Jlg G12-55A Service Manual- Manuals

Page 3 - EFFECTIVITY PAGE

EFFECTIVITY PAGE 3126019 G10-55A, G12-55A i December, 2003 - A - Original Issue Of Manual July 16, 2004 - B - Revised Manual March 11, 2005 - C - Added Main Pump Information July 7, 2006 - D - Revised Manual April 19, 2007 - E - Revised pages 2.7, 3.16, 5.11, 6.3, 6.4, 7.10, 8.4, 8.6, 8.20, 9.18 &am...

Page 4 - ii

Page 5 - SECTION CONTENTS; Section

SECTION CONTENTS Section Subject Page G10-55A, G12-55A i Section 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 7 - iii

Section Subject Page iii G10-55A, G12-55A 9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 9.8 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 9.9 Cab Heat...

Page 8 - iv

Page 9 - Contents; PARAGRAPH

1-1 G10-55A, G12-55A Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 10 - Safety Practices; INTRODUCTION; All references to; DISCLAIMER; Safety Alert System and Signal Words; DANGER

Safety Practices 1-2 G10-55A, G12-55A 1.1 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 manua...

Page 11 - SAFETY INSTRUCTIONS; Personal Hazards

1-3 G10-55A, G12-55A Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any...

Page 12 - SAFETY DECALS

Safety Practices 1-4 G10-55A, G12-55A 1.6.4 Operational Hazards ENGINE: Stop the engine before performing any service unless specifically instructed otherwise. VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation. SOFT SURFACES AND SLOPES: NEVER work on a mach...

Page 14 - General Information and Specifications

General Information and Specifications 2-2 G10-55A, G12-55A 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure. Note: The replacement o...

Page 15 - TORQUE CHARTS; SAE Fastener Torque Chart; REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND; Description; Values for Zinc Yellow Chromate Fasteners; SAE GRADE 5 BOLTS & GRADE 2 NUTS

2-3 G10-55A, G12-55A General Information and Specifications 2.2 TORQUE CHARTS 2.2.1 SAE Fastener Torque Chart REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND Description 0100011 242 TM Vibra-TITE TM 121 Medium Strength (Blue) 0100019 271 TM Vibra-TITE TM 140 High Strength (Red) 0100071 262 TM Vibra-T...

Page 17 - SOCKET HEAD CAP SCREWS

2-5 G10-55A, G12-55A General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 32 0.1640 ...

Page 18 - Zinc Yellow Chromate Fasteners*

General Information and Specifications 2-6 G10-55A, G12-55A 2.2.1 SAE Fastener Torque Chart (Continued) Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 32 0.1640 ...

Page 19 - CLASS 8.8 METRIC BOLTS

2-7 G10-55A, G12-55A General Information and Specifications 2.2.2 Metric Fastener Torque Chart Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263 TM ) Torque (Lub) Sq mm KN [N.m] [N.m] [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3....

Page 20 - CLASS 10.9 METRIC BOLTS

General Information and Specifications 2-8 G10-55A, G12-55A 2.2.2 Metric Fastener Torque Chart (Continued) Size PITCH Tensile Stress Area Clamp Load K = 0.20 K= 0.18 K=0.15 Sq mm KN [N.m] [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25....

Page 21 - CLASS 12.9 SOCKET HEAD CAP SCREWS

2-9 G10-55A, G12-55A General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Size PITCH Tensile Stress Area Clamp Load See Note 4 K = .17 K = .16 K = .15 Sq mm kN [N.m] [N.m] [N.m] 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 ...

Page 22 - Size

General Information and Specifications 2-10 G10-55A, G12-55A 2.2.3 Hydraulic Hose Torque Chart Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible. Torque Wrench: 1. Identify the appropriate applicatio...

Page 23 - SPECIFICATIONS; Travel Speeds; FUNCTION

2-11 G10-55A, G12-55A General Information and Specifications 2.3 SPECIFICATIONS 2.3.1 Travel Speeds 2.3.2 Hydraulic Cylinder Performance Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature. FUNCTION G10-55A G1...

