Document Outline

• 3126019_H_JLG_G10-55A G12-55A_Service
  • Effectivity
  • Table of Contents
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operation & Safety Manual
    • 1.4 Do Not Operate Tags
    • 1.5 Safety Information
      • 1.5.1 Safety Alert System and Signal Words
    • 1.6 Safety Instructions
      • 1.6.1 Personal Hazards
      • 1.6.2 Equipment Hazards
      • 1.6.3 General Hazards
      • 1.6.4 Operational Hazards
    • 1.7 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Torque Charts
      • 2.2.1 SAE Fastener Torque Chart
      • 2.2.2 Metric Fastener Torque Chart
      • 2.2.3 Hydraulic Hose Torque Chart
    • 2.3 Specifications
      • 2.3.1 Travel Speeds
      • 2.3.2 Hydraulic Cylinder Performance
      • 2.3.3 Electrical System
      • 2.3.4 Engine Performance Specifications - John Deere
      • 2.3.5 Engine Performance Specifications - Perkins
      • 2.3.6 Engine Performance Specifications - Cummins
      • 2.3.7 Tires
    • 2.4 Fluid and Lubricant Capacities
    • 2.5 Service and Maintenance Schedules
      • 2.5.1 10, 1st 50 & 50 Hour
      • 2.5.2 1st 250, 250 & 500 Hour
      • 2.5.3 1000 & 1500 Hour
    • 2.6 Lubrication Schedules
  • Section 3 Boom
    • 3.1 Boom System Component Terminology
    • 3.2 Boom System - Four Section
      • 3.2.1 Boom System Operation
    • 3.3 Boom Assembly Maintenance
    • 3.4 Complete Boom Removal/ Installation
      • 3.4.1 Complete Boom Removal
      • 3.4.2 Complete Boom Installation
    • 3.5 Boom Section Removal/ Installation
      • 3.5.1 Second, Third & Fourth Boom Section Removal
      • 3.5.2 Third & Fourth Boom Section Removal
      • 3.5.3 Fourth Boom Section Removal
      • 3.5.4 Hose Carrier Removal
      • 3.5.5 Fourth Boom Section Assembly
      • 3.5.6 Hose Carrier Installation
      • 3.5.7 Third Boom Section Assembly
      • 3.5.8 Fourth Boom Section Installation
      • 3.5.9 Second Boom Section Assembly
      • 3.5.10 Third & Fourth Boom Section Installation
      • 3.5.11 Second, Third and Fourth Boom Section Installation
    • 3.6 Extend/Retract Chain Removal/Installation
      • 3.6.1 Retract Chain Removal
      • 3.6.2 Retract Chain Installation
      • 3.6.3 Extend Chain Removal
      • 3.6.4 Extend Chain Installation
    • 3.7 Boom Section Separation Adjustment
    • 3.8 Hose Carrier Assembly Removal/Installation
      • 3.8.1 Hose Carrier Assembly Removal
      • 3.8.2 Assembling the Hose Carrier Assembly
      • 3.8.3 Hose Carrier-Assembly Installation
      • 3.8.4 Boom Hose Adjustment
    • 3.9 Quick Switch Assembly
      • 3.9.1 Quick Switch Removal
      • 3.9.2 Quick Switch Installation
      • 3.9.3 Quick Switch Removal
      • 3.9.4 Quick Switch Installation
    • 3.10 Boom Head - Mounted Winch
      • 3.10.1 Boom Head-Mounted Winch Removal
      • 3.10.2 Boom Head-Mounted Winch Installation
    • 3.11 Boom Wear Pads
      • 3.11.1 Wear Pad Inspection
      • 3.11.2 Wear Pad Installation and Lubrication
    • 3.12 Boom Extend and Retract Chains
      • 3.12.1 Boom Chain Inspection
      • 3.12.2 Inspection Guidelines
      • 3.12.3 Expose Chains for Inspection
      • 3.12.4 Chain Lubrication
    • 3.13 Forks
    • 3.14 Troubleshooting
  • Section 4 Cab and Covers
    • 4.1 Operator’s Cab and Covers Component Terminology
    • 4.2 Operator’s Cab
      • 4.2.1 Cab Safety
      • 4.2.2 Serial Number Decal
    • 4.3 Cab Components
