Document Outline

• 31200452_A_G10-55A G12-55A AccuPlace_JLG_Service
  • Effectivity
  • Section 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 Torques
      • 2.2.1 ASTM Fastener Torque Chart (English)
      • 2.2.2 ASTM Fastener Torque Chart (Metric)
      • 2.2.3 Metric Fastener Torque Chart
    • 2.3 Specifications
      • 2.3.1 Travel Speeds
      • 2.3.2 Electrical System
      • 2.3.3 Engine Performance Specifications
      • 2.3.4 Tires
    • 2.4 Fluid and Lubricant Capacities
    • 2.5 Service and Maintenance Schedules
      • 2.5.1 10, 1st 100 & 50 Hour
      • 2.5.2 250, 500, 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
      • 3.3.1 Boom Removal
      • 3.3.2 Second, Third & Fourth Boom Section Removal
      • 3.3.3 Third & Fourth Boom Section Removal
      • 3.3.4 Fourth Boom Section Removal
      • 3.3.5 Fourth Boom Section Installation
      • 3.3.6 Third & Fourth Boom Section Installation
      • 3.3.7 Second Boom Section Installation
      • 3.3.8 Boom Installation
    • 3.4 Boom Extend and Retract Chains
      • 3.4.1 Boom Chain Inspection
      • 3.4.2 Inspection Guidelines
      • 3.4.3 Expose Chains for Inspection
      • 3.4.4 Chain Lubrication
      • 3.4.5 Retract Chain Removal
      • 3.4.6 Retract Chain Installation
      • 3.4.7 Extend Chain Removal
      • 3.4.8 Extend Chain Installation
    • 3.5 Boom Section Separation Adjustment
    • 3.6 Hydraulic Sub-Assembly Removal/Installation
      • 3.6.1 Hydraulic Sub-Assembly Removal
      • 3.6.2 Assembling the Hydraulic Sub- Assembly
      • 3.6.3 Hydraulic Sub-Assembly Installation
    • 3.7 Boom Wear Pads
      • 3.7.1 Wear Pad Inspection
      • 3.7.2 Boom Wear Pad Replacement
      • 3.7.3 Boom Wear Pad Lubrication
    • 3.8 Quick Switch Assembly
      • 3.8.1 Quick Switch Removal
      • 3.8.2 Quick Switch Installation
    • 3.9 Forks
    • 3.10 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 Level, Auxiliary Hydraulic and Outrigger Joysticks
      • 4.3.6 Windshield Wiper Assembly
      • 4.3.7 Heater/Defroster 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 Description
    • 6.3 Transmission Serial Number
    • 6.4 Transmission Specifications
      • 6.4.1 Transmission Maintenance
      • 6.4.2 Transmission Maintenance Schedule
    • 6.5 Transmission Replacement
      • 6.5.1 Transmission Removal
      • 6.5.2 Transmission Inspection and Internal Repair
      • 6.5.3 Transmission Installation
      • 6.5.4 After Transmission Service or Replacement
    • 6.6 Troubleshooting
      • 6.6.1 Transmission Troubleshooting
  • Section 7 Engine
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
      • 7.1.3 Engine Serial Number
      • 7.1.4 Specifications and Maintenance Information
    • 7.2 Engine Cooling System
      • 7.2.1 Radiator Pressure Cap
      • 7.2.2 Thermostat Replacement
      • 7.2.3 Radiator Replacement
    • 7.3 Engine Electrical System
    • 7.4 Fuel System
      • 7.4.1 Diesel Fuel
      • 7.4.2 Fuel Tank
      • 7.4.3 After Fuel System Service
    • 7.5 Engine Exhaust System
      • 7.5.1 Exhaust System Removal
      • 7.5.2 Exhaust System Installation
    • 7.6 Air Cleaner Assembly
      • 7.6.1 Air Cleaner Assembly Removal
      • 7.6.2 Air Cleaner Assembly Installation
    • 7.7 Engine Replacement
      • 7.7.1 Engine Removal
      • 7.7.2 Engine Installation
    • 7.8 Torque Convertor Diaphragm
      • 7.8.1 Torque Convertor Diaphragm Removal
      • 7.8.2 Torque Convertor Diaphragm Installation
    • 7.9 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
    • 8.5 Hydraulic System Schematics and Diagrams
      • 8.5.1 Chassis Schematic
      • 8.5.2 Boom Schematic
      • 8.5.3 Hydraulic Diagram
    • 8.6 Hydraulic Reservoir
      • 8.6.1 Hydraulic Oil Reservoir Draining
      • 8.6.2 Hydraulic Oil Reservoir Filling
      • 8.6.3 Hydraulic Oil Reservoir Removal/ Installation
    • 8.7 Engine Implement Pump
      • 8.7.1 Pump Description
      • 8.7.2 Pump Failure Analysis
      • 8.7.3 Pump Replacement
    • 8.8 Control Valves
      • 8.8.1 Lift Valve
      • 8.8.2 ISP Valve
      • 8.8.3 Stabilizer Valve
      • 8.8.4 Auxiliary Valve
      • 8.8.5 Telescope Valve
      • 8.8.6 Tilt Valve
      • 8.8.7 Service Brake Valve
      • 8.8.8 Brake Test
      • 8.8.9 Steering Orbitrol Valve
      • 8.8.10 Steer Select Valve
      • 8.8.11 Valve Controllers
    • 8.9 Hydraulic Piston Accumulator
      • 8.9.1 Accumulator Removal
      • 8.9.2 Accumulator Pre-Charge & Check Procedure
    • 8.10 Hydraulic Cylinders
      • 8.10.1 General Cylinder Removal Instructions
      • 8.10.2 Cylinder Pressure Checking
      • 8.10.3 Steering Cylinders
      • 8.10.4 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview
    • 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)
      • 9.4.4 Optional Power Distribution Unit (VEC)
    • 9.5 Control Modules
      • 9.5.1 CAN Distribution Module
      • 9.5.2 Universal Ground Control Module (UGM)
      • 9.5.3 Frame Level, Auxiliary Hydraulic and Outrigger Joysticks Module
    • 9.6 Electrical System Schematics And Diagrams
      • 9.6.1 Cab Schematic
      • 9.6.2 Options Schematic
      • 9.6.3 CAN Distribution Schematic
      • 9.6.4 Chassis Schematic
      • 9.6.5 Power Unit Schematic
      • 9.6.6 Boom Schematic
      • 9.6.7 CAN Diagram
    • 9.7 Engine Start Circuit
      • 9.7.1 Starter
    • 9.8 Charging Circuit
      • 9.8.1 Alternator
    • 9.9 Window Wiper/Washer Windshield Wiper Motor
      • 9.9.1 Windshield/Rear Window Washer Reservoir
    • 9.10 Cab Heater and Fan
      • 9.10.1 Cab Heater Controls
    • 9.11 Solenoids, Senders and Sensors
      • 9.11.1 Intelligent Control Valves (INCOVA) Solenoids
      • 9.11.2 Park Brake Solenoid Valve
      • 9.11.3 Sway Solenoid Valve
      • 9.11.4 Pump Solenoid Valve
      • 9.11.5 Boom Ride Control Solenoid Valve
      • 9.11.6 Lift Isolation Solenoid Valves
      • 9.11.7 Steer Solenoid Valves
      • 9.11.8 Transmission Solenoid Valves
      • 9.11.9 Transmission Temperature Sender
      • 9.11.10 Engine Coolant Temperature Sender / Switch
      • 9.11.11 Fuel Level Sender
      • 9.11.12 Boom Angle Sensors
      • 9.11.13 Boom Length Sensor
    • 9.12 Display Monitor and Gauges
      • 9.12.1 3-N-1 Digital Gauge
    • 9.13 Dash Switches
      • 9.13.1 Ignition Key Switch
      • 9.13.2 Dash Switches
    • 9.14 Engine Indicator Lamps
    • 9.15 Hand Held Analyzer
      • 9.15.1 Analyzer Description
      • 9.15.2 Debug Functionality
      • 9.15.3 Personality Settings
      • 9.15.4 Machine Setup
      • 9.15.5 Calibrations
      • 9.15.6 Emergency Boom Lowering Procedure
      • 9.15.7 Diagnostics
      • 9.15.8 Diagnostic Trouble Code (DTC) Table