Page 24 - Battery

General Information and Specifications 2-12 G10-55A, G12-55A 2.3.3 Electrical System 2.3.4 Engine Performance Specifications - John Deere 2.3.5 Engine Performance Specifications - Perkins Battery Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free Quantity 1 Reserve Capacity 1,000 Cold Cranki...

Page 26 - Note: Pressure for foam filled tires are for initial fill ONLY.

General Information and Specifications 2-14 G10-55A, G12-55A 2.3.7 Tires Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm). Note: Pressure for foam filled tires are for initial fill ONLY. a. G10-55A b. G12-55A Size Tire Type Minimum Ply/ Star Rating Fill Type Pressure 14.00 x 24 G-2/...

Page 27 - FLUID AND LUBRICANT CAPACITIES; Engine Crankcase Oil

2-15 G10-55A, G12-55A General Information and Specifications 2.4 FLUID AND LUBRICANT CAPACITIES Engine Crankcase Oil Capacity with Filter Change John Deere (G10-55A) 14.3 quarts (13,5 liters) John Deere (G12-55A) 15.8 quarts (15,0 liters) Perkins 7 quarts (6,5 liters) Cummins 13.5 quarts (12,8 liter...

Page 28 - Hydraulic System

General Information and Specifications 2-16 G10-55A, G12-55A Hydraulic System System Capacity G10-55A 63 gallons (238 liters) G12-55A 65 gallons (246 liters) Reservoir Capacity 38 gallons (144 liters) Type of Fluid 0° to 104° F (-20° to 40° C) Mobilfluid 424 ® Tractor Hydraulic Fluid -40° to 0° F (-...

Page 29 - st; EVERY

2-17 G10-55A, G12-55A General Information and Specifications 2.5 SERVICE AND MAINTENANCE SCHEDULES 2.5.1 10, 1st 50 & 50 Hour MY4740 Check Wheel Lug Nut Torque LB/FT (N m) 50 1 st 50 EVERY Drain Fuel/ Water Separator Check Engine Coolant Level Check Battery Lubrication Schedule Check Transmissio...

Page 32 - LUBRICATION SCHEDULES

General Information and Specifications 2-20 G10-55A, G12-55A 2.6 LUBRICATION SCHEDULES a. 50 Hour OAL0450 50 EVERY

Page 36 - Boom

Boom 3-2 G10-55A, G12-55A 3.10 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 3.10.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 3.10.2 Boom Head-Mounted Winch Installation . . . . . . . . ...

Page 38 - BOOM SYSTEM - FOUR SECTION; Boom System Operation; BOOM ASSEMBLY MAINTENANCE; During service of the boom, perform the following:; WARNING

Boom 3-4 G10-55A, G12-55A 3.2 BOOM SYSTEM - FOUR SECTION 3.2.1 Boom System Operation The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chain and a single fourth section retract chain. As...

Page 46 - Place the third boom section onto suitable supports.; Fourth Boom Section Installation; Clean and lubricate the bottom of the fourth boom

Boom 3-12 G10-55A, G12-55A 13. Install guide bracket (16) P/N using the previously removed hardware (17). Torque as required. 3.5.7 Third Boom Section Assembly Note: Inspect and lubricate all extend and retract chains before re-assembly. Refer to Section 3.12.1, “Boom Chain Inspection,” for detailed...

Page 48 - 42 to all boom assembly bolts.

Boom 3-14 G10-55A, G12-55A 3.5.10 Third & Fourth Boom Section Installation Note: Refer to Section 2.2, “Torque Charts,” for standard bolt torque information. Note: Refer to Section 2.2.3, “Hydraulic Hose Torque Chart,” for standard hose torque information. Note: Apply Loctite ® 242 to all boom a...

Page 57 - QUICK SWITCH ASSEMBLY; Inspect the above pins for nicks or surface corrosion.; Align the quick switch with the tilt cylinder rod end; Inspect the above pins for nicks or surface corrosion.; Align the quick switch with the tilt cylinder rod end

3-23 G10-55A, G12-55A Boom 3.9 QUICK SWITCH ASSEMBLY 3.9.1 Quick Switch Removal Before S/N 0160037689 1. Remove the lock bolt (1) holding the tilt cylinder rod end pin (2) to the quick switch assembly (3). Remove the Tilt Cylinder pin. 2. Support the quick switch assembly (3).Remove the capscrew (4)...

