machines Prior to

S/N 1300006701)

3931832 2in Length (Belgium Built Machines S/N 1300006701 to

Present & Romanian Built Machines S/N E300000100 to

S/N E300001114) 4 0682040 18 Bolt 5/8in-11NC x 5in (Grade 8) 5 0682048 24 Bolt 5/8in-11NC x 6in 6 1 Swing Motor Assembly Options:

Use 1001105455 Motor for Belgium Built Machines Prior to S/N 1300006701

(See Figure 2-4 for Breakdown - was p/n 3160287)

1001104850 Motor for Belgium Built Machines S/N 1300006701 to Present

& Romanian Built Machines S/N E300000100 to

S/N E300001114 (See Figure 2-5 for Breakdown) 7 2 Flatwasher 1/2in Hardened Options:

4891800 Belgium Built Machines Prior to S/N 1300006701 4740171 Belgium Built Machines S/N 1300006701 to Present 4740171 Romanian Built Machines S/N E300000100 to

S/N E300001114 8 4892000 42 Flatwasher 5/8in Hardened 9 A/R Grease, Bearing (Not Shown) Options:

Not Required Belgium Built Machines Prior to S/N 1300000353

2160001 Belgium Built Machines S/N 1300000353 to Present 2160001 Romanian Built Machines S/N E300000100 to

S/N E300001114

0258400 Ref. REMOTE BEARING LUBE INSTALLATION B

101 0641609 2 Bolt 3/8in-16NC x 1-1/8in 102 0902520 1 Bracket 103 2160002 1 Fitting, Grease 104 2180344 1 Fitting, Bulkhead 105 2180822 1 Fitting, Tee 106 2200261 1 Fitting, Coupling 107 2220001 1 Fitting, Straight 108 2220124 2 Fitting, 45° 109 2750529 2 Hose 110 2750807 1 Hose

3121182 510AJ 2-7

Page 54

SECTION 2 TURNTABLE

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

111 3311605 2 Locknut 3/8in-16NC 112 4751600 4 Flatwasher 3/8in Regular

1001102695 Ref. DRIVE ORIENTATION INSTALLATION (BELGIUM BUILT

MACHINES S/N 1300006701 TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

201 0100011 A/R Compound, Locking 202 0641406 1 Bolt 1/4in-20NC x 3/4in 203 0641606 2 Bolt 3/8in-16NC x 3/4in 204 0641614 2 Bolt 3/8in-16NC x 1-3/4in 205 1320041 1 Clamp 206 3311005 2 Locknut #10 207 3311405 1 Locknut 1/4in 208 3931010 2 Screw #10-24 x 5/8in 209 4360517 1 Switch, Proximity

4460320 1 Connector, Male

4460227 2 Pin, Male 210 4711000 2 Flatwasher #10 Thin 211 4711400 1 Flatwasher 1/4in Thin 212 4711600 4 Flatwasher 3/8in Thin 213 Use 1001145163 2 Spacer (was p/n 7116691 & 1001114757) 214 1001102526 1 Cam 215 1001102527 1 Bracket, Switch 216 4740120 2 Flatwasher, Special

2-8 510AJ 3121182

Page 55

SECTION 2 TURNTABLE

FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 2-9

Page 56

SECTION 2 TURNTABLE

571

GENUINE PARTS

FIGURE 2-4.SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT FOR BELGIUM BUILT

MACHINES PRIOR TO S/N 1300006701)

2-10 510AJ 3121182

Page 57

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT FOR BELGIUM BUILT

MACHINES PRIOR TO S/N 1300006701)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160287 Ref. SWING MOTOR ASSEMBLY B

Ref. Note: Original Equipment motor p/n 3120287 may have been

replaced with Service Replacement motor p/n 1001105455. Visually identify component before ordering parts. Service Replacement motor shown on next illustration

1 Use 2900477 1 Seal, Dust 2 Use 2900477 1 Ring, Retaining 3 Use 2900477 1 Shim, Metal Back-Up 4 Use 2900477 1 Seal, High Pressure 5 Use 2900477 1 Shim, Metal Back-Up 6 Use 2900477 1 Shim, Teflon Back-Up 7 Use 2900477 1 Seal, Shaft 8 Use 2900477 3 Seal, Body

9 Use 2900477 1 Washer, Carrier 10 Use 2900477 1 Thrustwasher 11 See Note 1 Bearing, Thrust (Note: Not Available - Replace Complete

Motor)

12 7005889 1 Link, Drive 13 See Note 1 Plate, Wear (Note: Not Available - Replace Complete Motor) 14 7016432 1 Rotor Set Assembly 15 7016433 1 Pin, Drive Link 16 See Note 1 Ball (Note: Not Available - Replace Complete Motor) 17 See Note 1 Cover, End (Note: Not Available - Replace Complete Motor) 18 See Note 1 Nameplate (Note: Not Available for Purchase) 19 7016434 1 Bolt Set (Includes 4 Bolts) 20 Use 7016435 1 Housing 21 Use 7016435 1 Plug, Cooling 22 7005843 1 Shaft 23 7005887 1 Key 24 Not Used 25 2900477 1 Seal Kit (Includes Items 1-10) 26 7016435 1 Housing/Shaft Kit (Includes Items 20-23)

3121182 510AJ 2-11

Page 58

SECTION 2 TURNTABLE

FIGURE 2-5.SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT FOR BELGIUM BUILT

MACHINES PRIOR TO S/N 1300006701 & ORIGINAL EQUIPMENT FOR BELGIUM BUILT

MACHINES S/N 1300006701 TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100

TO S/N E300001114)

2-12 510AJ 3121182

Page 59

SECTION 2 TURNTABLE

FIGURE 2-5. SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT FOR BELGIUM BUILT

MACHINES PRIOR TO S/N 1300006701 & ORIGINAL EQUIPMENT FOR BELGIUM BUILT

MACHINES S/N 1300006701 TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100

TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. SWING MOTOR ASSEMBLY

1001105455 Ref. Service Replacement for Belgium Built Machines Prior to

S/N 1300006701

1001104850 Ref. Original Equipment for Belgium Built Machines

S/N 1300006701 to Present

1001104850 Ref. Original Equipment for Romanian Built Machines

S/N E300000100 to S/N E300001114

1 See Note 5 Bolt (Note: Not Available - Replace Complete Motor)

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 - Replace 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)

3121182 510AJ 2-13

Page 60

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

107

101

116

131

GENUINE PARTS

150

151

FIGURE 2-6.SWING BEARING & ROTATION BOX ASSEMBLY

2-14 510AJ 3121182

Page 61

SECTION 2 TURNTABLE

FIGURE 2-6. SWING BEARING & ROTATION BOX ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. SWING BEARING & ROTATION BOX ASSEMBLY 0440255 Ref. Belgium Built Machines S/N 1300000001 to S/N 1300000353 B 0440272 Ref. Belgium Built Machines S/N 1300000353 to Present C 0440272 Ref. Romanian Built MachineS S/N E300000100 to S/N E300001114 C

1 to 100 Not Used

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 See Note 1 Plug 1/4in (0440255 Bearing Only) (Note: Not Available -

Purchase Locally)

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 See Note 2 Fitting, Grease 45° (0440255 Bearing Only)

(Note: Not Available - Purchase Locally)

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 Assy) 126 7026053 1 Cover, Gear Options: 127 Use 7026059 A/R Shim, Brown (.010)

2 0440255 Bearing

A/R 0440272 Bearing

128 Use 7026059 A/R Shim, Clear (.0075) Options:

2 0440255 Bearing

A/R 0440272 Bearing

129 Use 7026059 A/R Shim, Blue (.005) Options:

3 0440255 Bearing

A/R 0440272 Bearing

130 Use 7026059 A/R Shim, Yellow (.020) Options:

2 0440255 Bearing

A/R 0440272 Bearing

3121182 510AJ 2-15

Page 62

SECTION 2 TURNTABLE

FIGURE 2-6. SWING BEARING & ROTATION BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

131 1 Bearing, Turntable Options:

7026054 0440255 Bearing

Use 1001104627 0440272 Bearing (Bearing Kit, Turntable p/n 1001104627

includes bearing & hardware to mount bearing/rotation box

assembly to machine) (was p/n 70000042) 132 Use 7026060 1 O-Ring 133 7026055 1 Cap, Gear 134 1 Cap, Worm Options:

7026056 0440255 Bearing

7027354 0440272 Bearing 135 70000681 8 Screw #6-32NC x 3/8in 136 Use 7026059 A/R Shim, Natural (.0075in) Options:

4 0440255 Bearing

A/R 0440272 Bearing

137 Use 7026059 A/R Shim, Blue (.005in) Options:

4 0440255 Bearing

A/R 0440272 Bearing

138 Use 7026059 A/R Shim, Green (.003in) Options:

4 0440255 Bearing

A/R 0440272 Bearing 139 7026057 1 Worm, Ground 140 Use 7026059 A/R Shim, Blue (.005in) Options:

3 0440255 Bearing

A/R 0440272 Bearing 141 Use 7026059 A/R Shim, Yellow (.020in) Options:

2 0440255 Bearing

A/R 0440272 Bearing 142 1 Adapter, Motor Options:

7026058 2 0440255 Bearing

7027356 A/R 0440272 Bearing 143 Use 7026060 1 Seal, Face 144 Use 7026059 A/R Shim, Green (.003in) Options:

0 0440255 Bearing

A/R 0440272 Bearing

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)

2-16 510AJ 3121182

Page 63

SECTION 2 TURNTABLE

FIGURE 2-6. SWING BEARING & ROTATION BOX ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 2-17

Page 64

SECTION 2 TURNTABLE

243

245

244

209

235

311

939

6679697889792

95873316313571658

1662409910094594136631947

210

211

246

229

236

227

228

201

208

234

671

333

163

20520523323

022622623

233

072341019

247

245

241

2-18 510AJ 3121182

FIGURE 2-7.CATERPILLAR ENGINE INSTALLATION (WITH UGM)

Page 65

231

212

239

206

214

223

225

220

212

216

224

213

212

203

233

221

218

223

TO WATER

SEPARATER

TO FUEL

TANK

VENT

LINE

FUEL

RETURN

TO FUEL

PUMP

219

202

212

STARTER

BATTERY

AUX.PW R.

PUMP

GRD.

98C

98A

98B

AUX.

PWR.

RELAY

694062621

742

3858

308

316

315

307

306

310

309

304

301

314

313

319

317

320

233

226

303

302

SECTION 2 TURNTABLE

3121182 510AJ 2-19

Page 66

SECTION 2 TURNTABLE

FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Belgium Built Machines use S/Ns 13xxxxxxxx.

Romanian Built Machines use S/Ns E3xxxxxxxx.

Ref. Note: For Module (with/without UGM) Identification, refer to

Revision Log page A.

1001108389 Ref. CATERPILLAR ENGINE ASSEMBLY D

1 0080181 1 Adapter, Pump Mounting Plate 2 0080201 1 Adapter, 90° Air Intake 3 0100011 A/R Compound, Locking 4 0641812 2 Bolt 1/2in-13NC x 1-1/2in 5 0340041 2 Band, Air Cleaner Mounting 6 0340046 2 Band, Muffler Mounting 7 2111010 1 Fitting, Straight 8 2111612 1 Fitting, Straight

9 0630569 9 Bolt M14 x 30mm 10 0641406 8 Bolt 1/4in-20NC x 3/4inin 11 0641408 3 Bolt 1/4in-20NC x 1in 12 0641410 2 Bolt 1/4in-20NC x 1-1/4in 13 0641506 8 Bolt 5/16in-18NC x 3/4in 14 0641507 6 Bolt 5/16in-18NC x 7/8in 15 0641609 5 Bolt 3/8in-16NC x 1-1/8in 16 0641610 39 Bolt 3/8in-16NC x 1-1/4in 17 0641611 2 Bolt 3/8in-16NC x 1-3/8in 18 0641614 2 Bolt 3/8in-16NC x 1-3/4in 19 0641820 4 Bolt 1/2in-13NC x 2-1/2in 20 0741610 2 Screw, Flat Head 3/8in-16NC x 1-1/4in 21 0760815 4 Bolt M8 x 35mm 22 0962172 1 Bushing, Flanged 23 1320012 4 Clamp 24 1320016 4 Clamp 25 1320022 3 Clamp 26 1320058 1 Clamp 27 1320223 6 Clamp 28 1320318 2 P-Clamp 29 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner 30 1580011 1 Container, Coolant Overflow 31 1660255 1 Coupling, Pump 32 1703162 2 Decal - Caution Fan 33 2131212 1 Fitting, 90° 34 2720058 2.5ft/0.8m Hose 35 1001106426 1 Caterpillar Engine Assembly (See Items 301-321 for Breakdown) 36 3200378 4 Mount, Motor 37 1 Muffler Options:

3220113 Spark Arresting Muffler

70001017 1 Clamp

Use 1001107116 Catalytic Muffler

70002705 1 Clamp 70002706 1 Plug, Brass

2-20 510AJ 3121182

Page 67

SECTION 2 TURNTABLE

FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

38 3311405 11 Locknut 1/4in-20NC 39 3311505 6 Locknut 5/16in-18NC 40 3311605 22 Locknut 3/8in-16NC 41 3311805 4 Locknut 1/2in-13NC 42 3340399 2 Pad, Wear 43 3577133 1 Plate, Air 44 3577132 1 Plate, Baffle 45 3573937 1 Plate, Radiator Support 46 3577130 1 Plate, Engine Mounting (Front) 47 3577135 2 Plate, Engine Mounting (Rear) 48 3740067 1 Relay 49 3960438 28in/

71cm 50 4031711 4 Bolt M6 x 35mm 51 4070497 4 Shim 52 4070498 2 Shim 53 4100025 1.6ft/

0.49mm 54 4568743 1 Pipe, Exhaust 55 4569176 1 Tube, Air Intake 56 4711400 12 Flatwasher, 1/4in Thin 57 4711500 8 Flatwasher 5/16in Thin 58 4711600 26 Flatwasher 3/8in Thin 59 4740274 4 Washer, Snubbing 60 4751400 12 Flatwasher 1/4in Regular 61 4751500 12 Flatwasher 5/16in Regular 62 4751600 42 Flatwasher 3/8in Regular 63 4751800 13 Flatwasher 1/2in Regular 64 4791400 2 Starwasher 1/4in 65 4846821 1 Mount, Motor/Generator 66 4891500 4 Flatwasher 5/16in Hardened 67 4891600 4 Flatwasher 3/8in Hardened 68 85941018 1 P-Clamp 69 1001097588 1 Clip, Tube 70 1001098525 1 Plate, Muffler Support 71 Not Used 72 1001106793 1 Plate, Radiator Mount 73 1001100577 1 Hose, Radiator (Top) 74 1001100818 1 Hose, Radiator (Bottom) 75 1001100825 2 Strap, Ties 76 1001100837 1 Bracket, Bottle 77 1001101201 1 Spacer, Fan 78 1001106790 1 Weldment, Engine Tray 79 1001101681 1 Elbow, Rubber 80 1001101950 1 Tube, Air Intake 81 1001102706 1 Radiator

7027412 1 Cap, Radiator

82 2720271 1.25ft/

0.38m

Seal, Self Gripping

Sleeve, Fiberglass

Hose

3121182 510AJ 2-21

Page 68

SECTION 2 TURNTABLE

FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

83 2720615 1.5ft/

0.46m 84 1001101408 1 Fan 85 8405006 1 Clamp, Gear 86 2151212 2 Fitting, 45° 87 2170316 1 Fitting, Tee 88 2170808 2 Fitting, Tee

89 to 90 Not Used

91 2221084 1 Fitting, Tee 92 3600318 1 Gear Pump Assembly

7023929 1 Seal Kit - 3600318 Pump 93 3600385 1 Piston Pump Assembly (See Figure 2-16 for Breakdown) 94 3600423 1 Auxiliary Pump Assembly (See Figure 2-17 for Breakdown) 95 3790152 1 O-Ring 96 3931620 2 Capscrew, Socket Head 3/8in-16NC x 1-1/4in 97 4641199 2 Valve, Check 98 1001102860 1 Battery Cable Kit A

