Description

JLG 510AJ, 510A 2007 Service Manual

If you’re wrenching on a JLG boom lift without the factory documentation, you’re gambling with time and money. I’ve seen guys guess on a swing bearing torque and end up with a machine that wobbles under load. That’s not a fix—that’s a liability. This 262-page JLG 510AJ, 510A 2007 Service Manual is the exact binder that rolled off the factory line. No aftermarket interpretation, no missing pages. It’s what I reach for when a 510A comes in with a drive hub failure or a Perkins engine that won’t hold oil pressure.

Torque Specs and Fluid Capacities

Section 1.6 lists torque requirements for every critical fastener on the machine. Wheel lug nuts, swing bearing bolts, drive hub cap screws—they’re all there. Section 1.1 gives you capacities for hydraulic oil, engine oil, fuel tank, and coolant. If you’re replacing a drive motor on a 510AJ, you need those numbers before you start. Page 1.6 has the torque table. Don’t guess on the swing bearing; the manual calls for a specific value in ft-lbs, and I’ve seen what happens when you under-torque it.

Do You Have the Right Engine Section?

Two engine options are covered: the Deutz (Section 3.9) and the Perkins (Section 3.11). The Deutz section includes EMR 2 controller info for serial numbers after 1300000981. The Perkins section walks you through replacing the crankcase breather, setting the actuator, and changing the oil filter. If you’re working on a 510A with a Deutz, you need to pay attention to the fuel strainer cleaning procedure—Section 3.9 spells it out. Both sections include torque specs for cylinder head bolts and oil pan fasteners.

262 Pages of Factory Data

That’s what you’re buying—262 pages of OEM content that was printed October 10, 2007. The book is divided into five major sections: Introduction and Safety (Section A), Specifications (Section 1), General Maintenance (Section 2), Chassis & Turntable (Section 3), Boom & Platform (Section 4), and Hydraulics (Section 5). Every chapter is where it should be. No reprints from third parties. The hydraulic system safety warnings are from Section A—they’re not optional reading.

Understand the Welding Precautions

Section 2.6 covers welding on JLG equipment. If you need to weld a bracket or repair a crack, read those two pages first. The manual tells you exactly where to ground the welder and which electronic components to disconnect. I’ve seen techs fry a controller because they didn’t follow that section. The warning about never welding on the fluid reservoir is there for a reason. Use the factory procedures or don’t weld at all.

Hydraulic System Safety: What the Manual Covers

Hydraulics operate at high pressures. Section 5 details the entire system, including O-ring lubrication methods (cup and brush, dip, spray, brush-on). The cylinder drift test in Section 2.4 is something every owner-operator should run regularly. Pressure feed lines and loop flushing valves are covered in Section 3.5 for the drive motor. If you’re rebuilding a torque hub on a 510AJ built after S/N 1300000064, Section 3.3 has the full disassembly and assembly steps with a tool list.

Boom Maintenance and Platform Drift

Section 4.1 walks you through removal, disassembly, inspection, and assembly of the main boom. The rotator section (4.2) includes theory of operation and testing. If your platform drifts down unexpectedly, Section 2.4 gives the cylinder drift test procedure. That’s a safety issue—don’t ignore it. The manual also includes reach specifications and dimensional data in Section 1.4. Know your limits before you extend.

I’ve been turning wrenches for 28 years. This manual is on my bench because it’s the real deal. If you want to keep your 510A or 510AJ running without chasing gremlins, you need the factory spec sheet. Access the Factory Manual.

Does this manual cover both the 510A and 510AJ?

Yes. The title says 510A/AJ, and the content applies to both models. Sections for engines, hubs, and hydraulics are common. Differences are noted where serial number breaks apply.

What torque values are listed for the swing bearing?

Section 3.8 gives the swing bearing torque value in ft-lbs. The manual also includes a wear tolerance check and mounting bolt condition check. Use the number from the table, not an internet forum.

Related manuals you might need: JLG 450A 450AJ 510AJ Boom Lift Operation & Safety Manual, JLG RS10 2013 Service Manual – Factory Specs & Diagnostics, JLG 544D-10 2007 Service Manual – 392 Pages OEM Factory Specs. For general knowledge on transmissions, see Manual Transmission or Manual Transmission.