Page 58 - BOOM HEAD - MOUNTED WINCH; Boom Head-Mounted Winch Removal; BOOM WEAR PADS; Wear Pad Inspection; • The wear pad inserts and mounting bolts MUST be

Boom 3-24 G10-55A, G12-55A 3.10 BOOM HEAD - MOUNTED WINCH 3.10.1 Boom Head-Mounted Winch Removal 1. Using a suitable lifting device, secure the winch assembly (4) with a nylon strap. 2. Disconnect the hydraulic hoses (5). 3. Loosen and remove the mounting bolts, washers and nuts (6)(not shown). 4. L...

Page 60 - • High velocity movement of load, followed by; Inspection Guidelines; Edge Wear

Boom 3-26 G10-55A, G12-55A Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. • High velocity movement of load, followed by sudden, abrupt stops. • Carrying loads in suspension over irregular surfaces such as railroad track...

Page 61 - The types of cracks are:

3-27 G10-55A, G12-55A Boom Distorted or Battered Link Plates Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing. Turning or Protruding Pins Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and...

Page 62 - Fully extend the boom until both extend chains are; Chain Lubrication

Boom 3-28 G10-55A, G12-55A 3.12.3 Expose Chains for Inspection d. Extend Chains 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom until both ext...

Page 63 - FORKS; Daily Inspection; of shank should not exceed 93 degrees.

3-29 G10-55A, G12-55A Boom 3.13 FORKS Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. Daily Inspection 1. Inspect forks (1) for cracks, paying special attention to heel (2) and mounting t...

Page 64 - TROUBLESHOOTING; Boom will not extend or; not operating properly.; Boom shifts to right or left; Boom side wear pads; Excessive boom pivot pin; lubricate at regular intervals.

Boom 3-30 G10-55A, G12-55A 3.14 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem Cause Remedy 1. Boom will not extend or retract 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locat...

Page 65 - excessively worn or damaged.; Problem

3-31 G10-55A, G12-55A Boom 5. Drooping chain, or jerky boom extend or retract functions. 1. Chain(s) tension not properly adjusted. 1. Adjust chain(s). 2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to Section 3.7, “Boom Section Separation Adjustment.” 3. Wear pads loose, conta...

Page 66 - Check wear pad gaps and; Auxiliary hydraulics will not; Auxiliary hydraulic system not

Boom 3-32 G10-55A, G12-55A 8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.11, “Boom Wear Pads.” 2. Rapid cycle times with heavy loads. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3. Remove ...

Page 68 - Cab and Covers

Cab and Covers 4-2 G10-55A, G12-55A 4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machin...

Page 69 - OPERATOR’S CAB; Cab Safety; CAB COMPONENTS; Steering Column and Orbitrol Valve; a. Orbitrol Valve Removal; Place a Do Not Operate Tag on both the ignition key

4-3 G10-55A, G12-55A Cab and Covers 4.2 OPERATOR’S CAB 4.2.1 Cab Safety 4.2.2 Serial Number Decal The cab serial number decal is located on the left side of the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data....

Page 70 - b. Orbitrol Valve Installation; Service Brake Pedal; a. Brake Valve Removal

Cab and Covers 4-4 G10-55A, G12-55A b. Orbitrol Valve Installation 1. Secure the steering valve to the steering column with four hex-flange capscrews and four lockwashers. 2. Install the steering column through the dash panel opening. Position steering valve to its original orientation in the cab. 3...

Page 71 - a. Throttle Pedal Removal; Boom Joystick Assembly; a. Boom Joystick Assembly Removal

4-5 G10-55A, G12-55A Cab and Covers 4.3.3 Throttle Pedal a. Throttle Pedal Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. ...

Page 72 - b. Joystick Installation; Windshield Wiper Assembly; a. Heater Assembly Removal

Cab and Covers 4-6 G10-55A, G12-55A a. Move the joystick handle rearward, activating the boom lift function. The boom should RISE. b. Move the joystick handle forward, activating the boom lower function. The boom should LOWER. c. Move the joystick handle to the right, activating the boom extend func...