98A 7027025 1 Cable - Battery to Auxiliary Relay

98B 7027026 1 Cable - Battery & Auxiliary Pump to Ground 98C 7027023 1 Cable - Auxiliary Relay to Starter 98D 7027024 1 Cable - Auxiliary Relay to Auxiliary Pump

99 2110604 2 Fitting, Straight 100 2131210 1 Fitting, 90° 101 2170110 1 Fitting, Straight

Hose

1001108388 Ref. CATERPILLAR ENGINE INSTALLATION A

201 0100011 A/R Compound, Locking 202 0100020 A/R Sealant, Pipe 203 0641406 3 Bolt 1/4in-20NC x 3/4in 204 0641408 7 Bolt 1/4in-20NC x 1in 205 0641418 2 Bolt 1/4in-20NC x 2-1/4in 206 0641420 1 Bolt 1/4in-20NC x 2-1/2in 207 0641608 3 Bolt 3/8in-16NC x 1in 208 0641610 2 Bolt 3/8in-16NC x 1-1/4in 209 0642010 1 Bolt 5/8in-11NC x 1-1/4in 210 0902443 1 Bracket, Hood Latch Mount 211 0902444 1 Bracket, Hood Support 212 1320022 7 Clamp, Fuel Line 213 1320223 1 Clamp, J Clip 214 1320318 2 Clamp 215 1701505 1 Decal, Diesel (Not Shown) 216 2180536 1 Fitting, Barbed 217 2220250 1 Fitting, Reducer 218 2220273 1 Fitting, Reducer 219 2220313 1 Fitting, 90° Barbed 220 2220459 1 Fitting, 90° 221 2220794 1 Fitting, Straight Barbed 222 2300004 2.7 Gal Coolant, Anti-Freeze (Not Shown) 223 2720058

10ft/3.05m

Hose

2-22 510AJ 3121182

Page 69

SECTION 2 TURNTABLE

FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

224 2720271 8ft/2.4m Hose 225 2750532 7ft/2.1m Hose 226 3311405 13 Locknut 1/4in-20NC 227 3312005 1 Locknut 5/8in-11NC 228 3340399 1 Pad, Wear 229 3900254 1 Screw, Shoulder 230 4641317 1 Valve Assembly

7012941 2 Cartridge without Coil 7010543 2 Seal Kit - 7012941 Cartridge

7012944 2 Coil 231 4711400 3 Flatwasher 1/4in Thin 232 4740362 7 Washer, Fender 233 4751400 25 Flatwasher 1/4in Regular 234 4751600 5 Flatwasher 3/8in Regular 235 4752000 1 Flatwasher 5/8in Regular 236 4752200 2 Flatwasher 3/4in Regular

237 to 238 Not Used

239 1001100857 1 Separator, Fuel-Water

70002377 1 Filter

70002378 1 Seal, O-Ring 240 1001103791 1 Panel, Rubber 241 1787217 1 Clamp, Battery Holddown 242 3020016 2.5 gal Motor Oil Mobil Delvac MX 15W-40 243 3311505 2 Locknut 5/16in-18NC 244 0641512 1 Bolt 5/16in-18NC x 1-1/2in 245 4751500 4 Flatwasher 5/16in Regular 246 8008750 1 Battery 247 1706098 1 Decal - Warning Explosion/Fire

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 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)

3121182 510AJ 2-23

Page 70

SECTION 2 TURNTABLE

FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

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 2 Element, Fuel Filter (was p/n 7026871)

7026872 2 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

2-24 510AJ 3121182

Page 71

SECTION 2 TURNTABLE

FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (WITH UGM) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 2-25

Page 72

SECTION 2 TURNTABLE

103

105

102

101

MOUNTED ON PLATFORM

CONTROL BOX

USE

EXISTING

HARDWARE

6 11 18

1 5

41OR

9C9B151419

102016

FIGURE 2-8.2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM)

(OPTIONAL)

2-26 510AJ 3121182

Page 73

SECTION 2 TURNTABLE

FIGURE 2-8. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM)

(OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: For Module (with/without UGM) Identification, refer to

Revision Log page A.

Ref. GENERATOR INSTALLATION 1001111285 Ref. 110V/60Hz Generator A 1001100944 Ref. 110V/50Hz Generator B 1001100943 Ref. 220V/50HZ Generator B

Ref. Note: Refer to Sky Power Accessories Manual p/n 3124242 for

the Miller 7500W Generator.

1 0100011 A/R Compound, Locking 2 0200742 1 Arm, Adjusting 3 1 V-Belt Options:

0480121 110V/60Hz 0480120 110V/50Hz

0480120 220V/50Hz 4 0641404 1 Bolt 1/4in-20NC x 1/2in 5 0641508 1 Bolt 5/16in-18NC x 1in 6 0641772 1 Bolt 7/16in-14NC x 9in 7 0701217 3 Bolt M12 x 45mm 8 0962449 1 Bushing 9 1 Generator and Control Box Assembly Options:

2460055 110V/60Hz

2460049 110V/50Hz Generator

1001100321 220V/50Hz Generator

9A 7012558 1 Replacement Generator - 110V/60Hz

2460049 1 Replacement Generator - 110V/50Hz

1001100321 1 Replacement Generator - 220V/50Hz

Note: All Replacement Generators come standard with P/N 3580134 Pulley. This Pulley may not be correct for all applications. Refer to Pulley options below.

7026199 1 110V/60Hz Armature with Slip Rings

70000122 1 110V/50Hz Armature with Slip Rings 70000123 1 220V/50Hz Armature with Slip Rings

7020109 4 Holder, Brush

7020108 4 Brush

7012513 4 Cap, Brush Holder

7012514 1 Fan

7020190 2 Bearing

7020110 1 End Bell, Front

7020111 1 End Bell, Rear

7020193 1 Cord, Power

9B 1 Replacement Control Box Options:

7019680 110V

70000127 220V

1 Circuit Breaker Options:

4360542 110V

70000126 220V

4460190 1 Receptacle, Double (110V Box)

3121182 510AJ 2-27

Page 74

SECTION 2 TURNTABLE

FIGURE 2-8. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM)

(OPTIONAL) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

9B (cont’d) 4460027 1 Receptacle, Double Twist Lock (110V Box)

70000124 1 Receptacle, Double (220V Box) 70000125 1 Receptacle, Single Twist Lock (220V Box)

3520028 1 Plug, Hole

9C 1 Voltmeter Options:

2420203 110V 7020192 220V

9D 1 Pulley Options:

3580276 110V/60Hz 3580134 110V/50Hz 3580134 220V/50Hz

7027887 1 Key, Woodruff 10 3290505 1 Locknut M5 11 3311705 1 Locknut 7/16in-14NC 12 3580315 1 Pulley 13 3740080 1 Relay 14 4031608 1 Bolt M5 x 20mm 15 4420060 3in/8cm Tape, Double Sided Foam Acrylic 16 4460968 3 Connector, Strain Relief 17 4751500 1 Flatwasher 5/16in Regular 18 4751700 A/R Flatwasher 7/16in Regular 19 4811600 1 Flatwasher M5 20 1001099869 1 Box, Junction 21 1 Light, Red Options:

1001100233 125V

1001100234 250V 22 3311005 2 Locknut #10-24NC 23 4751000 8 Flatwasher #10 Regular

Ref. PLATFORM COMPONENTS

1001111285 Ref. 110V/60Hz Generator A

1001111815 Ref. 110V/50Hz Generator A

1001111814 Ref. 220V/50HZ Generator A

101 4360336 1 Switch, Toggle 102 4740397 1 Washer 103 4060802 1 Guard, Switch 104 2820031 1 Heatshrink (Not Shown) 105 3251102 1 Nameplate

2-28 510AJ 3121182

Page 75

SECTION 2 TURNTABLE

FIGURE 2-8. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (WITH UGM)

(OPTIONAL) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 2-29

Page 76

SECTION 2 TURNTABLE

FIGURE 2-9.DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N

1300000981)

2-30 510AJ 3121182

Page 77

SECTION 2 TURNTABLE

FIGURE 2-9. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N

1300000981)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Belgium Built Machines use S/Ns 13xxxxxxxx.

