Service Manual Models G10-55A G12-55A 3126019 Revised January 5, 2011 An Oshkosh Corporation Company
EFFECTIVITY PAGE 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 & 9.22. August 8, 2007 - F - Revised pages 2.7, 7.4, 7.5, 7.6, 7.14, 9.4, 9.9, 9.12, 9.15 & 9.17. May 1, 2008 - G - Revised Danger, Warning & Caution text and pages 1.4, 2.10, 3.14, 3.15, 3.16, 3.17 & 3.19.
EFFECTIVITY PAGE ii G10-55A, G12-55A 3126019
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . .
Section Subject Page Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5-1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 G10-55A, G12-55A Subject Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section iv Subject Page G10-55A, G12-55A
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 G10-55A, G12-55A TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS 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. Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
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 work instructions to provide safety information before the potential of a hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding. 1.6.
Safety Practices 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 machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 G10-55A, G12-55A TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . .
General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 1 MY1000 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 of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty.
General Information and Specifications 2.2 2.2.1 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque (Dry) Tensile Clamp Load Stress Area Torque Lubricated Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque (Dry or Loctite® 263) K= 0.20 Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K=.18 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Magni Coating* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Loctite® Torque Loctite® 262™ 242™ or 271™ OR OR Vibra-TITE™ 131 Vibra-TITE™ 111 or 140 [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 3.1 2.3 2.8 3.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque Lube OR Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K= 0.18 Torque Loctite® 262™ OR Vibra-TITE™ 131 [N.m] [N.m] [N.m] Torque Dry or Loctite® 263™ K = 0.20 Sq mm KN K=0.15 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Magni Coating* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Clamp Load See Note 4 Sq mm kN Torque Lube OR Loctite® Torque Torque Dry 242™ or 271™ Loctite® 262™ or OR OR Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131 111 or 140 K = .17 K = .16 K = .15 [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 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.
General Information and Specifications 2.2.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Size ORFS JIC Flats Method 4 13 lb-ft (18 Nm) 13 lb-ft (18 Nm) 1.5 to 1.75 6 23 lb-ft (31 Nm) 23 lb-ft (31 Nm) 1 to 1.5 8 40 lb-ft (54 Nm) 40 lb-ft (54 Nm) 1.5 to 1.75 10 60 lb-ft (81 Nm) 60 lb-ft (81 Nm) 1.5 to 1.75 12 74 lb-ft (100 Nm) 85 lb-ft (115 Nm) 1.0 to 1.5 16 115 lb-ft (156 Nm) 115 lb-ft (156 Nm) 0.75 to 1.0 20 170 lb-ft (230 Nm) 170 lb-ft (230 Nm) 0.
General Information and Specifications 2.3 SPECIFICATIONS 2.3.1 Travel Speeds FUNCTION G10-55A G12-55A First Gear 3.4 mph (5,4 km/h) 3.5 mph (5,6 km/h) Second Gear 6.1 mph (9,8 km/h) 6.3 mph (10,1 km/h) Third Gear 13.8 mph (22,2 km/h) 14.1 mph (22,7 km/h) Fourth Gear 20.0 mph (32,2 km/h) 20.4 mph (32,8 km/h) 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.
General Information and Specifications 2.3.3 Electrical System Battery Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free Quantity 1 Reserve Capacity 1,000 Cold Cranking Amps @ 0° F (-18° C) Group/Series Group 31 Alternator 12V, 95 Amps 2.3.
General Information and Specifications 2.3.
General Information and Specifications 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 Size Tire Type Minimum Ply/ Star Rating 14.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply 14.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply 14.00 x 24 G-2/L-2 Radial 1 Star 14.
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 Cummins 7 quarts (6,5 liters) 13.
General Information and Specifications 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 (-40° to 20° C) Exon Univis HVl All Season Hyd Fluid Auxiliary Hydraulic Circuit Max Flow 10 gpm (37,9 lpm) Transmission Capacity with Filter Change 4 gallons (16 liters) Type of Fluid 0° to 104° F (-20° to 40° C) Mobilfl
General Information and Specifications 2.5 2.5.
General Information and Specifications 2.5.
General Information and Specifications 2.5.
General Information and Specifications 2.6 LUBRICATION SCHEDULES a.
General Information and Specifications b.
General Information and Specifications c.
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 G10-55A, G12-55A TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom 3.10 3.11 3.12 3.13 3.14 3-2 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Boom Head-Mounted Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . .
Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section.
Boom 3.2 3.2.1 BOOM SYSTEM - FOUR SECTION 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 the extend/retract cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section.
Boom 3.4 3.4.1 COMPLETE BOOM REMOVAL/ INSTALLATION Complete Boom Removal 1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual. 2. Remove the quick switch assembly. Refer to Section 3.9.1, “Quick Switch Removal.” 3. If equipped, remove the Boom Head Mounted Winch. Refer to Section 3.10.1, “Boom HeadMounted Winch Removal.” 4.
Boom 3.5 3.5.1 BOOM SECTION REMOVAL/ INSTALLATION Second, Third & Fourth Boom Section Removal 1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual. 8. Using a suitable lifting device, secure the tilt cylinder barrel with a nylon strap. 9. Remove both retaining clips (4) from each side of the tilt cylinder mounting pin (5). 10. Remove the tilt cylinder mounting pin (5). 11. Lower tilt cylinder from the boom head. 12.