Page 73 - b. Heater Assembly Installation

4-7 G10-55A, G12-55A Cab and Covers 10. Remove the bolts securing the front plate (10) to the seat riser weldment (11). 11. Remove the bolts securing the seat riser weldment to the cab. Remove the riser weldment. 12. Loosen the hose and disconnect the heater air duct hoses (12). 13. Loose the hose c...

Page 74 - CAB REMOVAL

Cab and Covers 4-8 G10-55A, G12-55A 4.4 CAB REMOVAL Note: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information. Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued me...

Page 75 - CAB INSTALLATION

4-9 G10-55A, G12-55A Cab and Covers 19. Open Cab: Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) under the inner four braces (13) and behind the center cross support above the wind shield or install two lifting eye bolts (14) in the threaded holes on the roof of the cab above the...

Page 77 - Section 5

5-1 G10-55A, G12-55A Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH TITLE PAGE 5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2 5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 79 - Axle Serial Number Plate

5-3 G10-55A, G12-55A Axles, Drive Shafts, Wheels and Tires 5.2 GENERAL INFORMATION Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if compone...

Page 82 - Axle Assembly and Drive Shaft Troubleshooting; Excessive axle noise while

Axles, Drive Shafts, Wheels and Tires 5-6 G10-55A, G12-55A 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem Cause Remedy 1. Excessive axle noise while driving. 1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Axle and/or wheel ...

Page 85 - DRIVE SHAFTS; Drive Shaft Inspection and Service

5-9 G10-55A, G12-55A Axles, Drive Shafts, Wheels and Tires 5.4 DRIVE SHAFTS 5.4.1 Drive Shaft Inspection and Service Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can he...

Page 86 - WHEELS AND TIRES; • Equal or greater ply/load rating and size of original.

Axles, Drive Shafts, Wheels and Tires 5-10 G10-55A, G12-55A 5.5 WHEELS AND TIRES It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, It is reco...

Page 87 - Manually Releasing the Park Brake

5-11 G10-55A, G12-55A Axles, Drive Shafts, Wheels and Tires 5.5.2 Installing Wheel and Tire Assembly onto Machine Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. 1. Position wheel onto studs on wheel end of ...

Page 88 - Manually Resetting the Park Brake; Remove the screws along with the nuts and seals.

Axles, Drive Shafts, Wheels and Tires 5-12 G10-55A, G12-55A 5.7.2 Manually Resetting the Park Brake Note: Block the wheels of the machine BEFORE attempting to reset the machine’s park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable. 1. Loosen each re...

Page 90 - Transmission

Transmission 6-2 G10-55A, G12-55A 6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission...

Page 91 - TRANSMISSION SERIAL NUMBER; Transmission Removal

6-3 G10-55A, G12-55A Transmission 6.2 TRANSMISSION SERIAL NUMBER The transmission serial number plate (1) is located on the front of the transmission case behind the oil dipstick. Information on the serial number plate is required in correspondence regarding the transmission. 6.3 TRANSMISSION SPECIF...

Page 94 - TORQUE CONVERTOR DIAPHRAGM

Transmission 6-6 G10-55A, G12-55A 6. Transmission transfer case fluid may be added through the fill plug (6). Remove the fill plug and add approximately 1.5 quarts (1,4 liters) of hydraulic oil. Install fill plug and tighten. 7. Run the engine for two minutes at idle to help prime the torque convert...

Page 95 - Transmission will not engage; Fill transmission to correct level

6-7 G10-55A, G12-55A Transmission 6.6 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the local distributor if internal transmission repair is required during the warranty period. The t...

Page 96 - Low or no pump flow or

Transmission 6-8 G10-55A, G12-55A 2. Low or no pump flow or pressure. 1. Low oil level. 1. Fill transmission to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Transmission filled with incorrect oil, or oil contaminated. 2. Drain transmission and fill to ...

Page 97 - Transmission overheating

6-9 G10-55A, G12-55A Transmission 5. Transmission overheating (oil above 248° F (120° C)). 1. Low oil level. 1. Fill transmission to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Clogged radiator. 2. Remove debris from the radiator. 3. Transmission fill...

Page 98 - Remove drain plug and drain oil

Transmission 6-10 G10-55A, G12-55A 7. Oil leaking from transmission. 1. Oil leaking from vent (high oil level). 1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.” Replace o-rings as needed and tighten plugs to 96 lb-ft...