Romanian Built Machines use S/Ns E3xxxxxxxx.

DEUTZ ENGINE INSTALLATION

Ref. 4WD Machines Options:

Manufactured in Belgium (S/N 1st digit is 1)

0272490 Ref. Belgium Built Machines Prior to S/N 1300000353 H 0273754 Ref. Belgium Built Machines S/N 1300000353 to S/N 1300000981 E

1 0100011 A/R Compound, Locking 2 0100020 A/R Sealant 3Not Used 4 0641406 1 Bolt 1/4in-20NC x 3/4in (Prior to S/N 1300000178) 5 0641610 2 Bolt 3/8in-16NC x 1-1/4in 6 0642010 1 Bolt 5/8in-11NC x 1-1/4in 7 0902443 1 Bracket, Hood Latch Mount 8 0902444 1 Bracket, Hood Support

9 1320022 5 Clamp, Fuel Line 10 1320223 1 Clamp, J-Clip 1/2in (Prior to S/N 1300000178) 11 2180536 1 Fitting, Straight (Prior to S/N 1300000353) 12 2220250 1 Fitting, Reducer (Prior to S/N 1300000353) 13 2220313 1 Fitting, 90° 14 2220459 1 Fitting, 90° (Prior to S/N 1300000353) 15 2220794 1 Fitting, Straight (Prior to S/N 1300000353) 16 2720058 17 2720271 18 2750532 7ft/2.14m Hose 19 3311405 2 Locknut 1/4in-20NC 20 3312005 1 Locknut 5/8in-11NC 21 3340958 1 Pad, Wear 22 3900254 1 Bolt, Shoulder 23 4751400 12 Flatwasher 1/4in Regular 24 4751600 6 Flatwasher 3/8in Regular 25 4752000 1 Flatwasher 5/8in Regular 26 4752200 2 Flatwasher 3/4in Regular 27 0641418 2 Bolt 1/4in-20NC x 2-1/4in 28 Use 1001099391 1 Valve, Dual Select (was p/n 4641108)

28A 7012974 1 Cartridge without Coil (4641108 Valve)

7010543 1 Seal Kit - 7012974 Cartridge 7012941 1 Cartridge without Coil (1001099391 Valve) 7010543 1 Seal Kit - 7012974 Cartridge 7012944 1 Coil

28B 7012995 1 Cartridge without Coil

7012518 1 Seal Kit - 7012995 Cartridge 7012943 1 Coil

29 0181727 1 Angle, Battery Tie-Down (Prior to S/N 1300000238)

15.1ft/4.6m

12ft/3.66m

Ref. Note: Original Equipment Valve may have been replaced

Hose Hose

with Service Replacement Valve. Identify p/n stamped on valve before ordering parts.

3121182 510AJ 2-31

Page 78

SECTION 2 TURNTABLE

FIGURE 2-9. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N

1300000981) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

30 1 Battery (Wet)

Use 8008750 Prior to S/N 1300000238 (was p/n 0400075)

8008750 S/N 1300000238 to S/N 1300000981 31 0630498 2 Bolt, Battery Tie-Down (Prior to S/N 1300000238) 32 3311605 2 Locknut 3/8in-16NC (Prior to S/N 1300000238) 33 2200222 1 Fitting, Pipe Plug (Not Shown) 34 2220273 1 Fitting, Reducer (Not Shown) (Prior to S/N 1300000353) 35 4240099 1 Tie, Wire (Not Shown) 36 1701505 1 Decal, Diesel Fuel (Not Shown) 37 1787217 1 Clamp, Battery Hold 38 Not Used 39 0641512 2 Bolt, 5/16in-20NC x 1-1/2in 40 4751500 4 Flatwasher 5/16in Regular 41 3311505 2 Locknut, 5/16in-18NC 42 2180348 1 Fitting, Barb (S/N 1300000353 to S/N 1300000981) 43 2221176 1 Fitting, 90° (S/N 1300000353 to S/N 1300000981) 44 4922978 1 Harness, Start Assist Solenoid (S/N 1300000353 to S/N

1300000981)

Ref. DEUTZ ENGINE ASSEMBLY OPTIONS: 0272489 Ref. Belgium Built Machines Prior to S/N 1300000353 F 2000228 Ref. Belgium Built Machines S/N 1300000353 to S/N 1300000981 D

101 0080231 1 Adapter, Fan Spacer 102 0100011 A/R Compound, Locking 103 0100020 A/R Sealant

104 to 105 Not Used

106 0340041 2 Band, Muffler Bracket

107 to 108 Not Used

109 0641406 6 Bolt 1/4in-20NC x 3/4in 110 0641410 4 Bolt 1/4in-20NC x 1-1/4in 111 0641510 3 Bolt 5/16in-18NC x 1-1/4in 112 0641608 9 Bolt 3/8in-16NC x 1in 113 0641610 16 Bolt 3/8in-16NC x 1-1/4in 114 0641812 2 Bolt 1/2in-13NC x 1-1/2in 115 0641820 4 Bolt 1/2in-13NC x 2-1/2in 116 0700816 4 Bolt M8 x 40mm 117 0701012 8 Bolt M10 x 25mm 118 0711414 6 Bolt M14 x 30mm 119 0741610 2 Screw, Flathead 3/8in-16NC x 1-1/4in 120 0902740 1 Bracket, Front Engine Mounting (Right Side) 121 0962172 1 Bushing, Flanged 122 1320016 4 Clamp, Hose 123 1320022 1 Clamp, Hose 124 1320223 3 Clamp, J-Clip 1/2in 125 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner

126 1703162 2 Decal, Fan Blade

2-32 510AJ 3121182

Page 79

SECTION 2 TURNTABLE

FIGURE 2-9. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N

1300000981) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

127 1 Engine, Deutz Options:

2000190 Prior to S/N 1300000353

2000217 S/N 1300000353 to S/N 1300000981 128 2060025 1 Fan, Suction 129 2180798 1 Fitting, Restriction Indicator 130 2220451 2 Fitting, Straight 131 2720434 1 Hose, 90° Elbow 132 2720449 1 Hose 133 2720467 2 Hose 134 2750532 380mm Hose 135 2902060 1 Cable Kit - Battery B

135A 7016817 1 Cable - Battery to Starter Relay 135B Use 7027041 1 Cable - Battery & Auxiliary Pump to Ground (was p/n

7016837) 135C 7016834 1 Cable - Starter Relay to Starter 135D 7016838 1 Cable - Starter Relay to Auxiliary Relay 135E 7016820 1 Cable - Auxiliary Relay to Auxiliary Pump

136 Not Used 137 4 Mount, Engine Options:

3200378 Prior to S/N 1300000353

3200406 S/N 1300000353 to S/N 1300000981 138 3311401 1 Nut 1/4in-20NC 139 3311405 10 Locknut 1/4in-20NC 140 3311505 3 Locknut 5/16in-20NC 141 3311605 19 Locknut 3/8in-16NC 142 3311805 4 Locknut 1/2in-13NC 143 3340958 2 Pad, Wear 144 3570801 1 Plate, Engine Mounting 145 3573895 1 Plate, Radiator Mount 146 3573937 1 Plate, Radiator Support 147 3600279 1 Auxiliary Pump Assembly (See Figure 2-17 For Breakdown) 148 Piston Pump Assembly Options (See Figure 2-16 for

Breakdown)

Use 3600385 Prior to S/N 1300000129 (was p/n 3600296)

3600385 S/N 1300000129 to S/N 1300000981 149 3600318 1 Gear Pump Assembly

7023929 1 Seal Kit - 3600318 Pump 150 Use 1001150998 1 Radiator (was p/n 3620033) 151 3740140 2 Relay, Power 152 3790152 1 O-Ring 153 3960407 1 Gasket, Air Intake Adapter 154 4360392 1 Switch, Restriction Indicator 155 4567495 1 Tube, Tee 156 4640751 1 Valve, Oil Drain 157 4740274 4 Washer, Snubbing 158 4751400 17 Flatwasher 1/4in Regular 159 4751600 40 Flatwasher 3/8in Regular 160 4751900 6 Flatwasher 9/16in Regular 161 4845395 1 Air Intake Adapter Weldment

