JLG Telehandlers G10 55A, G12 55A Shop Manual 2003 – 2015
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JLG Telehandlers G10 55A, G12 55A Shop Manual 2003 – 2015
INTRODUCTION :
This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability. Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local distributor.
- Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.
- Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine.
- All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction. Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.
TABLE OF CONTENTS:
JLG Telehandlers G10 55A, G12 55A Shop Manual 2003 – 2015
3126019_H_JLG_G10-55A G12-55A_Service............................................................................. 1 Effectivity................................................................................................... 3 Table of Contents............................................................................................. 5 Section 1 Safety Practices.................................................................................... 9 1.1 Introduction.......................................................................................... 10 1.2 Disclaimer............................................................................................ 10 1.3 Operation & Safety Manual............................................................................. 10 1.4 Do Not Operate Tags................................................................................... 10 1.5 Safety Information.................................................................................... 10 1.5.1 Safety Alert System and Signal Words............................................................ 10 1.6 Safety Instructions................................................................................... 11 1.6.1 Personal Hazards................................................................................ 11 1.6.2 Equipment Hazards............................................................................... 11 1.6.3 General Hazards................................................................................. 11 1.6.4 Operational Hazards............................................................................. 12 1.7 Safety Decals......................................................................................... 12 Section 2 General Information and Specifications.............................................................. 13 2.1 Replacement Parts and Warranty Information............................................................ 14 2.2 Torque Charts......................................................................................... 15 2.2.1 SAE Fastener Torque Chart....................................................................... 15 2.2.2 Metric Fastener Torque Chart.................................................................... 19 2.2.3 Hydraulic Hose Torque Chart..................................................................... 22 2.3 Specifications........................................................................................ 23 2.3.1 Travel Speeds................................................................................... 23 2.3.2 Hydraulic Cylinder Performance.................................................................. 23 2.3.3 Electrical System............................................................................... 24 2.3.4 Engine Performance Specifications - John Deere.................................................. 24 2.3.5 Engine Performance Specifications - Perkins..................................................... 24 2.3.6 Engine Performance Specifications - Cummins..................................................... 25 2.3.7 Tires........................................................................................... 26 2.4 Fluid and Lubricant Capacities........................................................................ 27 2.5 Service and Maintenance Schedules..................................................................... 29 2.5.1 10, 1st 50 & 50 Hour............................................................................ 29 2.5.2 1st 250, 250 & 500 Hour......................................................................... 30 2.5.3 1000 & 1500 Hour................................................................................ 31 2.6 Lubrication Schedules................................................................................. 32 Section 3 Boom................................................................................................ 35 3.1 Boom System Component Terminology..................................................................... 37 3.2 Boom System - Four Section............................................................................ 38 3.2.1 Boom System Operation........................................................................... 38 3.3 Boom Assembly Maintenance............................................................................. 38 3.4 Complete Boom Removal/ Installation................................................................... 39 3.4.1 Complete Boom Removal........................................................................... 39 3.4.2 Complete Boom Installation...................................................................... 39 3.5 Boom Section Removal/ Installation.................................................................... 40 3.5.1 Second, Third & Fourth Boom Section Removal..................................................... 40 3.5.2 Third & Fourth Boom Section Removal............................................................. 42 3.5.3 Fourth Boom Section Removal..................................................................... 43 3.5.4 Hose Carrier Removal............................................................................ 44 3.5.5 Fourth Boom Section Assembly.................................................................... 44 3.5.6 Hose Carrier Installation....................................................................... 45 3.5.7 Third Boom Section Assembly..................................................................... 46 3.5.8 Fourth Boom Section Installation................................................................ 46 3.5.9 Second Boom Section Assembly.................................................................... 47 3.5.10 Third & Fourth Boom Section Installation....................................................... 48 3.5.11 Second, Third and Fourth Boom Section Installation............................................. 49 3.6 Extend/Retract Chain Removal/Installation............................................................. 50 3.6.1 Retract Chain Removal........................................................................... 50 3.6.2 Retract Chain Installation...................................................................... 51 3.6.3 Extend Chain Removal............................................................................ 51 3.6.4 Extend Chain Installation....................................................................... 