Page 100 - Engine; INTRODUCTION - JOHN DEERE; Disclaimer and Scope

Engine 7-2 G10-55A, G12-55A 7.1 INTRODUCTION - JOHN DEERE 7.1.1 Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in suc...

Page 102 - INTRODUCTION - PERKINS

Engine 7-4 G10-55A, G12-55A 7.2 INTRODUCTION - PERKINS 7.2.1 Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a...

Page 104 - INTRODUCTION - CUMMINS

Engine 7-6 G10-55A, G12-55A 7.3 INTRODUCTION - CUMMINS 7.3.1 Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a...

Page 106 - ENGINE COOLING SYSTEM; Radiator Pressure Cap; a. Thermostat Removal

Engine 7-8 G10-55A, G12-55A 7.4 ENGINE COOLING SYSTEM 7.4.1 Radiator Pressure Cap John Deere/Perkins: For a 210° F (99° C) system, use a 13 psi (90 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. Cummins: For a 210° F (99° C) system, ...

Page 107 - b. Thermostat Installation; Radiator/Oil Cooler and Replacement

7-9 G10-55A, G12-55A Engine b. Thermostat Installation 1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews and torque as required. 2. Connect the engine water temperature sender if connected to the thermostat housing. 3. Properly connect the batt...

Page 108 - ENGINE ELECTRICAL SYSTEM; Diesel Fuel

Engine 7-10 G10-55A, G12-55A 12. Loosen and remove the hoses (7) attached to the transmission cooler. Plug and/or cap the hoses to prevent dirt and debris from entering the transmission system. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect ...

Page 109 - c. Cleaning and Drying; To clean the fuel tank:

7-11 G10-55A, G12-55A Engine a. Fuel Tank Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on bo...

Page 110 - Fuel Tank Installation; After Fuel System Service; ENGINE EXHAUST SYSTEM; Exhaust System Removal

Engine 7-12 G10-55A, G12-55A the exterior and look for bubbles to appear at the cracked or damaged area. f. Fuel Tank Installation 1. Set fuel tank in its original orientation at the rear of the cab. 2. Install the fuel tank hold down bar. 3. Install the fuel sender with new gasket into the fuel tan...

Page 111 - AIR CLEANER ASSEMBLY; 42 to the capscrew threads

7-13 G10-55A, G12-55A Engine 7.7.2 Exhaust System Installation Note: Keep all clamps loosened until entire exhaust system is in place. 1. Install the exhaust pipe/flex pipe (8) with a new seal (9) to the turbo charger. 2. Install the exhaust pipe/flex pipe clamp (5) at the bottom rear corner of the ...

Page 112 - ENGINE REPLACEMENT; Engine Removal

Engine 7-14 G10-55A, G12-55A 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Loosen the clamp (15) securing the air int...

Page 113 - 42 to the engine mount bracket

7-15 G10-55A, G12-55A Engine 14. Remove the exhaust pipe from the exhaust manifold. Refer to Section 7.7.1, “Exhaust System Removal.” 15. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe. 16. Remove the air cleaner tube assembly. Refer to Section 7.8.1, “Air Cleaner ...

Page 114 - • DO NOT operate any hydraulic function.

Engine 7-16 G10-55A, G12-55A 17. Install the engine cover and adjust. 18. Install and properly connect the battery. Install and properly connect the second battery if equipped. 19. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are corr...

Page 116 - This Page Intentionally Left Blank

Engine 7-18 G10-55A, G12-55A This Page Intentionally Left Blank

Page 119 - SAFETY INFORMATION; Hydraulic Pressure Test Kit; • Gauges for testing high and low pressure circuits

8-3 G10-55A, G12-55A Hydraulic System 8.2 SAFETY INFORMATION Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when a...

Page 120 - HYDRAULIC CIRCUITS; Hydraulic Pressures; b. Adjusting Hydraulic Pressure

Hydraulic System 8-4 G10-55A, G12-55A 8.3.1 Pressure Checks and Adjustments When diagnosing trouble in the hydraulic system, use the hydraulic testing information in Section 8.4.1, “ Hydraulic Pressures.” In general, follow the steps below whenever conducting pressure checks and performing adjustmen...