3121182 510AJ 2-33

Page 80

SECTION 2 TURNTABLE

FIGURE 2-9. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N

1300000981) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

162 4846567 1 Motor Mount Weldment 163 4846683 1 Engine Tray Weldment 164 4891600 2 Flatwasher 3/8in Hardened

Ref. ENGINE COMPONENTS OPTIONS: 2000190 Ref. Belgium Built Machines Prior to S/N 1300000353 2000217 Ref. Belgium Built Machines S/N 1300000353 to S/N 1300000981

201 7020461 1 Switch, Oil Pressure 202 7020479 1 Starter

7026608 1 Relay, Starter

203 7016331 1 Filter, Oil - Spin-on

7027236 1 Sensor, Oil Temperature (Not Shown - Located in Rear of

Filter Mount)

204 1 Pump, Oil Options:

7020467 Prior to S/N 1300000353 7020495 S/N 1300000353 to S/N 1300000981

205 7020468 1 Ring, Sealing (Prior to S/N 1300000353) 206 Pump, Fuel Injection Options:

7023418 1 Prior to S/N 1300000353 7027242 3 S/N 1300000353 to S/N 1300000981 (Not Shown) 7027246 Series A Injector 7027608 Series B Injector 7027609 Series C Injector 7027610 Series D Injector 7020447 3 Gasket, Injection Pump

207 1 Pump, Fuel Supply Options:

7024413 Prior to S/N 1300000353

Use 70000916 S/N 1300000353 to S/N 1300000981 (was p/n 7027238) (Not

Shown) 208 7020411 1 O-Seal 209 7020023 1 Filter, Fuel

70001423 1 Bracket, Fuel Filter (S/N 1300000353 to S/N 1300000981)

210 7020471 3 Gasket, Exhaust (Not Shown)

7020449 3 Gasket, Intake (Not Shown) 211 7020408 1 V-Belt 212 Use 7000663 1 Alternator (was p/n 7020410)

70002234 1 Bracket, Adjusting 213 7020464 1 Voltage Regulator 214 1 Transmitter, Temperature Options (Not Shown - Located on

Front Left of Engine): 7020168 Prior to S/N 1300000353 7027241 S/N 1300000353 to S/N 1300000981

214 7020168 1 Transmitter, Temperature (Not Shown) 215 7020480 1 Ring, Sealing (Not Shown) 216 7020458 1 Actuator, Throttle

7027276 2 Spring, Actuator

2-34 510AJ 3121182

Page 81

SECTION 2 TURNTABLE

FIGURE 2-9. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES PRIOR TO S/N

1300000981) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

217 7020026 1 Dipstick

7020403 1 Seal, Ring

1 Tube, Dipstick Options:

70001002 Tube for p/n 2000217

See Note Tube for p/n 2000190 (Note: For correct component, must

supply engine serial number to JLG Parts Department)

218 7020465 1 Cap, Filler 219 7020488 2 Connector, Electrical (Not Shown - Located at Sensors) 220 Use 7024565 1 Sensor, Tach (was p/n 7020481)

70003932 1 Sleeve, Spacer 221 7020482 1 Gasket Kit (Not Shown) 222 7027241 1 Sender, Oil Temperature (Not Shown - Located on Front of

Engine beside Fuel Injector) (S/N 1300000353 to S/N 1300000981)

223 7020459 1 Thermostat (Not Shown) (S/N 1300000353 to S/N 1300000981)

7020460 Spring, Compression

224 70000264 1 Flywheel/Gear Assembly (Not Shown) (2000190 Engine Only)

7024579 1 Rim, Gear (Not Shown) See Note 1 Flywheel (Not Shown) (S/N 1300000353 to S/N 1300000981)

Note: Not Available for Purchase)

225 7027239 Solenoid, Start (S/N 1300000353 to S/N 1300000981) 226 7027769 2 Connector, Radiator (S/N 1300000353 to S/N 1300000979) 227 7027245 1 Fuel Filter In-Line (Not Shown)

Ref. MUFFLER INSTALLATION OPTIONS:

250 1 Muffler Options:

3220110 Standard 3220112 Catalytic

250A 1320176 1 Clamp, Muffler

0256847 Ref. PUMP COUPLING INSTALLATION 2

301 1660234 1 Coupling, Hayes 302 0080163 1 Plate, Pump Adapter 303 0700810 6 Bolt M8 x 20mm 304 4831900 6 Lockwasher M8 305 Not Used 306 4832000 8 Lockwasher M10 (Prior to S/N 1300000981) 307 3020021 A/R Grease, Coupling

3121182 510AJ 2-35

Page 82

SECTION 2 TURNTABLE

411

412

301

307

303

304

302

257

409

402

405

2727B27A2929215

228

231

226

210

209

257

240

257

240

216

258

20523825620

642

128422

223220220225214215257

243

210

235

218

235

240

241

255

257

212

210

240

257

216

202

022022022

02203

258

260A

260B

245

212

236

224

213

228

206

256

238

231

252

239

208

259

244

249

209

257

240

227

253

230

201

211248251

2092622

2662682702472702672

63264

265

229A

220

229

FIGURE 2-10.DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

2-36 510AJ 3121182

Page 83

SECTION 2 TURNTABLE

404

413

406

4024104

07415

O INJECTO

PUMPVENTLIN

1111201726191822432

O FUELPUM

11191111420

232533

250

207

256

238

219

217

202

242

222

237

256

242

210

257

261

025

246

27327

254

221

232

221

STARTER

ITEM #233 BATTERY CABLE KIT

AUX. POWER

RELAY

BATT.

GRD.

AUX. PWR.

PUMP

233A

233B

233D

233C

233B

233A

GLOW PLUG

271

272

START

RELAY

272

414

421

202

222

202

423

3121182 510AJ 2-37

Page 84

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Belgium Built Machines use S/Ns 13xxxxxxxx.

Romanian Built Machines use S/Ns E3xxxxxxxx.

Ref. DEUTZ ENGINE INSTALLATIONS 0274335 Ref. Belgium Built Machines S/N 1300000981 to S/N 1300003223 D 0275871 Ref. Belgium Built Machines S/N 1300003223 to Present C 0275871 Ref. Romanian Built Machines S/N E300000100 to S/N E300001114 C

1 0100011 A/R Compound, Locking 2 0100020 A/R Sealant, Pipe 3 Not Used 4 0641410 4 Bolt 1/4in-20NC x 1-1/4in 5 0641418 2 Bolt 1/4in-20NC x 2-1/4in 6 0641512 2 Bolt 5/16in-18NC x 1-1/2in 7 0641610 2 Bolt 3/8in-16NC x 1-1/4in 8 0642010 1 Bolt 5/8in-11NC x 1-1/4in

9 0902443 1 Bracket, Hood Latch Mount 10 0902444 1 Bracket, Hood Support 11 1320022 5 Clamp, Fuel Line 12 1701505 1 Decal, Diesel Fuel (Not Shown) 13 1787217 1 Clamp, Battery Hold-Down 14 Not Used 15 2180348 1 Fitting, Barbed 16 2200222 1 Plug, Pipe (Not Shown - Located on Bottom of Fuel Tank) 17 2220313 1 Fitting, 90° Barbed 18 2221176 1 Fitting, 90° 19 2720058 15.1ft/

4.6m 20 2750532 6ft/1.83m Hose 21 3311405 6 Locknut 1/4in-20NC 22 3311505 2 Locknut 5/16in-18NC 23 3312005 1 Locknut 5/8in-11NC 24 1 Pad, Wear Options:

3340399 Belgium Built Machines S/N 1300000981 to S/N 1300003223 3340958 Belgium Built Machines S/N 1300003223 to Present 3340958 Romanian Built Machines S/N E300000100 to

25 3900254 1 Screw, Shoulder 26 4240099 A/R Wire, Tie 27 1 Valve Options:

Use 1001099391 Belgium Built Machines S/N 1300000981 to S/N 1300003223

4641317 Belgium Built Machines S/N 1300003223 to Present 4641317 Romanian Built Machines S/N E300000100 to

27A A/R Cartridge & Coil Options:

Ref. Note: Original Equipment Valve may have been

Hose

S/N E300001114

(was p/n 4641108)

S/N E300001114

replaced with Service Replacement Valve. Identify p/n stamped on valve before ordering parts.