Boom 21 19 14 24 9 22 23 23 20 MY3540 MY3440 17. Pull the three extend chain clevises (9) off of each chain roller (14) and lay each assembly on the third and fourth boom sections respectively. Note: It may be necessary to remove the extend chain rollers to help in the removal of the top wear pads. 18. Verify all fittings, tubes and hoses are properly capped and /or plugged. 19. Extend the second boom section to access the retract chain adjusting block. 25.
Boom 32. Remove the top rear wear pads, spacers, shims and hardware (30) from the rear of the second boom section. 33. Remove the left (or right) side rear wear pad, spacer, shims and hardware (31) from the rear of the second boom section. 3.5.2 Third & Fourth Boom Section Removal 1 1 2 2 34. Pull each boom section slightly forward to relieve the tension in retract chain (32). 35. Remove the snap rings and pin connecting the rear retract chain (32) from the chain clevis at the rear of the boom.
Boom 6. Place a sling around the third boom section. With a suitable lifting device, slowly pull the third and fourth boom sections approximately 25% out of the second boom section. 5 5 4 4 4 4 6 7 6 MY3450 7. With the third and fourth boom section still connected to a suitable lifting device, remove all wear pads, spacers, shims, and hardware (4) from the front sides of the second boom section. 8.
Boom 3.5.4 Hose Carrier Removal 1 2 C 11 12 13 13 MY3630 MY3470 1. Remove the guide bracket (11) at the front of the hose carrier (12). Reuse the existing hardware. 2. Loosen and remove the front two mounting bolts (13) holding the hose carrier in place. Tag all hardware. 3. Remove the hose carrier through the front of the fourth boom section. 4.
Boom 3.5.6 Hose Carrier Installation 14 6 6 13 MY3610 FRONT OF BOOM MY3480 1. Inspect the hose carrier track (6) for any broken or missing clips. Repair or replace as needed. 2. Remove the caps from the tubes on the hose carrier. 10 11 8 9. Install the previously removed hose carrier guide bracket (13). Torque as required. 10. Install the hose carrier (14) into the front of the fourth boom section. Remove each nylon tie or nylon strap as the hose carrier is installed. 11.
Boom 4. Install the previously removed wear pads (3) at the bottom rear of the third boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 17 16 5. Install the previously removed wear pads and spacers (4) at top rear of the third boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
Boom 6. Install the previously removed wear pads, spacers and shims at the bottom front of the third boom section (11). Snug mounting bolts. 7 7 8 8 Note: Longer bolts (12) may be required to fully engage the threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to page 6, Wear Pad Installation and Lubrication for detailed information. 3.5.9 8 8 MY3510 1. Place the second boom section onto suitable supports. 14 14 15 15 3.
Boom 3.5.10 6. Retract the second boom section pulling both retract chains at the same time. 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 assembly bolts.
Boom 9. Install the wear pad support plate (27) with existing hardware at the inside front of the second boom section. 3 2 3 2 1 2 2 10. Install the previously removed wear pads, spacers and shims at the bottom front of the second boom section (28 & 29). Snug mounting bolts. Note: Longer bolts (30) may be required to fully engage the threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication.
Boom 11. Install both hose sheave covers (9).Torque mounting bolts as required. 10 11 5 4 MY3440 MY3590 6. Connect the rear retract chain (4) to the chain clevis with the previously removed pin at the rear of the third boom section. Secure the pin with the previously removed snap rings. 7. Pull hose carrier from the rear as far as possible to access the hydraulic and if equipped, the electrical connections. 8. If equipped, connect the electrical cable (5) to the fitting on the hose carrier. 12.
Boom 4. Attach a suitable sling to the extend/retract cylinder. Remove the extend/retract cylinder support. 5. Remove the rod end pin and lower the cylinder onto the frame rails. Lowering the extend/retract cylinder will allow access to the chains. 4 3.6.2 Retract Chain Installation Inspect and lubricate chains thoroughly before installation. Articulate the chains to make sure all working surfaces are thoroughly lubricated. Note: If the inner retract chain was removed, it must be installed first. 1.
Boom 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. Properly disconnect the battery. 4. Secure the boom sections together to prevent uncontrolled boom run out when the extend chains are removed. 5. On the chain being removed, loosen and remove the jam nut from the rear chain clevis and back off the adjusting nut on the chain clevis to the end of the threads. Do not completely remove the nut. 9.
Boom 3 2 4 Note: BOTTOM OF BOOM SHOWN WITH EXTEND/RETRACT CYLINDER REMOVED FOR CLARITY MY3810 MY3820 4. After adjusting, check to see that the boom sections and access holes (2) are aligned. If they are not, the retract chain will need to be adjusted as well. Adjust the retract chain as follows: 3. Loosen the second to third boom section retract chain lock nut and adjusting nut (3) as far as possible. 4.
Boom 3.8 HOSE CARRIER ASSEMBLY REMOVAL/INSTALLATION 3 The hose carrier assembly locates primarily in the fourth boom section. It is fastened at the bottom front of the fourth boom section and at the rear of the third boom section. 3.8.1 Hose Carrier Assembly Removal 1 1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual. Note: Allow adequate room in front of the machine when removing and installing the hose carrier assembly. 2.