Page 122 - If the pressure requires adjustment and if the

Hydraulic System 8-6 G10-55A, G12-55A 21. If the pressure requires adjustment and if the machine is equipped with a Rexroth main control valve, adjust the relief on the (B) port and repeat steps 17 and 18.If the machine is equipped with a Husco main control valve, the relief on the (B) port is non-a...

Page 128 - AUXILIARY HYDRAULICS OPTION

Hydraulic System 8-12 G10-55A, G12-55A 8.4.3 Hydraulic Schematic (Continued) AUXILIARY HYDRAULICS PORTS DECOMPRESSION VALVE AUX SWAY/AUX JOYSTICKS .050 SWAY CYLINDER .040 SWAY AUXILIARY HYDRAULICS OPTION 1 2 1 2 T P b B A a b B A a MY1190H

Page 129 - HYDRAULIC RESERVOIR; Hydraulic Oil Reservoir Draining

8-13 G10-55A, G12-55A Hydraulic System 8.5 HYDRAULIC RESERVOIR The hydraulic reservoir (1) is located on the frame between the engine compartment and the cab. 8.5.1 Hydraulic Oil Reservoir Draining 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boo...

Page 130 - To clean the hydraulic oil reservoir:; e. Reservoir Installation; IMPLEMENT PUMP; Implement Pump Replacement

Hydraulic System 8-14 G10-55A, G12-55A c. Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the hydraulic oil reservoir, contact your local distributor. To clean the hydraulic oil reservoir: 1. Have ...

Page 131 - CONTROL VALVES; Main Control Valve; a. Main Control Valve Removal

8-15 G10-55A, G12-55A Hydraulic System Note: DO NOT disassemble the operating pump. The pump is pre-set from the manufacturer. Any adjustments or repairs performed by anyone other than an authorized dealer could void the warranty. b. Pump Installation 1. Place the pump and a new, oiled o-ring into p...

Page 132 - b. Main Control Valve Disassembly; Disassemble each Valve Section; c. Main Control Valve Parts Cleaning; Main Control Valve Assembly; Assemble each Valve Section

Hydraulic System 8-16 G10-55A, G12-55A 12. Remove the four bolts, washers and nuts (1) securing the main control valve to the frame. b. Main Control Valve Disassembly 1. To disassemble the individual sections of the main control valve, remove the nuts from one end of the tie rods (2). Pull the tie r...

Page 133 - e. Main Control Valve Installation; Service Brake Valve; a. Service Brake Valve Removal

8-17 G10-55A, G12-55A Hydraulic System 4. Using the proper o-rings and load sense shuttle, repeat step three for the remaining valve sections and lastly the inlet end valve section. 5. Install the three washers and nuts on the tie rods. Torque to 30 lb-ft (41 Nm). e. Main Control Valve Installation ...

Page 134 - b. Service Brake Valve Installation; Service Brake Bleeding

Hydraulic System 8-18 G10-55A, G12-55A b. Service Brake Valve Installation 1. Install the service brake valve (4) with the four capscrews, four lockwashers and four nuts (3) onto the service brake bracket (5). 2. Install the service brake pedal. Refer to Section 4.3.2, “Service Brake Pedal.” Note: A...

Page 136 - a. Steer Select Manifold and Valve Removal

Hydraulic System 8-20 G10-55A, G12-55A 8.7.8 Steer Select Valve The machine can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve (8) controls the direction of hydraulic fluid flow to the steering cylinder mounted on each axle. The steer select valve is attached to...

Page 137 - HYDRAULIC CYLINDERS; a. General Cylinder Disassembly

8-21 G10-55A, G12-55A Hydraulic System 6. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 7. Wipe up any hydraulic fluid spillage in, on...

Page 138 - b. Cylinder Cleaning Instructions; Cleaner prior to; Cylinder Inspection; c. General Cylinder Assembly Instructions; AFTER; the head gland

Hydraulic System 8-22 G10-55A, G12-55A Note: Protect the finish of the rod at all times. Damage to the surface of the rod can cause seal failure. 5. Using a pin spanner wrench, unscrew the head gland (4) from the tube (2). A considerable amount of force will be needed to remove the head gland. 6. Ca...