2-38 510AJ 3121182

Page 85

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

27A Cont’d 7012974 1 Cartridge without Coil (4641108 Valve)

7010543 1 Seal Kit - 7012974 Cartridge 7012941 1 Cartridge without Coil (1001099391 & 4641317 Valve) 7010543 1 Seal Kit - 7012941 Cartridge 7012944 1 Coil

27B A/R Cartridge & Coil Options:

Ref. Note: Original Equipment Valve may have been

replaced with Service Replacement Valve. Identify p/n stamped on valve before ordering parts.

7012995 1 Cartridge without Coil (4641108 & 1001099391 Valves) 7012518 1 Seal Kit - 7012995 Cartridge 7012941 1 Cartridge without Coil (4641317 Valve) 7010543 1 Seal Kit - 7012941 Cartridge 7012943 1 Coil (1001099391 & 4641108 Valve)

7012944 1 Coil (4641317 Valve) 28 4711400 8 Flatwasher 1/4in Thin 29 4751400 12 Flatwasher 1/4in Regular 30 4751500 4 Flatwasher 5/16in Regular 31 4751600 6 Flatwasher 3/8in Regular 32 4752000 1 Flatwasher 5/8in Regular 33 4752200 2 Flatwasher 3/4in Regular 34 8008750 1 Battery (Wet) 35 1 Decal - Warning Explosion/Fire Options:

1704972 ANSI Spec

1706098 Australian & CE Spec

1706059 Brazilian Spec

1706060 Chinese Spec

1706064 CSA Spec

1706062 Japanese Spec

1706061 Korean Spec

1706063 Spanish Language

36 to 200 Not Used

2000291 Ref. ENGINE ASSEMBLY O

201 0080231 1 Adapter, Fan Spacer 202 0100011 A/R Compound, Locking 203 0100020 A/R Sealant, Pipe 204 Not Used 205 0340041 2 Band, Muffler Bracket 206 0641406 6 Bolt 1/4in-20NC x 3/4in 207 0641410 6 Bolt, 1/4in-20NC x 1-1/4in 208 0641510 3 Bolt, 5/16in-10NC x 1-1/4in 209 0641608 A/R Bolt 3/8in-16NC x 1in 210 0641610 16 Bolt 3/8in-16NC x 1-1/4in 211 0641812 2 Bolt 1/2in-13NC x 1-1/2in 212 0641820 4 Bolt 1/2in-13NC x 2-1/2in 213 0700816 4 Bolt M8 x 40mm

3121182 510AJ 2-39

Page 86

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

214 4 Bolt M10 x 25mm Options:

0701012 Belgium Built Machines S/N 1300000981 to S/N 1300001788 0771012 Belgium Built Machines S/N 1300001788 to Present 0771012 Romanian Built Machines S/N E300000100 to

S/N E300001114

215 4 Bolt M10 x 30mm Options:

0701014 Belgium Built Machines S/N 1300000981 to S/N 1300001788 0711014 Belgium Built Machines S/N 1300001788 to Present 0711014 Romanian Built Machines S/N E300000100 to

S/N E300001114 216 0711414 A/R Bolt M14 x 30mm 217 0741610 2 Screw, Countersunk 3/8in-16NC x 1-1/4in 218 0902740 1 Bracket, Engine Mounting 219 0962172 1 Bushing, Flanged 220 1320016 A/R Clamp 221 1320022 1 Clamp, Hose 222 1320222 3 Clamp, J Clip 223 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner 224 1703162 2 Decal, Fan Blade 225 1 Engine, Deutz Options:

2000273 Belgium Built Machines S/N 1300000981 to S/N 1300001788

(F3M2011 Tier II)

2000338 Belgium Built Machines S/N 1300001788 to S/N 1300003197

(F3M2011 Tier II)

1001092723 Belgium Built Machines S/N 1300003197 to Present

(D2011L03 Tier III)

1001092723 Romanian Built Machines S/N E300000100 to

S/N E300001114 (D2011L03 Tier III) 226 2060025 1 Fan 227 2200221 1 Plug (Belgium Built Machines Prior to S/N 1300003197 Only) 228 2220451 1 Fitting 229 1 Hose, 90° Elbow Options:

229A 2720434 Belgium Built Machines S/N 1300000981 to S/N 1300003196 229B 1001091179 Belgium Built Machines S/N 1300003196 to Present &

Romanian Built Machines S/N E300000100 to

S/N E300001114 230 2720449 1 Hose, Air Cleaner Intake (Belgium Built Machines Prior to

S/N 1300003197 Only) 231 2720467 2 Hose, Oil Cooler 232 2750532 380mm Hose 233 2902060 1 Battery Cable Kit C

233A 1 Cable (Battery + to Relays) Options:

7027050 Cable (Battery + to 2 Relays) (Romanian Built Machines

S/N E300001037 to S/N E300001114)

7016817 Cable (Battery + to 1 Relay) (All Belgium Built Machines &

Romanian Built Machines S/N E300000100 to S/N E300001037)

7016820 Cable, Jumper (Relay to Relay) (All Belgium Built Machines

& Romanian Built Machines S/N E300000100 to S/N E300001037)

2-40 510AJ 3121182

Page 87

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

233B Use 7027041 1 Cable (Battery - to Ground) (was p/n 7016837) 233C 7016820 1 Cable (Auxilliary Relay to Starter) 233D 7016834 1 Cable (Auxilliary Relay to Auxilliary Pump)

234 3020016 2.5gal/

9.46l 235 3200406 4 Mount, Rubber 236 1 Muffler Options:

3220110 Standard 3220112 Catalytic

236A 1320176 1 Clamp, Muffler

237 3311401 1 Nut 1/4in-20NC 238 3311405 12 Locknut 1/4in-20NC 239 3311505 3 Locknut 5/16in-18NC 240 3311605 A/R Locknut 3/8in-16NC 241 3311805 4 Locknut 1/2in-13NC 242 3340399 2 Pad, Wear 243 0903063 1 Plate, Engine Mounting (was p/n 3570801) 244 3573895 1 Plate, Radiator Mounting 245 3573937 1 Support, Radiator 246 3600279 1 Auxiliary Pump Assembly 246 1 Auxiliary Pump Assembly Options (See Figure 2-17 for

Use 3600423 Belgium Built Machines S/N 1300000981 to S/N 1300002754

3600423 Belgium Built Machines S/N 1300002754 to Present 3600423 Romanian Built Machines S/N E300000100 to

247 3600318 1 Gear Pump Assembly

7023929 1 Seal Kit - 3600318 Pump

248 3600385 1 Piston Pump Assembly with Fittings (See Figure 2-16 for

249 Use 1001150998 1 Radiator (was p/n 3620033) 250 A/R Relay Options:

3740140 2 Belgium Built Machines S/N 1300000981 to S/N 1300001981 3740067 3 Belgium Built Machines S/N 1300001981 to Present 3740067 3 Romanian Built Machines S/N E300000100 to

251 3790152 1 O-Ring 252 3960407 1 Gasket, Air Intake 253 4567495 1 Tube, Tee (Belgium Built Machines S/N 1300000981 to S/N

254 4640751 1 Valve, Oil Drain 255 4740274 4 Washer, Snubbing 256 4751400 21 Flatwasher 1/4in Regular 257 4751600 A/R Flatwasher 3/8in Regular 258 A/R Flatwasher Options:

4751900 Flatwasher 9/16in Regular 4812200 Flatwasher M14

259 4845395 1 Adapter

Motor Oil Mobil Delvac MX 15W-40 (Not Shown)

Breakdown):

(Was p/n 3600279)

S/N E300001114

Breakdown)

S/N E300001114

1300003197 Only)

3121182 510AJ 2-41

Page 88

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

260 1 Bracket, Motor Mount Options:

260A 4846567 All Machines with Generator Option

4846567 All Belgium Built Machines 4846567 Romanian Built Machines S/N E300000100 to S/N

E300000981 without Generator Option

260B 1001138135 Romanian Built Machines S/N E300000981 to

S/N E300001114 without Generator Option 261 4846683 1 Tray, Engine Mounting 262 4891600 2 Flatwasher 3/8in Hardened 263 2111010 2 Fitting, Straight (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