52 3.7 Boom Section Separation Adjustment.................................................................... 52 3.8 Hose Carrier Assembly Removal/Installation............................................................ 54 3.8.1 Hose Carrier Assembly Removal................................................................... 54 3.8.2 Assembling the Hose Carrier Assembly............................................................ 55 3.8.3 Hose Carrier-Assembly Installation.............................................................. 55 3.8.4 Boom Hose Adjustment............................................................................ 56 3.9 Quick Switch Assembly................................................................................. 57 3.9.1 Quick Switch Removal............................................................................ 57 3.9.2 Quick Switch Installation....................................................................... 57 3.9.3 Quick Switch Removal............................................................................ 57 3.9.4 Quick Switch Installation....................................................................... 57 3.10 Boom Head - Mounted Winch............................................................................ 58 3.10.1 Boom Head-Mounted Winch Removal................................................................ 58 3.10.2 Boom Head-Mounted Winch Installation........................................................... 58 3.11 Boom Wear Pads....................................................................................... 58 3.11.1 Wear Pad Inspection............................................................................ 58 3.11.2 Wear Pad Installation and Lubrication.......................................................... 58 3.12 Boom Extend and Retract Chains....................................................................... 59 3.12.1 Boom Chain Inspection.......................................................................... 59 3.12.2 Inspection Guidelines.......................................................................... 60 3.12.3 Expose Chains for Inspection................................................................... 62 3.12.4 Chain Lubrication.............................................................................. 62 3.13 Forks................................................................................................ 63 3.14 Troubleshooting...................................................................................... 64 Section 4 Cab and Covers...................................................................................... 67 4.1 Operator’s Cab and Covers Component Terminology....................................................... 68 4.2 Operator’s Cab........................................................................................ 69 4.2.1 Cab Safety...................................................................................... 69 4.2.2 Serial Number Decal............................................................................. 69 4.3 Cab Components........................................................................................ 69 4.3.1 Steering Column and Orbitrol Valve.............................................................. 69 4.3.2 Service Brake Pedal............................................................................. 70 4.3.3 Throttle Pedal.................................................................................. 71 4.3.4 Boom Joystick Assembly.......................................................................... 71 4.3.5 Frame Sway, Auxiliary and Outrigger Control Joysticks........................................... 72 4.3.6 Windshield Wiper Assembly....................................................................... 72 4.3.7 Heater/Air Conditioning System (if equipped).................................................... 72 4.4 Cab Removal........................................................................................... 74 4.5 Cab Installation...................................................................................... 75 Section 5 Axles, Drive Shafts, Wheels and Tires............................................................... 77 5.1 Axle, Drive Shaft and Wheel Component Terminology..................................................... 78 5.2 General Information................................................................................... 79 5.3 Axle Assemblies....................................................................................... 79 5.3.1 Axle Serial Number Plate........................................................................ 79 5.3.2 Axle Specifications............................................................................. 79 5.3.3 Axle Internal Service........................................................................... 79 5.3.4 Axle Maintenance................................................................................ 79 5.3.5 Axle Removal.................................................................................... 80 5.3.6 Axle Installation............................................................................... 80 5.3.7 Axle Assembly and Drive Shaft Troubleshooting................................................... 82 5.4 Drive Shafts.......................................................................................... 85 5.4.1 Drive Shaft Inspection and Service.............................................................. 85 5.4.2 Drive Shaft Maintenance......................................................................... 85 5.4.3 Drive Shaft Removal............................................................................. 85 5.4.4 Drive Shaft Cleaning and Drying................................................................. 85 5.4.5 Drive Shaft Installation........................................................................ 85 5.5 Wheels and Tires...................................................................................... 86 5.5.1 Removing Wheel and Tire Assembly from Machine................................................... 86 5.5.2 Installing Wheel and Tire Assembly onto Machine................................................. 87 5.6 Brakes................................................................................................ 87 5.7 Towing a Disabled machine............................................................................. 87 5.7.1 Manually Releasing the Park Brake............................................................... 87 5.7.2 Manually Resetting the Park Brake............................................................... 88 Section 6 Transmission........................................................................................ 89 6.1 Transmission Assembly Component Terminology........................................................... 90 6.2 Transmission Serial Number............................................................................ 91 6.3 Transmission Specifications And Maintenance Information............................................... 91 6.4 Transmission Replacement.............................................................................. 