Page 139 - d. General Cylinder Installation; Cylinder Pressure Checking

8-23 G10-55A, G12-55A Hydraulic System Note: Avoid using excess force when clamping the cylinder barrel in a vise. Apply only enough force to hold the cylinder barrel securely. Excessive force can damage the cylinder barrel. 5. Place the cylinder barrel in a soft-jawed vise or other acceptable holdi...

Page 144 - Electrical System

Electrical System 9-2 G10-55A, G12-55A 9.8 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 9.8.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . 9-29 9.9 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . ...

Page 148 - Engine Compartment

Electrical System 9-6 G10-55A, G12-55A 9.2 SPECIFICATIONS Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 SAFETY INFORMATION 9.4 FUSES AND RELAYS 9.4.1 Engine Compartment The starter relay (1) and power distribution unit (2) is located on the p...

Page 149 - Connector Legend

9-7 G10-55A, G12-55A Electrical System 9.4.3 Power Distribution Unit (VEC) - John Deere/Perkins Connector Legend No. Function Amp Rating CB1 Options Power 3 20 CB2 Options Power 4 20 CB3 Options Power 1 20 CB4 Options Power 2 20 F1 Trans/Park Brake Power 15 F2 Alternator Excite 5 F3 Engine ECU Ignit...

Page 152 - ELECTRICAL SYSTEM SCHEMATICS; Cab Schematic - John Deere

Electrical System 9-10 G10-55A, G12-55A 9.5 ELECTRICAL SYSTEM SCHEMATICS 9.5.1 Cab Schematic - John Deere MY1060 Y6 (ONL Y IF P ARK BRAKE OFF) N1 N3 N4 N2 Y6 (ONL Y IF P ARK BRAKE OFF) Y6 (ONL Y IF P ARK BRAKE OFF) Y6 (ONL Y IF P ARK BRAKE OFF) R4 R3 R2 R1 F4 F3 F2 F1 GEAR Y2, Y3, Y4, Y6 Y2, Y3, Y5,...

Page 164 - CIRCUIT BREAKDOWNS; Constant Power Circuit from Battery - John Deere & Perkins

Electrical System 9-22 G10-55A, G12-55A 9.6 CIRCUIT BREAKDOWNS 9.6.1 Constant Power Circuit from Battery - John Deere & Perkins MY1102 F GRAY-5 20 20 20 BLACK-1 H G E F D 25 C B A H G 10 15 CB3 CB4 F8 IGNITION-1 86 30 87 87a 85 F9 CB1 F7 ACCY-1 87 87a 30 86 85 86 87a 30 87 85 ACCY-2 87 87a 30 86...

Page 165 - ALTERNATOR

9-23 G10-55A, G12-55A Electrical System 9.6.2 Constant Power Circuit from Battery - Cummins 1 2 3 4 ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG FUSE HOLDER, ATO FUSE HOLDER, ATO 30A FC206 1 2 87 30 86 85 STARTER RELAY, 12V, 75 AMP STARTER RELAY, 12V, 75 AM...

Page 168 - ENGINE START CIRCUIT; Starter; a. Testing the Starter on the Engine

Electrical System 9-26 G10-55A, G12-55A 9.7 ENGINE START CIRCUIT 9.7.1 Starter The starter (1) is located on the left side of the engine (the right side of the machine - John Deere). The starter (1) is located on the right side of the engine (the right side of the machine - Perkins & Cummins). a...

Page 169 - a. Alternator Removal

9-27 G10-55A, G12-55A Electrical System 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 9.7.2 Charging Circuit Before using a battery charger, an attempt can be made to recharge the battery by jump-starting the machine (Refer to the appropriate Operation &...

Page 170 - c. Inspection and Replacement

Electrical System 9-28 G10-55A, G12-55A 9.8 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR a. Removal Note: It may be necessary to remove several hydraulic hoses from behind the dash in order to remove and install the wiper motor housing. (Refer to Section 4.3.1, “Steering Column and Orbitrol Valve.”) 1...

Page 171 - c. Installation and Testing

9-29 G10-55A, G12-55A Electrical System 9.8.1 Windshield/Rear Window Washer Reservoir The windshield washer motor and reservoir (4) is located in the cab behind the seat. It is labeled as a unit and cannot be serviced separately. a. Removal 1. Park the machine on a firm, level surface, level the mac...