264 2111612 1 Fitting, Straight (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

265 2131212 1 Fitting, 90° (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

266 2151212 2 Fitting, 45° (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

267 2170316 1 Fitting, Tee (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

268 2170808 2 Fitting, Tee (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

269 2221084 1 Fitting, Tee (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

270 4641199 2 Valve, Check (Belgium Built Machines S/N 1300001259 to

Present & Romanian Built Machines S/N E300000100 to S/N E300001114)

271 4923451 1 Harness, Glow Plug (Not Shown) (Belgium Built Machines

S/N 1300001788 to Present & Romanian Built Machines

S/N E300000100 to S/N E300001114) 272 1060904 1 Cable, Jumper 273 2110604 2 Fitting Straight 274 2131210 1 Fitting, 90°

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

2-42 510AJ 3121182

Page 89

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. ENGINE COMPONENTS

2000273 Ref. Belgium Built Machines S/N 1300000981 to S/N 1300001788

(F3M2011 Tier II)

2000338 Ref. Belgium Built Machines S/N 1300001788 to S/N 1300003197

(F3M2011 Tier II)

1001092723 Ref/ Belgium Built Machines S/N 1300003197 to Present

(D2011L03 Tier III)

1001092723 Ref/ Romanian Built Machines S/N E300000100 to S/N E300001114

(D2011L03 Tier III)

401 7020026 1 Dipstick (was p/n 7027244) 402 7020465 2 Cap, Filler 403 7020495 1 Pump, Oil Lube (Not Shown)

7020468 1 Seal Between Oil Pump & Engine Block (Not Shown)

404 7016331 1 Filter, Oil

7027236 1 Sensor, Oil Temperature (Not Shown - Located in Rear Of Filter

Mount)

405 3 Pump, Injector Options:

7027246 Series A Injector 7027608 Series B Injector 7027609 Series C Injector 7027610 Series D Injector 7020447 3 Gasket, Injector Pump

406 7020023 1 Filter, Fuel

70001423 1 Bracket, Fuel Filter

407 Use 70000916 1 Pump Fuel Supply (was p/n 7027238)

7020411 1 O-Seal Between Fuel Pump & Engine Block (Not Shown)

70001435 1 Replacement Filter

408 7020449 3 Gasket, Intake Manifold (Not Shown)

7020471 3 Gasket, Exhaust (Not Shown)

70002200 6 Stud, Exhaust (Not Shown) 410 7027791 1 Sensor, Temperature 411 Use 7000663 1 Alternator (was p/n 7020410)

7020464 Regulator, Voltage (Not Shown)

412 7020479 1 Starter

7026608 1 Relay, Starter

413 7024565 1 Tacho-Generator

70003932 1 Sleeve, Spacer 414 7027792 1 Actuator, Throttle

7027276 2 Spring, Actuator

415 7027790 1 Sensor, Oil Pressure

416 to 417 Not Used

418 7020459 1 Thermostat

7020460 1 Spring, Compression

419 See Note 1 Flywheel (Not Shown) Note: Not Available for Purchase)

7024579 1 Rim, Gear (Not Shown) 420 7027245 1 Filter, Fuel 421 7027239 1 Solenoid, Start

3121182 510AJ 2-43

Page 90

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

422 7027795 1 Module, EMR2 423 7027769 2 Connector, Radiator 424 70001181 1 Valve (Not Shown - Located behind oil filter) (2000338 Engine) 425 1 Gasket, Head Options (Not Shown):

70003479 Gasket - 1 Notch 70003480 Gasket - 2 Notch 70003481 Gasket - 3 Notch

2-44 510AJ 3121182

Page 91

SECTION 2 TURNTABLE

FIGURE 2-10. DEUTZ ENGINE INSTALLATION (BELGIUM BUILT MACHINES S/N 1300000981

TO PRESENT & ROMANIAN BUILT MACHINES S/N E300000100 TO S/N E300001114)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 2-45

Page 92

SECTION 2 TURNTABLE

FIGURE 2-11.2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

2-46 510AJ 3121182

Page 93

SECTION 2 TURNTABLE

FIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: For Module (with/without UGM) Identification, refer to

Revision Log page A.

Ref. Note: All Romanian Built Machines are equipped with UGM.

GENERATOR INSTALLATION OPTIONS:

Ref. Without UGM Ref. 110V/60Hz Generator

0271593 Ref. Belgium Built Machines Prior to S/N 1300000316 2/B

Use 0274079 Ref. Belgium Built Machines S/N 1300000316 to S/N

1300000731 (was p/n 0272614)

0274079 Ref. Belgium Built Machines S/N 1300000731 to Present 2/B

1001100732 Ref. 110V/50Hz Generator B

Ref. 220V/50Hz Generator

Use 0274085 Ref. Belgium Built Machines Prior to S/N 1300000731 (was p/n

0272615)

0274085 Ref. Belgium Built Machines S/N 1300000731 to 1300006619

(was p/n 0274085)

1001100749 Ref. Belgium Built Machines S/N 1300006619 to Present B

Ref. With UGM 1001115403 Ref. 110V/60Hz Generator A 1001100732 Ref. 110V/50Hz Generator Options: B 1001100749 Ref. 220V/50Hz Generator B

Note: Refer to Sky Power Accessories Manual p/n 3124242 for the Miller 7500W Generator.

4/C

2/B

1 0100011 A/R Compound, Locking 2 0200742 1 Arm, Adjusting 3 1 V-Belt Options:

0480120 110V/60Hz (Belgium Built Machines Prior to S/N

1300000316)

0480122 110V/60Hz (Belgium Built Machines S/N 1300000316 to

Present)

0480122 110V/60Hz (Romanian Built Machines S/N E300000100 to

S/N E300001114) 0480120 110V/50Hz 0480120 220V/50Hz

4 0641404 1 Bolt 1/4in-20NC x 1/2in 5 0641508 1 Bolt 5/16in-18NC x 1in 6 0641610 1 Bolt 3/8in-16NC x 1-1/4in 7 0641772 1 Bolt 7/16in-14NC x 9in 8 0962449 1 Bushing 9 1 Generator and Control Box Assembly Options:

2460032 110V/60Hz Assembly (Belgium Built Machines Prior to S/N

1300000731)

2460055 110V/60Hz Assembly (Belgium Built Machines S/N

1300000731 to Present) 2460055 110V/60Hz Assembly (Romanian Built Machines S/N

E300000100 to S/N E300001114) 2460049 110V/50Hz Generator Only 2460013 220V/50Hz Assembly (Belgium Built Machines Prior to S/N

1300000731)

3121182 510AJ 2-47

Page 94

SECTION 2 TURNTABLE

FIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

9 cont’d 2460056 220V/50Hz Assembly (Belgium Built Machines S/N

1300000731 to S/N 1300006619)

1001100321 220V/50Hz Generator Only (Belgium Built Machines S/N

1300006619 to Present)

1001100321 220V/50Hz Generator Only (Romanian Built Machines S/N

E300000100 to S/N E300001114)

9A 1 Generator Options:

7012558 Generator - 110V/60Hz 2460049 Generator - 110V/50Hz

1001100321 1 Generator - 220V/50Hz

Ref. Note: Replacement Generators come standard with

P/N 3580134 Pulley. This Pulley may not be correct for all applications. Refer to Pulley options below.