91 6.4.1 Transmission Removal............................................................................ 91 6.4.2 Transmission Inspection and Internal Repair..................................................... 92 6.4.3 Transmission Installation....................................................................... 93 6.4.4 After Transmission Service or Replacement....................................................... 93 6.5 Torque Convertor Diaphragm............................................................................ 94 6.5.1 Torque Convertor Diaphragm Removal.............................................................. 94 6.5.2 Torque Convertor Diaphragm Installation......................................................... 94 6.6 Troubleshooting....................................................................................... 95 Section 7 Engine.............................................................................................. 99 7.1 Introduction - John Deere.............................................................................100 7.1.1 Disclaimer and Scope............................................................................100 7.1.2 Engine Serial Number............................................................................100 7.1.3 Specifications and Maintenance Information......................................................100 7.1.4 Component Terminology...........................................................................101 7.2 Introduction - Perkins................................................................................102 7.2.1 Disclaimer and Scope............................................................................102 7.2.2 Engine Serial Number............................................................................102 7.2.3 Specifications and Maintenance Information......................................................102 7.2.4 Component Terminology...........................................................................103 7.3 Introduction - Cummins................................................................................104 7.3.1 Disclaimer and Scope............................................................................104 7.3.2 Engine Serial Number............................................................................104 7.3.3 Specifications and Maintenance Information......................................................104 7.3.4 Component Terminology...........................................................................105 7.4 Engine Cooling System.................................................................................106 7.4.1 Radiator Pressure Cap...........................................................................106 7.4.2 Thermostat Replacement..........................................................................106 7.4.3 Radiator/Oil Cooler and Replacement.............................................................107 7.5 Engine Electrical System..............................................................................108 7.6 Fuel System...........................................................................................108 7.6.1 Diesel Fuel.....................................................................................108 7.6.2 Fuel Tank.......................................................................................108 7.6.3 After Fuel System Service.......................................................................110 7.7 Engine Exhaust System.................................................................................110 7.7.1 Exhaust System Removal..........................................................................110 7.7.2 Exhaust System Installation.....................................................................111 7.8 Air Cleaner Assembly..................................................................................111 7.8.1 Air Cleaner Assembly Removal (John Deere & Perkins).............................................111 7.8.2 Air Cleaner Assembly Installation (John Deere & Perkins)........................................111 7.8.3 Air Cleaner Assembly Removal (Cummins)..........................................................111 7.8.4 Air Cleaner Assembly Installation (Cummins).....................................................112 7.9 Engine Replacement....................................................................................112 7.9.1 Engine Removal..................................................................................112 7.9.2 Engine Installation.............................................................................113 7.10 Troubleshooting......................................................................................115 Section 8 Hydraulic System....................................................................................117 8.1 Hydraulic Component Terminology.......................................................................118 8.2 Safety Information....................................................................................119 8.3 Hydraulic Pressure Diagnosis..........................................................................119 8.3.1 Pressure Checks and Adjustments.................................................................120 8.4 Hydraulic Circuits....................................................................................120 8.4.1 Hydraulic Pressures.............................................................................120 8.4.2 Tilt Circuit Port Relief Adjustment.............................................................121 8.4.3 Hydraulic Schematic.............................................................................125 8.5 Hydraulic Reservoir...................................................................................129 8.5.1 Hydraulic Oil Reservoir Draining................................................................129 8.5.2 Hydraulic Oil Reservoir Filling.................................................................129 8.5.3 Hydraulic Oil Reservoir Removal/ Installation...................................................129 8.6 Implement Pump........................................................................................130 8.6.1 Implement Pump Replacement......................................................................130 8.7 Control Valves........................................................................................131 8.7.1 Main Control Valve..............................................................................131 8.7.2 Main Control Valve Assembly.....................................................................132 8.7.3 Service Brake Valve.............................................................................133 8.7.4 Service Brake Bleeding..........................................................................134 8.7.5 Service Brake Test..............................................................................135 8.7.6 Park Brake Test.................................................................................135 8.7.7 Steering Orbitrol