JLG 510AJ Boom Lift Service Manual
402 pages · Publication 3121181
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- Models
- 510AJ
- Serial coverage
- Prior to E300001115, 1300000100 to Present
- Manual type
- Service Manual
- Pages
- 402
- Publication
- 3121181
- Condition
- Brand new
What's inside
From the manual's own table of contents: 407 sections, 458 entries. See sample pages (PDF, 639 KB)
General
Hydraulic System Safety
Maintenance4 topics
- Capacities
- Tires
- Engine
- Specifications and Performance Data
Dimensional Data
Reach Specifications
Chassis1 topic
- Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes2 topics
- Torque Requirements
- Lubrication
Hydraulic Oil5 topics
- Operator Maintenance
- Major Component Weights
- Pressure Settings
- Serial Number Location
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Show all 407 sections
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications
Cylinder Drift Test
Platform Drift
Cylinder Drift3 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Torque Hub (Machines built Before S/N 1300000064)
Roll, Leak and Brake Testing
Tightening and Torquing Bolts
Main Disassembly
Input Carrier Disassembly
Output Carrier Disassembly
Housing-Spindle Disassembly
Spindle-Brake Disassembly
Input Carrier Sub-Assembly
Output Carrier Sub-Assembly
Spindle-Brake Sub-Assembly
Housing-Spindle Sub-Assembly
Integral Brake Check
Main Assembly1 topic
- Torque Hub (Machines built After S/N 1300000064)
Roll and Leak Testing
Oil Information
Main Disassembly for ”B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Carrier Assembly
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Tool List1 topic
- Re-Aligning torque hub input coupling
Equipment Required
Procedure1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures2 topics
- Adjustment Procedure For Lockout Valve
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding (Early Cylinders)
Lockout Cylinder Bleeding (Ram Cylinders)
Oscillating Axle Lockout Test1 topic
- Swing Bearing
Removal
Installation
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Torque Value1 topic
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
- Deutz Engine
Checking Oil Level
Changing Engine Oil
Changing the Oil Filter
Replacing Fuel Filter
Cleaning Fuel Strainer1 topic
- Perkins Engine General Maintenance
Replacing the Engine Crankcase Breather
Engine Oil Level - Check
Engine Oil and Filter - Change
Fuel Filter/Water Separator
Setting the Actuator
Speed Sensor Installation2 topics
- Engine Radiator Fill Procedure - Perkins & Caterpillar
- DGC Diagnostic Support and Trouble Code Definitions
Section Layout
List of Abbreviations in this Section
Fault Code Broadcast
Diagnostic Trouble Codes
MIL Output
Diagnostic Calibration Configuration and Corrective Actions
Fault/Diagnostic Trouble Code Interaction
DBW Diagnostic Test1 topic
- Diagnostic Trouble Code Fault Descriptions
DTC 116- ECT Higher Than Expected Stage 1
DTC 117- ECT/CHT Low Voltage
DTC 118- ECT/CHT High Voltage
DTC 122- TPS1 Signal Voltage Low
DTC 123- TPS1 Signal Voltage High
DTC 217- ECT Higher Than Expected 2
DTC 219- RPM Higher Than Max Allowed Governed Speed
DTC 336- Crank Signal Input Noise
DTC 337- Loss of Crank Input Signal
DTC 521- Oil Pressure Sender/Switch High Pressure
DTC 524- Oil Pressure Low
DTC 562- Battery Voltage (VBat) Low
DTC 563- Battery Voltage (VBat) High
DTC 601- Microprocessor Failure - FLASH
DTC 604- Microprocessor Failure - RAM
DTC 606- Microprocessor Failure - COP
DTC 642- 5 Volt External Low Voltage
DTC 643- 5 Volt External High Voltage
DTC 1612- Microprocessor Failure - RTI 1
DTC 1613- Microprocessor Failure - RTI 2
DTC 1614- Microprocessor Failure - RTI 3
DTC 1615- Microprocessor Failure - A/D
DTC 1616- Microprocessor Failure - interrupt
DTC 1625- CAN J1939 Shutdown Request
DTC 1626- CAN J1939 Transmit (Tx) Fault
DTC 1627- CAN J1939 Receive (Rx) Fault
DTC 1628- CAN Address Conflict Failure
DTC 1629- J1939 TSC1 Message Reciept Loss
Diagnostic Aids
DTC 1652- TPS1 Loss of Communications
DTC 2111- Unable to Reach Lower TPS
DTC 2112- Unable to Reach Higher TPS
DTC 9999- Throttle Actuator Failsafe Spring Failure
DTC to SPN/FMI Table1 topic
- Boom Maintenance
Remove Boom Assembly
Disassemble Main Boom
Assemble Main Boom
Install Boom Assembly1 topic
- Rotator
Disassembly and Inspection
Assembly and Testing
Theory of Operation
Required Tools
Installing Counterbalance Valve1 topic
- O-Ring Lubrication
Cup and Brush
Spray
Brush-On1 topic
- Hydraulic Cylinders
Tower Lift Cylinder
Main Lift Cylinder
Master Cylinder
Telescope Cylinder
Platform Level (Slave) Cylinder
Jib Lift Cylinder
Steer Cylinder
Axle Lockout Cylinder (Outside Frame)
Axle Lockout Cylinder (Inside Frame)1 topic
- Hydraulic Pump (Gear)
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Placing Pump Back Into Service1 topic
- Variable Pump
Ports and Pressure Gauges
NFPE Control
Removal and Installation of FNR and NFPE Modules
Removal and Installation of FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Charge Pump2 topics
- Hydraulic Component Start-Up Procedures and Recommendations
- Pressure Setting Procedure
Telescope Main Relief
Steer
Platform Level Up
Platform Level Down
Articulating Jib
Proportional Main Relief
Lift Down
Swing8 topics
- introduction
- To Connect the JLG Control System Analyzer
- Using the Analyzer
- Changing the Access Level of the Hand Held Analyzer
- Adjusting Parameters Using the Hand Held Analyzer
- Machine Setup
- Machine Personality Settings
- System Test
Test from the Platform
Test from the Ground Station2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Operator Maintenance and Lubrication Diagram
Serial Number Locations
Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Perkins
Main Disassembly Drawing 1