Boom 13. When the hose carrier is pulled approximately 25% out of the boom, fasten the two hydraulic carriers together using plastic tie wraps or nylon straps to keep them from separating. Note: Do Not wrap the hose carrier since it will not prevent the two hydraulic carriers from moving apart sideways. 3.8.3 Hose Carrier-Assembly Installation 1. Clean and lubricate the side surfaces where the hose carrier rides. 2.
Boom 11. Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the front of the fourth boom section. 12. If equipped, reconnect any electrical connections at the front and rear of the boom assembly. 87 6 12 11 4 MY4470 5 9 MY2691 5 13. Install the hose take-up compression spring (4) on each hose take-up bracket (5) at the bottom of the first boom section. Install the washer (6), adjusting nut (7) and jam nut (8).
Boom 3.9 QUICK SWITCH ASSEMBLY 3.9.3 Quick Switch Removal S/N 0160037689 & After 3.9.1 Quick Switch Removal 14 Before S/N 0160037689 7 9 13 8 2 6 1 11 12 10 4 5 3 MY5080 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) and locknut (5) securing the head pin (6) to the boom head (7). 3. Inspect the above pins for nicks or surface corrosion.
Boom 3.10 BOOM HEAD - MOUNTED WINCH 3.10.1 3.11 Boom Head-Mounted Winch Removal 3 BOOM WEAR PADS The wear pads on this machine are flat rectangular wear pads with metal inserts. A total of 42 wear pads are installed on the boom sections of the G10-55A and the G12-55A machines. 3.11.1 6 Wear Pad Inspection 1 1 4 5 Ma2070 MY3710 1. Using a suitable lifting device, secure the winch assembly (4) with a nylon strap. 2. Disconnect the hydraulic hoses (5). 3.
Boom 5 BOOM EXTEND AND RETRACT CHAINS 3.12 5 3.12.1 Boom Chain Inspection WARNING MY5510 • Maintain a total boom section clearance (5) of 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and vertical directions. A B MY3620 • The length of the wear pad bolt depends on the number of shims, spacers and washers being used. • The thickness of each threaded wear pad insert is 0.312 in (7,92 mm)(A).
Boom Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. Edge Wear • High velocity movement of load, followed by sudden, abrupt stops. • Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. • Attempting to “inch” loads which are beyond the rated capacity of the vehicle. The above load cycles and environmental conditions make it impossible to predict chain life.
Boom Cracked Plates Distorted or Battered Link Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. 85 It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.
Boom 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 extend chains are taut. Shut the engine OFF. The extend chains will be visible for inspection with the machine in this state.
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 3 6 7 5 4 2 1 9 8 11 10 MH6460 1. Inspect forks (1) for cracks, paying special attention to heel (2) and mounting tubes (3). 2. Inspect forks for broken or bent tips (4) and twisted blades (5) and shanks (6). Yearly Inspection 1.
Boom 3.14 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem 1. Boom will not extend or retract Cause Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/retract hydraulic system not operating properly. 2. Refer to Section 8.4, “Hydraulic Circuits.” 3. Faulty extend/retract cylinder. 3.
Boom Problem 5. Drooping chain, or jerky boom extend or retract functions. 6. Boom will not raise or lower. 7. Excessive Lift/Lower cylinder pivot pin noise and/or wear. G10-55A, G12-55A Cause Remedy 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, contaminated, excessively worn or damaged. 3. Replace wear pad. Refer to Section 3.
Boom Problem 8. Rapid boom pad wear. 9. Auxiliary hydraulics will not operate. 10. Excessive chain wear. 3-32 Cause Remedy 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 contamination and/or corrosion from wear pad sliding surfaces and lubricate.
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 G10-55A, G12-55A TITLE Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab and Covers 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 machine cab and covers. The following illustration identifies the components that are referred to throughout this section.
Cab and Covers WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2 4.2.1 OPERATOR’S CAB Cab Safety 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.
Cab and Covers 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. Install the travel select lever, connect the instrument panel harness connector, install the steering wheel assembly. Torque the steering wheel nut to 29-34 lb-ft (39-46 Nm). 4. Install new o-rings into the steering valve fittings.
Cab and Covers 4.3.3 4.3.4 Throttle Pedal a. Throttle Pedal Removal Boom Joystick Assembly a. Boom Joystick Assembly 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. 1.
Cab and Covers 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 function. The boom should EXTEND. b. Joystick Installation 1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 2. Install the bolts securing the joystick to the cab. 3.
Cab and Covers HEATER WITH AIR CONDITIONING SHOWN 14 15 MY4390 11 10 MY0190 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. 16 14 16 13 13. Loose the hose clamps securing the heater hoses (13). 14. Label and remove both heater hoses. 15. Label and disconnect any electrical connections (14). 16. Label and disconnect both air conditioning hoses (15). 17.
Cab and Covers 4.4 CAB REMOVAL WARNING The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value. 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.
Cab and Covers 13 24. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed. 14 25. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame. Readjust the position of the sling as needed to help balance the cab during removal. 26. When the cab is completely clear of the machine, carefully lower it to the ground.
Cab and Covers 4. Use a hoist or overhead crane and sling attached to the cab. Carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation. 14. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block.
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.7 G10-55A, G12-55A TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 5.1 AXLE, DRIVE SHAFT AND WHEEL 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 axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
Axles, Drive Shafts, Wheels and Tires 5.2 GENERAL INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 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 components are bent or damaged. Refer to the appropriate parts manual for ordering information.
Axles, Drive Shafts, Wheels and Tires 5.3.5 Axle Removal The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly. 9. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports.
Axles, Drive Shafts, Wheels and Tires 3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure. 4.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 5-6 Cause Remedy 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 end housings filled with incorrect oil or oil level low. 2.
Axles, Drive Shafts, Wheels and Tires Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. G10-55A, G12-55A Cause Remedy 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Hose fittings loose. 2. Tighten fittings. 3.
Axles, Drive Shafts, Wheels and Tires Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 5-8 Cause Remedy 1. Oil level too high. 1. Fill oil to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2.
Axles, Drive Shafts, Wheels and Tires 5.4 DRIVE SHAFTS To Transmission 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 help prevent further problems and down time later. Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts. Attempt to turn each drive shaft in both directions.
Axles, Drive Shafts, Wheels and Tires 5.5 WHEELS AND TIRES 5 WARNING Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. 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.
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. Tread “arrows” must point forward 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5.6 BRAKES Check the brake disks for wear every 1,000 hours of operation or yearly.
Axles, Drive Shafts, Wheels and Tires 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. 5 5 5 5 MZ1020 1. Loosen each release screw (5), only 1/4 turn at a time, in sequence, until each screw has lost contact with the guide pin. 2. Remove the screws along with the nuts and seals.
Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 G10-55A, G12-55A TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.
Transmission 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. The following illustration identifies the components that are referred to throughout this section.
Transmission WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 6.2 TRANSMISSION SERIAL NUMBER 6.4.1 Transmission Removal WARNING NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling with a minimum lifting capacity of 1000 lb (454 kg). 1.
Transmission 9. Transfer the used transmission oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug. 26. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings. 10. Remove the transmission-to-axle drive shafts. Refer to Section 5.4.3, “Drive Shaft Removal.
Transmission 6.4.3 Transmission Installation WARNING NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling. 1. Install both rear transmission mounts on the transmission. Torque capscrews to 125-140 lb-ft (170-190 Nm). 2. Install two guide studs near the top of the bell housing holes. 3. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission.
Transmission 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 converter and the transmission oil lines. 8. Recheck the level of the fluid in the transmission with the engine running at idle. 9. Add hydraulic oil as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick.
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. Problem 1. Transmission will not engage or will not shift properly.
Transmission Problem 2. Low or no pump flow or pressure. 3. Low clutch pressure. 4. Lack of power. 6-8 Cause Remedy 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 correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 3. Pump suction pipe screen clogged. 3.
Transmission Problem 5. Transmission overheating (oil above 248° F (120° C)). 6. Grinding or “clunking” noise from transmission. Cause Remedy 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 filled with incorrect oil, or oil contaminated. 3. Drain transmission and fill to correct level with hydraulic oil. Refer to Section 2.
Transmission Problem 7. Oil leaking from transmission. Cause 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 (130 Nm). 2. Drain plug loose and/or o-rings damaged or missing. 2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm). 3. Hose fittings loose. 3. Tighten fittings. 4.
Section 7 Engine Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 G10-55A, G12-55A TITLE Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3 Specifications and Maintenance Information . . . . . . . . . . . .
Engine 7.1 7.1.1 INTRODUCTION - JOHN DEERE 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 way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine 7.1.4 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 engine components. The following illustration identifies the components that are referred to throughout this section.
Engine 7.2 7.2.1 INTRODUCTION - PERKINS 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 way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine 7.2.4 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 engine components. The following illustration identifies the components that are referred to throughout this section.
Engine 7.3 7.3.1 INTRODUCTION - CUMMINS 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 way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine 7.3.4 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 engine components. The following illustration identifies the components that are referred to throughout this section.
Engine 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, use a 16 psi (110 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. a. Thermostat Removal 1.
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 battery. 4. Open the radiator cap, and fill the radiator completely with coolant. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full.
Engine 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 the hoses, and replace if necessary. 7.5 ENGINE ELECTRICAL SYSTEM The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9.5, “Electrical System Schematics.” 7.
Engine a. Fuel Tank Removal b. Disassembly 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. The fuel tank is a one-piece unit and cannot be disassembled. The fuel level indicator can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal. 2.
Engine 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 tank and secure with screws. DO NOT overtighten. 4. Connect the previously labeled fuel hoses to their appropriate locations. Secure with clamps. 5. Connect the fuel gauge harness. 6. Fill the fuel tank according to specifications.
Engine 7.7.2 Exhaust System Installation 4. Properly disconnect the battery. Note: Keep all clamps loosened until entire exhaust system is in place. 13 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 engine pod. 3. Install the exhaust pipe (6) to the exhaust/flex pipe (8). 14 11 4. Install the muffler (4) to the exhaust pipe (6). 5. Install the tail pipe (10) to the muffler (4). 6.
Engine 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. 15 16 17 7.9 7.9.1 ENGINE REPLACEMENT Engine Removal Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section 7.4, “Engine Cooling System.” Several additional components must be removed before engine removal.
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 Assembly Removal (John Deere & Perkins),” or Section 7.8.3, “Air Cleaner Assembly Removal (Cummins).” 7.9.2 Engine Installation 1. Secure the engine with a lifting strap or chain from the appropriate lifting points (1).
Engine 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 correct and connected tightly. 20. From within the cab, lightly depress the throttle pedal to full-throttle position. As needed, adjust the limitstop screw until it touches the pedal bracket.
Engine 7.
Engine This Page Intentionally Left Blank 7-18 G10-55A, G12-55A
Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 G10-55A, G12-55A TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . .
Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
Hydraulic System 8.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 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 an ignition source is present.
Hydraulic System 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 adjustments: 1. Park the machine on a firm, level surface. Engage the park brake, place the travel select lever in (N) NEUTRAL, level the boom and turn the engine OFF. 2.
Hydraulic System 3. Tighten the jam nut and recheck the pressure at full throttle. If the reading is within specification, shut the machine off, install the safety cap and remove the gauge from the test port. 10. Monitor the gauge and slowly raise the boom. The gauge should read 4100 psi (282 bar). 11. If pressure is correct, proceed to step 14. A 4. If the proper pressure cannot be set, use the accompanying hydraulic schematic and/or the electrical schematic to help troubleshoot and correct the problem.
Hydraulic System B HUSCO B REXROTH MY4490 FRONT OF MACHINE 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-adjustable and must be replaced. Replace and repeat steps 17 and 18. 22. Verify pressure is correct. 23. Shut engine OFF. 24.
Hydraulic System a.
Hydraulic System b.
G10-55A, G12-55A GP MY1170H 3.66 CID S P L,L1 1100 PSI BV BV1 STEERING ORBITROL 500 PSI JS LS2 LS JS1 PR SL CYLINDER FRONT STEERING PB T ST SR GLS SLS PLS BLS T T STEER SELECT VALVE A2 P B2 B1 A1 70 PSI RETURN FILTER B 8 = 75 CYLINDER REAR STEERING 10 MICRON BREATHER HYDRAULIC OIL COOLER STABILIZER CYLINDER W/O LOCK .030 TANK BT .
T2 T SLS LS JS P PR TO PUMP T LS PLS P RTT T LUP 1 2 CIN PR 2600 PSI P 3650 PSI LDN 3 JOYSTICK b COUT LIFT 4 a 5000 PSI B A CROWD 3150 PSI (-0/+25) LOD P T b a 1 B 2 LOU A 1 ROD LEFT OUTRIGGER 2 b a B A B A P T SRT 1 SWAY 2 b a B SLT SWAY OUTRIGGER P T .050 SWAY CYLINDER .
G10-55A, G12-55A T2 T SLS LS JS P PR T INLET GAGE GAGE P SLS LS 3400psi 2600psi PR HPCO PRIORITY FLOW INLET TO PUMP (SEE SHEET 1) RTT PPA LUP T P 1 LIFT CIN 2 A LDN 3 JOYSTICK 5000 PSI LIFT CYLINDER B 4 3300psi COUT PPA 5000 PSI A CROWD 3300psi LIFT CYLINDER B 3300psi LOD P T 5000 PSI LEFT OUTRIGGER CYLINDER PPA 2 LOU 2 A LEFT O/R 4100psi 1 ROD B ROU LEFT AND RIGHT OUTRIGGER JOYSTICK 1 CROWD CYLINDER 4100psi RIGHT O/R PPA 5000 PSI A B P T
Hydraulic System 8.4.3 Hydraulic Schematic (Continued) SWAY CYLINDER .050 .
Hydraulic System 8.5 HYDRAULIC RESERVOIR 8.5.2 Hydraulic Oil Reservoir Filling 1. Be sure the reservoir is clean and free of all debris. JOHN DEERE/PERKINS 1 2. Install a new hydraulic oil filter. 3. Fill the reservoir with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 4. Properly connect the battery. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. MY1150 CUMMINS 8.5.
Hydraulic System 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 a dry chemical (Class B) fire extinguisher near the work area. 2. Remove the hydraulic oil reservoir drain plug, and safely drain any hydraulic oil into a suitable container. Dispose of hydraulic oil properly. 3.
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 position on the transmission. Align the pump shaft with the internal transmission gear, so that the machined teeth mesh together. 2. Align the bolt holes with the pump mount holes. 3. Apply Loctite® 242 to the previously removed bolts.
Hydraulic System 3. Carefully separate each remaining sections, being careful not to lose the load sense shuttle ball. 4. Remove both end caps from each end of the valve sections then remove each control spool. 1 5. Remove any check valves, compensator valves, anti-cavitation valves or shock valves from individual valve section if equipped. 1 6. Keep all parts being removed from individual valve sections tagged and kept together. c.
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 1. Install the main control valve onto the frame, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts. 2.
Hydraulic System 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). 6 2. Install the service brake pedal. Refer to Section 4.3.2, “Service Brake Pedal.” Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 3. Use new oiled o-rings as required.
Hydraulic System 8.7.5 Service Brake Test This procedure is used in order to determine if the service brake is functional. This procedure is not intended to measure the maximum brake performance. the brake holding torque that is required to sustain an engine torque at a specific engine rpm varies depending on the machine configuration. The variations are the differences in the engine settings, power train efficiency and in the brake holding ability, etc.