      • 4.3.1 Steering Column and Orbitrol Valve
      • 4.3.2 Service Brake Pedal
      • 4.3.3 Throttle Pedal
      • 4.3.4 Boom Joystick Assembly
      • 4.3.5 Frame Sway, Auxiliary and Outrigger Control Joysticks
      • 4.3.6 Windshield Wiper Assembly
      • 4.3.7 Heater/Air Conditioning System (if equipped)
    • 4.4 Cab Removal
    • 4.5 Cab Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology
    • 5.2 General Information
    • 5.3 Axle Assemblies
      • 5.3.1 Axle Serial Number Plate
      • 5.3.2 Axle Specifications
      • 5.3.3 Axle Internal Service
      • 5.3.4 Axle Maintenance
      • 5.3.5 Axle Removal
      • 5.3.6 Axle Installation
      • 5.3.7 Axle Assembly and Drive Shaft Troubleshooting
    • 5.4 Drive Shafts
      • 5.4.1 Drive Shaft Inspection and Service
      • 5.4.2 Drive Shaft Maintenance
      • 5.4.3 Drive Shaft Removal
      • 5.4.4 Drive Shaft Cleaning and Drying
      • 5.4.5 Drive Shaft Installation
    • 5.5 Wheels and Tires
      • 5.5.1 Removing Wheel and Tire Assembly from Machine
      • 5.5.2 Installing Wheel and Tire Assembly onto Machine
    • 5.6 Brakes
    • 5.7 Towing a Disabled machine
      • 5.7.1 Manually Releasing the Park Brake
      • 5.7.2 Manually Resetting the Park Brake
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Transmission Serial Number
    • 6.3 Transmission Specifications And Maintenance Information
    • 6.4 Transmission Replacement
      • 6.4.1 Transmission Removal
      • 6.4.2 Transmission Inspection and Internal Repair
      • 6.4.3 Transmission Installation
      • 6.4.4 After Transmission Service or Replacement
    • 6.5 Torque Convertor Diaphragm
      • 6.5.1 Torque Convertor Diaphragm Removal
      • 6.5.2 Torque Convertor Diaphragm Installation
    • 6.6 Troubleshooting
  • Section 7 Engine
    • 7.1 Introduction - John Deere
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Engine Serial Number
      • 7.1.3 Specifications and Maintenance Information
      • 7.1.4 Component Terminology
    • 7.2 Introduction - Perkins
      • 7.2.1 Disclaimer and Scope
      • 7.2.2 Engine Serial Number
      • 7.2.3 Specifications and Maintenance Information
      • 7.2.4 Component Terminology
    • 7.3 Introduction - Cummins
      • 7.3.1 Disclaimer and Scope
      • 7.3.2 Engine Serial Number
      • 7.3.3 Specifications and Maintenance Information
      • 7.3.4 Component Terminology
    • 7.4 Engine Cooling System
      • 7.4.1 Radiator Pressure Cap
      • 7.4.2 Thermostat Replacement
      • 7.4.3 Radiator/Oil Cooler and Replacement
    • 7.5 Engine Electrical System
    • 7.6 Fuel System
      • 7.6.1 Diesel Fuel
      • 7.6.2 Fuel Tank
      • 7.6.3 After Fuel System Service
    • 7.7 Engine Exhaust System
      • 7.7.1 Exhaust System Removal
      • 7.7.2 Exhaust System Installation
    • 7.8 Air Cleaner Assembly
      • 7.8.1 Air Cleaner Assembly Removal (John Deere & Perkins)
      • 7.8.2 Air Cleaner Assembly Installation (John Deere & Perkins)
      • 7.8.3 Air Cleaner Assembly Removal (Cummins)
      • 7.8.4 Air Cleaner Assembly Installation (Cummins)
    • 7.9 Engine Replacement
      • 7.9.1 Engine Removal
      • 7.9.2 Engine Installation
    • 7.10 Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Hydraulic Pressure Diagnosis
      • 8.3.1 Pressure Checks and Adjustments
    • 8.4 Hydraulic Circuits
      • 8.4.1 Hydraulic Pressures
      • 8.4.2 Tilt Circuit Port Relief Adjustment