Page 172 - CAB HEATER AND FAN; Cab Heater Controls; a. Cab Heater Controls Removal

Electrical System 9-30 G10-55A, G12-55A 9.9 CAB HEATER AND FAN 9.9.1 Cab Heater Controls Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. a. Cab Heater Controls Removal 1. Park the machine on a firm, level surface, l...

Page 173 - c. Fuel Shut-off Solenoid Inspection and; Park Brake Solenoid Valve; a. Park Brake Solenoid Valve Removal

9-31 G10-55A, G12-55A Electrical System 5. Disconnect the wiring connector at the fuel shut-off solenoid (6) lead. 6. Remove the fuel shut-off solenoid from the fuel injector pump. b. Fuel Shut-off Solenoid Disassembly DO NOT disassemble a fuel shut-off solenoid. Replace a defective fuel shut-off so...

Page 175 - b. Engine Coolant Temperature Sender Inspection

9-33 G10-55A, G12-55A Electrical System 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the engine coolant t...

Page 177 - b. Engine Oil Pressure Sender Inspection and; Fuel Level Sender; a. Fuel Level Indicator Testing

9-35 G10-55A, G12-55A Electrical System 6. Unplug the wiring harness connector from the engine oil pressure sender (4) or switch (5). 7. John Deere/Perkins - The engine oil pressure sender/switch is threaded into a fitting on the bracket weldment. Remove the sender/switch.Cummins - The engine oil pr...

Page 178 - b. Fuel Level Circuit Tests; Inclinometer Switch; a. Inclinometer Switch Removal

Electrical System 9-36 G10-55A, G12-55A b. Fuel Level Circuit Tests If the fuel level sender (8) is suspected of giving a false reading, perform the following checks: 1. If the fuel level indicator needle does not move, check the fuel tank for fuel. 2. Check for loose or defective wiring, faulty gro...

Page 179 - DISPLAY MONITOR AND GAUGES; Analog Gauges

9-37 G10-55A, G12-55A Electrical System 9.10.10 Front and Rear Axle Proximity Sensors The sensors used on each axle allow the steering to be changed to one of three different settings. The sensors will not allow the change to be completed unless both axles are in the central location. Each sensor is...

Page 180 - c. Gauge Installation and Testing; DASH SWITCHES; Ignition Key Switch; a. Ignition Switch Removal; BA T

Electrical System 9-38 G10-55A, G12-55A b. Disassembly DO NOT disassemble the gauge. The gauge is not serviceable. Replace the gauge if found to be defective. c. Gauge Installation and Testing 1. Install the gauge (12) in the dash. Install the gauge bracket. 2. Connect the previously labeled wires t...

Page 182 - TROUBLESHOOTING - JOHN DEERE; Engine Fault Codes Retrieval; Fault Codes

Electrical System 9-40 G10-55A, G12-55A 9.13 TROUBLESHOOTING - JOHN DEERE 9.13.1 Engine Fault Codes Retrieval 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL and engage the park brake. 2. Tur...

Page 184 - ENGINE INDICATOR LAMPS - PERKINS

Electrical System 9-42 G10-55A, G12-55A 9.14 ENGINE INDICATOR LAMPS - PERKINS Warning Lamp Shutdown Lamp Lamp State Lamp Indication Engine State ON ON Bulb Check When the ignition is turned on, the EMS shall illuminate each bulb for 2 seconds and extinguish them afterwards Key on, but engine has yet...

Page 185 - SAE DIAGNOSTIC TROUBLE CODES AND FAULT CODES - CUMMINS

9-43 G10-55A, G12-55A Electrical System 9.15 SAE DIAGNOSTIC TROUBLE CODES AND FAULT CODES - CUMMINS Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 111 629 12 Red Controller #1 Engine Control Module Critical internal failure - Bad intelligent Device or Component 115 61...

Page 200 - JLG Worldwide Locations; JLG Drive

JLG Worldwide Locations An Oshkosh Corporation Company www.jlg.com 3126019 JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: +61 265 811 111Fax: +61 265 810 122 JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPho...