JLG 510AJ Parts Manual

Illustrated Parts Manual

Model

510AJ

S/N 1300000100

TO PRESENT

PRIOR TO

S/N E300001114

3121182

August 30, 2013

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

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

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

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

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

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 510AJ 3121182

SECTION 1

FRAME

3121182 510AJ 1-1

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

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

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

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

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

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

’

3121182 510AJ 1-7

SECTION 1 FRAME

FIGURE 1-2.TIRE AND WHEEL DRIVE INSTALLATIONS

1-8 510AJ 3121182

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

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

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-11

SECTION 1 FRAME

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

1-12 510AJ 3121182

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

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

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-15

SECTION 1 FRAME

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

1-16 510AJ 3121182

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

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

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121182 510AJ 1-19

SECTION 1 FRAME

FIGURE 1-5.DRIVE HUB ASSEMBLY (FRONT)

1-20 510AJ 3121182

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

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

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