      • 8.4.3 Hydraulic Schematic
    • 8.5 Hydraulic Reservoir
      • 8.5.1 Hydraulic Oil Reservoir Draining
      • 8.5.2 Hydraulic Oil Reservoir Filling
      • 8.5.3 Hydraulic Oil Reservoir Removal/ Installation
    • 8.6 Implement Pump
      • 8.6.1 Implement Pump Replacement
    • 8.7 Control Valves
      • 8.7.1 Main Control Valve
      • 8.7.2 Main Control Valve Assembly
      • 8.7.3 Service Brake Valve
      • 8.7.4 Service Brake Bleeding
      • 8.7.5 Service Brake Test
      • 8.7.6 Park Brake Test
      • 8.7.7 Steering Orbitrol Valve
      • 8.7.8 Steer Select Valve
    • 8.8 Hydraulic Cylinders
      • 8.8.1 General Cylinder Removal Instructions
      • 8.8.2 Cylinder Inspection
      • 8.8.3 Cylinder Pressure Checking
      • 8.8.4 Steering Cylinders
      • 8.8.5 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview - John Deere
      • 9.1.2 General Overview - Perkins
      • 9.1.3 General Overview - Cummins
    • 9.2 Specifications
    • 9.3 Safety Information
    • 9.4 Fuses and Relays
      • 9.4.1 Engine Compartment
      • 9.4.2 Cab
      • 9.4.3 Power Distribution Unit (VEC) - John Deere/Perkins
      • 9.4.4 Power Distribution Unit (VEC) - Cummins
      • 9.4.5 Optional Power Distribution Unit (VEC)
    • 9.5 Electrical System Schematics
      • 9.5.1 Cab Schematic - John Deere
      • 9.5.2 Cab Schematic - Perkins
      • 9.5.3 Cab Schematic - Cummins
      • 9.5.4 Options Schematic - John Deere/Perkins
      • 9.5.5 Options - Cummins
      • 9.5.6 Chassis Schematic - John Deere
      • 9.5.7 Chassis Schematic - Perkins Before S/N 0160037186
      • 9.5.8 Chassis Schematic - Perkins S/N 0160037186 Thru 0160039397 Excluding 0160039394 & 0160039397
      • 9.5.9 Chassis Schematic - Cummins S/N 0160039451 and After Including 0160039394 & 0160039397
      • 9.5.10 Power Unit Schematic - John Deere
      • 9.5.11 Power Unit Schematic - Perkins
      • 9.5.12 Power Unit Schematic - Cummins
    • 9.6 Circuit Breakdowns
      • 9.6.1 Constant Power Circuit from Battery - John Deere & Perkins
      • 9.6.2 Constant Power Circuit from Battery - Cummins
      • 9.6.3 Start & Charge Circuit - John Deere & Perkins
      • 9.6.4 Start & Charge Circuit - Cummins
    • 9.7 Engine Start Circuit
      • 9.7.1 Starter
      • 9.7.2 Charging Circuit
      • 9.7.3 Alternator
    • 9.8 Window Wiper/Washer Windshield Wiper Motor
      • 9.8.1 Windshield/Rear Window Washer Reservoir
    • 9.9 Cab Heater and Fan
      • 9.9.1 Cab Heater Controls
    • 9.10 Solenoids, Sensors and Senders
      • 9.10.1 Fuel Shut-off Solenoid - John Deere
      • 9.10.2 Park Brake Solenoid Valve
      • 9.10.3 Transmission Solenoid Valves
      • 9.10.4 Transmission Temperature Sender
      • 9.10.5 Engine Coolant Temperature Sender
      • 9.10.6 Air Manifold Temperature Sensor - John Deere
      • 9.10.7 Engine Oil Pressure Sender/Switch
      • 9.10.8 Fuel Level Sender
      • 9.10.9 Inclinometer Switch
      • 9.10.10 Front and Rear Axle Proximity Sensors
    • 9.11 Display Monitor and Gauges
      • 9.11.1 Analog Gauges
    • 9.12 Dash Switches
      • 9.12.1 Ignition Key Switch
      • 9.12.2 Dash Switches
    • 9.13 Troubleshooting - John Deere
      • 9.13.1 Engine Fault Codes Retrieval
      • 9.13.2 Engine Fault Codes Chart
    • 9.14 Engine Indicator Lamps - Perkins
    • 9.15 SAE Diagnostic Trouble Codes and Fault Codes - Cummins