Main Disassembly Drawing 2
Spindle Brake Disassembly
Spindle Brake Sub-Assembly
Main Assembly Drawing 1
Main Assembly Drawing 2
Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2
Assembly Drawing - Without Integral Input Brake - Sheet 2 of 2
Assembly Drawing - With Integral Input Brake - Sheet 1 of 2
Assembly Drawing - With Integral Input Brake - Sheet 2 of 2
Assembly Tools - Bearing Cone Pressing - “B” Bearing
Assembly Tools - Bearing Cone Pressing - “A” Bearing
Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings
Assembly Tools - Seal Pressing
Assembly Tools - Spacer - Brake Disc Installation
Assembly Tools - Brake Retaining Ring Installation
Cluster Gear Punch Marks
Drive Motor Cross Section
Removing Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Chassis Torque Values - Sheet 1 of 2
Chassis Torque Values - Sheet 2 of 2
Valve Adjustment
Swing Bearing Installation
Swing Bearing
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Torque Sequence
Auxiliary Pump - Sheet 1 of 2
Auxiliary Pump - Sheet 2 of 2
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Engine Oil Viscosity
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Crankcase Breather - Perkins
Perkins Engine
Faults Page with Active Fault Message
Faults Page with Historic Fault Message
Custom Fault Variable Interface
Historic Fault Information Interface
Snapshot Data Interface
Flight Data Recorder Interface
Clear Faults Prompt
Exhaust Venturi Adjustment
Counterweight
Location of Components - Boom Removal
Boom Assembly
Boom Limit Switches
Main Boom
Timing Marks
Rotator Assembly - Cutaway
Rotary Actuator - Exploded View
Rotary Actuator - Assembly Drawing
Rotator Counterbalance Valve
Platform Support Torque Values
Hydraulic Cylinder Locations
Cylinder Barrel Support
Cylinder Head Removal
Cylinder Rod Support
Piston And Spacer Disassembly
Cylinder Head Disassembly
Composite Bushing Installation
Cylinder Head Assembly
Piston And Spacer Assembly
Cylinder Head Installation
Piston Disassembly
Piston Assembly
Piston And Bushings Disassembly
Piston And Bushings Assembly
Removing Cylinder Head
Steer Cylinder Assembly
Piston Seal and Wear Ring
Axle Lockout Cylinder
Shim Adjustable Charge Relief Valve Components
Gauge Port Locations
Plugs/Fittings Size & Torque
Screw Adjustable Charge Relief Valve Components
Shaft Seal Components
Installation of Shaft Seal
Shaft Components
Charge Pump Components
Main Control Valve
Main Control Valve Torque Values
Platform Control Valve
Hydraulic Schematic - Sheet 2 of 6
Hydraulic Schematic - Sheet 3 of 6
Hydraulic Schematic - Sheet 4 of 6
Hydraulic Schematic - Sheet 5 of 6
Hydraulic Schematic - Sheet 6 of 6
Hand-Held Analyzer (WANALYZER Controls and Display Similar)
Analyzer Connecting Points
Control Module Location
ADE Control System Block Diagram
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart, Version 6.X Software - Sheet 1of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 2 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 3 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 4of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 5of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 6 of 6
System Test Flow Chart - Platform Tests
System Test Flow Chart - Ground Station Tests
Voltage Measurement (DC)
Current Measurement (DC)
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components Installation - Sheet 1
Electrical Components Installation - Sheet 2
Electrical Schematic - Sheet 1 of 4
Electrical Schematic - Sheet 2 of 4
Electrical Schematic - Sheet 3 of 4
Electrical Schematic - Sheet 4 of 4
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 2 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 3 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 4 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 5 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 6 of 6
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 4 (LH)
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1of 4 (RH)
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 4 (LH)
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 4 (RH)
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 3 of 4
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 4 of 4
Capacities
Tires
Caterpillar 3024/C2.2
Chassis Specifications
Function Speeds (In Seconds)
Torque Specification
Engine Torque Requirements
Mobilfluid 424 Specs
Mobil DTE 13M Specs
UCon Hydrolube HP-5046
Mobil EAL H 46 Specs
Quintolubric 888-46
Component Weights
Pressure Settings
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Chassis Torque Values
J1939 Diagnostic Lamp Configuration
Diagnostic Corrective Actions
Historic Fault Information Interface Functions
Hydraulic Pump Bolt Torque Chart
Recommended Gauge Size
Machine Set-Up Parameters
Personality Ranges/Defaults
Machine Configuration Programming Information Prior to Software Version P5.3
Machine Configuration Programming Information Software Version P5.3 to P6.1
Machine Configuration Programming Information Software Version P6.1 to Present
System Test Messages
Machine Diagnostics Parameters
Help Fault Codes, Displayed Faults, and Descriptions
Inside this manual
Real pages from this service manual (402 pages). Open the sample pages (PDF, 637 KB)
- Specifications, page 19: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 349: SECTION 6 - JLG CONTROL SYSTEM
- Diagram, page 385: SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS
- Color page, page 129: SECTION 3 - CHASSIS AND TURNTABLE
- Color page, page 221: SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 510AJ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3121181$69.71
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 402 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).