Valve.........................................................................135 8.7.8 Steer Select Valve..............................................................................136 8.8 Hydraulic Cylinders...................................................................................137 8.8.1 General Cylinder Removal Instructions...........................................................137 8.8.2 Cylinder Inspection.............................................................................138 8.8.3 Cylinder Pressure Checking......................................................................139 8.8.4 Steering Cylinders..............................................................................139 8.8.5 Cylinder Torque Specifications..................................................................140 Section 9 Electrical System...................................................................................143 9.1 Electrical Component Terminology......................................................................145 9.1.1 General Overview - John Deere...................................................................145 9.1.2 General Overview - Perkins......................................................................146 9.1.3 General Overview - Cummins......................................................................147 9.2 Specifications........................................................................................148 9.3 Safety Information....................................................................................148 9.4 Fuses and Relays......................................................................................148 9.4.1 Engine Compartment..............................................................................148 9.4.2 Cab.............................................................................................148 9.4.3 Power Distribution Unit (VEC) - John Deere/Perkins..............................................149 9.4.4 Power Distribution Unit (VEC) - Cummins.........................................................150 9.4.5 Optional Power Distribution Unit (VEC)..........................................................151 9.5 Electrical System Schematics..........................................................................152 9.5.1 Cab Schematic - John Deere......................................................................152 9.5.2 Cab Schematic - Perkins.........................................................................153 9.5.3 Cab Schematic - Cummins.........................................................................154 9.5.4 Options Schematic - John Deere/Perkins..........................................................155 9.5.5 Options - Cummins...............................................................................156 9.5.6 Chassis Schematic - John Deere..................................................................157 9.5.7 Chassis Schematic - Perkins Before S/N 0160037186...............................................158 9.5.8 Chassis Schematic - Perkins S/N 0160037186 Thru 0160039397 Excluding 0160039394 & 0160039397....159 9.5.9 Chassis Schematic - Cummins S/N 0160039451 and After Including 0160039394 & 0160039397..........160 9.5.10 Power Unit Schematic - John Deere..............................................................161 9.5.11 Power Unit Schematic - Perkins.................................................................162 9.5.12 Power Unit Schematic - Cummins.................................................................163 9.6 Circuit Breakdowns....................................................................................164 9.6.1 Constant Power Circuit from Battery - John Deere & Perkins......................................164 9.6.2 Constant Power Circuit from Battery - Cummins...................................................165 9.6.3 Start & Charge Circuit - John Deere & Perkins...................................................166 9.6.4 Start & Charge Circuit - Cummins................................................................167 9.7 Engine Start Circuit..................................................................................168 9.7.1 Starter.........................................................................................168 9.7.2 Charging Circuit................................................................................169 9.7.3 Alternator......................................................................................169 9.8 Window Wiper/Washer Windshield Wiper Motor............................................................170 9.8.1 Windshield/Rear Window Washer Reservoir.........................................................171 9.9 Cab Heater and Fan....................................................................................172 9.9.1 Cab Heater Controls.............................................................................172 9.10 Solenoids, Sensors and Senders.......................................................................172 9.10.1 Fuel Shut-off Solenoid - John Deere............................................................172 9.10.2 Park Brake Solenoid Valve......................................................................173 9.10.3 Transmission Solenoid Valves...................................................................174 9.10.4 Transmission Temperature Sender................................................................174 9.10.5 Engine Coolant Temperature Sender..............................................................174 9.10.6 Air Manifold Temperature Sensor - John Deere...................................................176 9.10.7 Engine Oil Pressure Sender/Switch..............................................................176 9.10.8 Fuel Level Sender..............................................................................177 9.10.9 Inclinometer Switch............................................................................178 9.10.10 Front and Rear Axle Proximity Sensors.........................................................179 9.11 Display Monitor and Gauges...........................................................................179 9.11.1 Analog Gauges..................................................................................179 9.12 Dash Switches........................................................................................180 9.12.1 Ignition Key Switch............................................................................180 9.12.2 Dash Switches..................................................................................181 9.13 Troubleshooting - John Deere.........................................................................182 9.13.1 Engine Fault Codes Retrieval...................................................................182 9.13.2 Engine Fault Codes Chart.......................................................................182 9.14 Engine Indicator Lamps - Perkins.....................................................................184 9.15 SAE Diagnostic Trouble Codes and Fault Codes - Cummins...............................................185
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