7026199 1 110V/60Hz Armature with Slip Rings 70000122 1 110V/50Hz Armature with Slip Rings 70000123 1 220V/50Hz Armature with Slip Rings

7020109 4 Holder, Brush

7020108 4 Brush

7012513 4 Cap, Brush Holder

7012514 1 Fan

7020190 2 Bearing

7020110 1 End Bell, Front

7020111 1 End Bell, Rear

7020193 1 Cord, Power

9B 1 Box, Control Options:

7003657 110V/60Hz (Belgium Built Machines Prior to S/N

1300000731)

7019680 110V/60Hz (Belgium Built Machines S/N 1300000731 to

Present)

7019680 110V/60Hz (Romanian Built Machines S/N E300000100

to S/N E300001114)

70002235 220V/50Hz (Belgium Built Machines Prior to S/N

1300000731)

70000127 220V/50Hz (Belgium Built Machines S/N 1300000731 to

S/N 1300006619)

70000127 220V/50Hz (Romanian Built Machines S/N E300000100

to S/N E300001114)

Circuit Breaker Options:

4360542 1 110V/60Hz 70000126 1 220V/50Hz

4460190 A/R Receptacle, Double (110V Box)

4460027 A/R Receptacle, Double Twist Lock (110V Box) 70000124 1 Receptacle, Double (220V) 70000125 1 Receptacle, Single Twist Lock (220V)

2920162 1 Lamp Assembly (Belgium Built Machines Prior to S/N

1300000731)

7020191 1 Switch, Toggle (Belgium Built Machines Prior to S/N

1300000731)

9C 1 Voltmeter Options:

2420203 110V/60Hz

7020192 220V/50Hz

2-48 510AJ 3121182

Page 95

SECTION 2 TURNTABLE

FIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

9D 1 Pulley Options:

3580276 110V/60Hz 3580134 110V/50Hz 3580134 220V/50Hz

7027887 1 Key, Woodruff 10 3290505 1 Locknut M5 11 3311605 1 Locknut 3/8in-16NC 12 3311705 1 Locknut 7/16in-14NC 13 3580158 1 Pulley 14 3740080 1 Relay 15 4031608 1 Bolt M5 x 20mm 16 4420060 3in/8cm Tape, Double Sided Foam Acrylic 17 4460968 3 Connector, Strain Relief 18 4751500 1 Flatwasher 5/16in Regular 19 4751600 2 Flatwasher 3/8in Regular 20 4751700 4 Flatwasher 7/16in Regular 21 4811600 1 Flatwasher M5 22 1001099869 1 Box, Junction 23 1 Light, Red Options:

1001100233 125V 1001100234 250V

24 4360294 1 Breaker, Circuit - 30 Amp (Belgium Built Machines Prior to

S/N 1300000731)

25 4460023 1 Connector, Strain Relief (Belgium Built Machines Prior to

S/N 1300000731) 26 3520028 1 Plug, Hole (Belgium Built Machines Prior to S/N 1300000731) 27 0721008 2 Bolt #10-24NC x 1in (Belgium Built Machines Prior to S/N

1300000731) 28 0721006 A/R Bolt #10-24NC x 3/4in 29 3311005 A/R Locknut #10-24NC 30 4751000 A/R Flatwasher #10 Regular

PLATFORM COMPONENTS

Ref. Note: For Module (with/without UGM) Identification, refer to

Revision Log page A.

Ref. Without UGM

0271593 Ref. 110V/60Hz Generator (Belgium Built Machines Prior to S/N

1300000316)

Use 0274079 Ref. 110V/60Hz Generator (Belgium Built Machines S/N

1300000316 to S/N 1300000731) (was p/n 0272614)

0274079 Ref. 110V/60Hz Generator (Belgium Built Machines S/N

1300000731 to Present)

1001100656 Ref. 110V/50Hz Generator A

Use 0274085 Ref. 220V/50Hz Generator (Belgium Built Machines Prior to S/N

1300000731) (was p/n 0272615)

0274085 Ref. 220V/50Hz Generator (Belgium Built Machines S/N

1300000731 to 1300006619)

1001100657 Ref. 220V/50Hz Generator (Belgium Built Machines S/N

1300006619 to Present)

Ref. With UGM

1001115403 Ref. 110V/60Hz Generator A

2/B

4/C

2/B

3121182 510AJ 2-49

Page 96

SECTION 2 TURNTABLE

FIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001115411 Ref. 110V/50Hz Generator A 1001115412 Ref. 220V/50Hz Generator A

101 4360336 1 Switch, Toggle 102 4740397 1 Washer 103 4060802 1 Guard, Switch 104 2820031 A/R Heatshrink (Not Shown) 105 3251102 1 Nameplate

2-50 510AJ 3121182

Page 97

SECTION 2 TURNTABLE

FIGURE 2-11. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 2-51

Page 98

SECTION 2 TURNTABLE

FIGURE 2-12.PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN)

(WITHOUT UGM)

2-52 510AJ 3121182

Page 99

SECTION 2 TURNTABLE

STARTER

BATTERY

AUX.PWR.

PUMP

AUX.PWR.

RELAY

GLOW

PLUG

RELAY

START

RELAY

GRD.

39C

39A

39D

39E

39B

89010

410

510

107

108

93A

100

949899

109

909195

102

103

241

111

1018696

401406404

407

409

416

408

403

421

410

411

TO WATER

SEPARATER

TO FUEL

TANK

VENT

LINE

221

210

202

216

219

242

222

243

240

210

227

204

222

218

215

217

FUEL

RETURN

214

210

220

237

204

227

211

227

TO FUEL

PUMP

420

402

422

423

425

426

427

429

3121182 510AJ 2-53

Page 100

SECTION 2 TURNTABLE

FIGURE 2-12. PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN)

(WITHOUT UGM)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: For Module (with/without UGM) Identification, refer to

Revision Log page A.

Ref. Note: All Romanian Built Machines are equipped with UGM. Ref. Note: No Romanian Built Machines were built with Perkins

Engines

2000396 Ref. PERKINS ENGINE ASSEMBLY J

1 2180482 1 Elbow, Rubber 2 0080181 1 Adapter, Pump Mounting Plate 3 0080201 1 Adapter, 90° Air Intake 4 0100011 A/R Compound, Locking 5 1 Engine, Perkins 404C-22 Options:

1001095205 Prior to S/N 1300005957

1001102270 S/N 1300005957 to Present 6 0641812 2 Bolt 1/2in-13NC x 1-1/2in 7 0340041 2 Band, Air Cleaner Mounting 8 0340046 2 Band, Muffler Mounting 9 2111010 2 Fitting, Straight

10 2111612 1 Fitting, Straight 11 0630569 8 Bolt, Metric M14 x 30mm 12 0641406 8 Bolt 1/4in-20NC x 3/4in 13 0641408 5 Bolt 1/4in-20NC x 1in 14 0641610 3 Bolt 3/8in-16NC x 1-1/4in 15 0641506 8 Bolt 5/16in-18NC x 3/4in 16 0641507 6 Bolt 5/16in-18NC x 7/8in 17 0641609 4 Bolt 3/8in-16NC x 1-1/8in 18 0641610 35 Bolt 3/8in-16NC x 1-1/4in 19 0641820 4 Bolt 1/2in-13NC x 2-1/2in 20 Not Used 21 0721004 4 Capscrew #10-24NC x 1/2in 22 0721006 1 Capscrew #10-24NC x 3/4in 23 0741610 2 Screw, Flat Head 3/8in-16NC x 1-1/4in 24 0962172 1 Bushing, Flanged 25 1060904 1 Cable, Jumper 26 1320012 A/R Clamp 27 1320016 4 Clamp 28 1320022 A/R Clamp 29 1340060 1 Air Cleaner Assembly

7012664 1 Element, Air Cleaner 30 1580011 1 Container, Coolant Overflow 31 1660255 1 Coupling, Pump 32 2131212 1 Fitting, 90° 33 2060032 1 Fan, Electric 34 2151212 2 Fitting, 45° 35 2720058 4in/10cm Hose

2-54 510AJ 3121182

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 INSTALLATIONS

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

FIGURE 1-4.DRIVE HUB/BRAKE ASSEMBLY (REAR)

FIGURE 1-5.DRIVE HUB ASSEMBLY (FRONT)

FIGURE 1-6.DRIVE HUB ASSEMBLY (FRONT)

FIGURE 1-9.DRIVE VALVES INSTALLATIONS

FIGURE 2-1.CONTROL VALVE INSTALLATION

FIGURE 2-2.MAIN CONTROL VALVE ASSEMBLY

FIGURE 2-3.TURNTABLE AND SWING DRIVE INSTALLATIONS

FIGURE 2-6.SWING BEARING & ROTATION BOX ASSEMBLY

FIGURE 2-7.CATERPILLAR ENGINE INSTALLATION (WITH UGM)

FIGURE 2-11.2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)