Hydraulic System 8.7.8 Steer Select Valve b. Steer Select Manifold and Valve Disassembly, Cleaning, Inspection and Assembly 1. Place the steer select assembly on a suitable work surface. 2. Separate the steer select valve from the manifold by removing the four socket head capscrews. Discard the four o-rings. 8 3. Remove the solenoid valves and cartridges from the steer select housing. 4. Clean all components with a suitable cleaner before inspection.
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, near and around the machine, work area and tools. a. General Cylinder Disassembly 1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder. 2.
Hydraulic System 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. Carefully slide the head gland down along the rod toward the rod eye, away from the cylinder barrel. Note: When sliding the rod and piston assembly out of the barrel, prevent the threaded end of the barrel from damaging the piston.
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 holding devise. Note: When sliding the rod and piston assembly into the cylinder barrel, prevent the threaded end of the cylinder barrel from damaging the piston head. Keep the cylinder rod centered within the barrel to prevent binding. 6.
Hydraulic System 8.8.5 Cylinder Torque Specifications a.
Hydraulic System c.
Hydraulic System e.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 G10-55A, G12-55A TITLE PAGE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.1.1 General Overview - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.1.2 General Overview - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.1.3 General Overview - Cummins . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9-2 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids, Sensors and Senders . . . . .
Electrical System 9.1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section. 9.1.
Electrical System 9.1.
Electrical System 9.1.
Electrical System 9.2 SPECIFICATIONS 9.4.2 Cab Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 3 SAFETY INFORMATION TILT SPEED CONTROL WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 9.4 9.4.1 FUSES AND RELAYS Engine Compartment MY0410 PERKINS JOHN DEERE 2 2 The optional power distribution unit is located in the cab.
Electrical System 9.4.3 Power Distribution Unit (VEC) - John Deere/Perkins F8 F3 CB3 F4 CB4 CB2 F9 F7 F10 F11 IGN1 CB1 F1 IGN3 ACCY1 F12 F5 F6 F2 ACCY2 MY1250 Connector Legend No.
Electrical System 9.4.4 Power Distribution Unit (VEC) - Cummins F8 F3 F15 F4 F16 F14 F9 F7 F10 F11 IGN1 F13 F1 IGN3 ACCY1 F12 F5 F6 F2 ACCY2 MY4610 Connector Legend No.
Electrical System 9.4.5 Optional Power Distribution Unit (VEC) F1 R1 F2 F3 R2 F4 F5 R3 F6 F7 R4 F8 R5 R6 R7 R8 MY1260 Connector Legend No.
G10-55A, G12-55A MY1060 KEY BAT PWR B S I A G ON DASH PANEL HARNESS HD34-24-31ST 3 2 OFF ON OFF SHTDN OVR 3 2 HORN (BLK, 18 GA GXL) CHECK ENG (RED, 18 GA GXL) TRANS TMP WRN (RED, 18 GA GXL) LEFT DASH PANEL TRAN/BRK PWR 4 5 6 2 3 ON OFF 1 7 PK BRK SOL 6 3 7 PARK BRAKE 5 CRAB ALL WHL 4 2 - 1 STEER MODE + DASH GND ST RLY PK BRK SOL SHIFT PWR 1 HR MTR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3 1 2 3 4 5 6 7 8 4 B+ (D BL
G10-55A, G12-55A 9-11 120 OHM CAN TERMINATOR MAL0160 A B C B S I A KEY/IGN ON OFF HORN DASH PANEL HARNESS HD34-24-31ST 3 2 ENG STOP (BLK, 18 GA GXL) (RED, 18 GA GXL) (RED, 18 GA GXL) ENG WARN TRAN/BRK PWR 4 5 6 2 3 ON OFF 1 7 7 PARK BRAKE 6 3 CRAB ALL WHL 5 2 - PK BRK SOL 4 1 STEER MODE + DASH GND ST RLY SHIFT PWR 1 PK BRK SOL HR MTR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3 1 2 3 4 5 6 7 8 9 10 11 12 4 G B+ WAIT TO S
CAN TERMINATOR 120 OHM (CAN H/904, YELLOW) (CAN L/905,GREEN) (SHIELD/020) A B C A B C A B C 6 7 8 3 4 5 2 1 1 3 2 B S I A KEY/IGN YEL (CAN H/904) GRN (CAN L/905) BRN/BLK (SHIELD/020) SHIELDED CABLE 3 2 ON OFF HORN ENG STOP (RED, 18 GA GXL) ENG WARN (RED, 18 GA GXL) 6 3 7 4 5 1 2 ON OFF PARK BRAKE PK BRK SOL 5 6 2 3 7 4 1 ALL WHL CRAB STEER MODE DASH GND STR CRB STEER/SWAY PWR STR AW TRAN/BRK PWR DASH PANEL HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
2 3 5 6 2 3 AUX ELECTRIC OPTION EXTRA 1 4 1 SIDESHIFT MAST 6 5 4 7 1 2 3 4 5 6 7 8 9 10 11 12 F1 F2 F3 F4 F5 F6 F7 F8 20A 15A 15A 25A 20A 20A 10A 10A WIPER PWR 15A OPTION 1 PWR 15A OPTION 2 PWR 25A OPTION PWR HEATER/BLOWER PWR LIGHT PWR BEACON PWR DASH FAN PWR OPTIONS FUSE LEGEND 87a 30 86 87 LIGHTS 85 OPTION (15A) BCN/FAN 87a 30 OPTION (25A) 87a 30 AUX ELEC1 F6 20 F8 10 AUX ELEC2 GRAY-2 H G F E D C B A BLACK-1 H G F E D C B A 87a 30 86 87 87 87 87a 30 87a 30 86
AUX ELECTRIC OPTION 6 3 1 2 3 4 5 6 7 8 9 10 11 12 F1 F2 F3 F4 F5 F6 F7 F8 WIPER PWR 15A OPTION 1 PWR 15A OPTION 2 PWR 25A OPTION PWR HEATER/BLOWER PWR LIGHT PWR BEACON PWR DASH FAN PWR OPTIONS FUSE LEGEND 20A 15A 15A 25A 20A 20A 10A 10A 86 87 LIGHTS 87a 30 85 OPTION (15A) 87a 30 87a 30 BCN/FAN 87 85 OPTION (25A) 87 F7 10 AUX ELEC1 F6 20 F8 10 AUX ELEC2 25A OPT 25A OPT GND TO CHASSIS ASSEMBLY A B OPTION 25 A A OPTION 2 B 15 A SEE SHEET 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
87 IGNITION-1 87 ACCY-2 85 1 2 1 2 IGNITION-2 C BAT GND BLACK-6 A BAT GND ALL WHEEL STEER MODE VALVE CRAB 87a 30 ACCY-1 A C 5 F1 15 F6 10 GRAY-2 H G F E D C B A A B C D (-) A B C D E F G H A B C D E F G H A B SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2 POWER DIST VEC STR CRB STR/SWAY GND STR AW STR/SWAY GND F5 15 F2 GRAY-5 BAT POS BLACK-1 H G F E
POWER DISTRIBUTION IGNITION-1 87a 30 ACCY-2 ALL WHEEL STEER MODE VALVE CRAB A BLACK-6 IGNITION-2 C 1 2 1 2 OPTIONS POWER 3 OPTIONS POWER 4 OPTIONS POWER 1 OPTIONS POWER 2 TRANS/PARK BRK PWR ALTERNATOR EXCITE ENGINE ECU IGN PWR GAGE (INST PANEL) PWR SPARE ACCESSORY PWR AUX ELECTRIC PWR HORN PWR SPARE BATTERY PWR ENGINE ECU BAT PWR STEER/SWAY PWR R.
86 86 CB4 87a 30 A BLACK-6 IGNITION-2 C 1 2 1 2 ACCY-1 GRAY-5 A A B 5 F1 15 F6 10 F5 15 F2 C GRAY-2 H G F E D C B A A B C D E F G H A B C D E F G H (-) A B C D GRN RED BLK A B SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2 POWER DIST VEC STR CRB STR/SWAY GND STR AW STR/SWAY GND WORK LT LT GND BLACK-1 H G F E D C B A 87a 30 IGNITION-1 87 ACCY-2 85
CB1 CB2 CB3 CB4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 87 87 CB4 A IGNITION-2 C 1 2 1 2 ACCY-1 GRAY-5 A 5 F1 15 F6 10 F5 15 F2 C GRAY-2 H G F E D C B A A B C D E F G H A B C D E F G H A B SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2 POWER DIST VEC STR CRB STR/SWAY GND STR AW STR/SWAY GND (-) A B C D GRN RED BLK REVERSE STOP LT WORK LT LT GND A B WORK
TO CHASSIS ASSEMBLY HD36-24-29SE POWER UNIT HARNESS 120 OHM CAN TERMINATOR 120 OHM CAN TERMINATOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 A B C A B C 6A/400V (CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020) (CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020) SHTDN/941 ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND CLT TMP PK BRK SOL OVR SGN/918 FAULT LT/473 ALT EXC OVR SUP/911 THR SGN/915 THR RTN/914 ST RLY HR MTR OIL PSI GAGE PWR TRANS TMP SW PLUGGED TRANS
TO CHASSIS ASSEMBLY HD36-24-29SE POWER UNIT HARNESS 120 OHM CAN TERMINATOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 A B C 6A/400V (CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020) ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND CLT TMP PK BRK SOL ENG WARN LT ENG STOP LT ALT EXC THR SUP/911 THR SGN/915 THR RTN/914 ST RLY HR MTR OIL PSI GAGE PWR TRANS TMP SW IVS TRANS SOL Y1 WAIT TO START TRANS SOL Y2 TRANS SOL Y3 PLUGGED PLUGGED TRANS SOL Y4 TRANS SOL Y5 CAN H/904 C
9-21 1 1 VEH GND BTTY - BLK 2/0AWG TO VEH GND NEG BATTERY CABLE 1 SPLICE 1 SPLICE 11 POSITIVE BATTERY CABLE BTTY - BLK 2/0AWG 1 1 BTTY - BLK 2/0AWG IVS VIO 18AWG THR SGN/915 GRN 18AWG ON-IDLE ORG 18AWG SPLICE 2 SPLICE 3 THR SUP/911 BRN 18AWG THR RTN/914 YEL 18AWG VEC PWR RED 8AWG VEC PWR RED 8AWG IVR BLU 18AWG VEC GND BLK 8AWG VEC GND BLK 8AWG 1 STRT PWR TO STRT PWR, F7 1 ENG GND 30A TBD FUSE HOLDER, ATO WAIT TO START WHT 18AWG VEC POS A B B STARTER RELAY, 12V, 75 AMP 1 2 FC206
Electrical System CIRCUIT BREAKDOWNS Constant Power Circuit from Battery - John Deere & Perkins BAT POS BAT POS TRAN/BRK PWR ST RLY HORN PWR STARTER ST RLY PWR (3/0 AWG, RED) (4 AWG, RED) (4 AWG, RED) ALT EXC A 6A/400V TO SHIFTER HARNESS ALTERNATOR G B+ A D+ 6A/400V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 SP BAT PWR REVERSE RELAY 3 TRAN/BRK PWR OPT PWR 1 KEY/IGN B M STRT SOL TRAN/BRK PWR ST RLY HORN PWR KEY ACC KEY BAT PWR OPT PWR 4
Electrical System 9.6.
Electrical System 9.6.
Electrical System REVERSE ALARM F2 5 GREEN-4 F5 15 F6 10 F1 15 BLUE-3 F12 20 F11 10 15 ST RLY TRAN/BRK PWR A B C D E F G H ENG WARN LT VIO 18AWG GRAY-2 H G F E D C B A 12 VDC BATTERY 1 6 BATT GROUND K3 RL196 2 1 ST RLY ORG 16AWG ST RLY PWR RED 10AWG RL196-30 1 RL196-87 STRT SOL ORG 10AWG 1 STRT PWR RED 2/0AWG 1 PWR STUD STRT SOL ORG 10AWG 1 30 87 M SOL STUD 1 GND STUD POWER UNIT TRANS TEMP SW REVERSE TRAN/BRK PWR 85 86 STARTER ENGINE 29 28 27 26 25 24 23 22 21 20 19 18 17 16
Electrical System 9.7 ENGINE START CIRCUIT 9.7.1 Starter 1 2. If a “whirring” noise is heard but the engine does not turn over, the starter is spinning but not engaging the flywheel. The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective. Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine. 3.
Electrical System 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 9.7.2 4. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket. 5. While lifting the automatic belt tensioner away from the belt, remove the fan serpentine belt. Charging Circuit 2 Note: Record how the alternator is installed to ensure correct installation later. 6. Label and disconnect the wire leads attached to the alternator. 7.
Electrical System 9.8 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. 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.
Electrical System 9.8.1 Windshield/Rear Window Washer Reservoir 2. Connect the cab wiring harness connectors to the reservoir connectors. 3. Install the reservoir tank onto the mounting bracket. 4. Install the lock washers and nuts and secure. 4 5. Fill the washer fluid reservoir with washer fluid. 6. Properly connect the battery. 7. Turn the ignition key switch to the RUN position and press the washer switch. Verify that fluid is sprayed on both the windshield and rear glass. 8.
Electrical System 9.9 9.9.1 CAB HEATER AND FAN c. Installation and Testing 1. Check that the variable speed fan control is in the OFF position. 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 2. Install the heater controls to the dash panel with the previously used hardware. 3. Connect the cab electrical harness connector to the controls. 4. Install the control knobs.
Electrical System 9.10.2 Park Brake Solenoid Valve a. Park Brake Solenoid Valve Removal 6 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, engage the park brake and shut the engine OFF. 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. MY1030 5.
Electrical System 2. Slide the park brake coil over the solenoid. Tighten the nut to secure the solenoid. DO NOT overtighten. 3. Connect the wiring connector to the park brake coil lead. 4. Properly connect the battery. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 9.10.3 Transmission Solenoid Valves 1.
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. CUMMINS ENGINE SHOWN 4. Start the engine, allow it to reach operating temperature and observe the operator’s instrument cluster for warning indication.
Electrical System 9.10.6 Air Manifold Temperature Sensor John Deere a. Air Manifold Temperature Sensor Removal 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, engage the park brake and shut the engine OFF. 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.
Electrical System PERKINS c. Engine Oil Pressure Sender Installation and Testing JOHN DEERE 1. Thread the engine oil pressure sender into the fitting or engine block snugly, then connect the sender connector to the wiring harness connector. 5 2. Properly connect the battery. 3. Check for proper oil level. 4 4 MY1810 CUMMINS 4. Start the engine, and observe the operator’s display for warning indication.
Electrical System b. Fuel Level Circuit Tests 9 If the fuel level sender (8) is suspected of giving a false reading, perform the following checks: 10 1. If the fuel level indicator needle does not move, check the fuel tank for fuel. 2. Check for loose or defective wiring, faulty ground connections, and corrosion on the fuel tank sender and wiring lead. 3.
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 mounted in the center of each steer cylinder. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. JOHN DEERE 12 11 a. Removal 1. Open engine cover. Allow system fluids to cool. 2.
Electrical System b. Disassembly b. Disassembly DO NOT disassemble the gauge. The gauge is not serviceable. Replace the gauge if found to be defective. DO NOT disassemble the ignition switch. Replace a defective switch with a new part. c. Gauge Installation and Testing c. Inspection and Replacement 3. Install the dash panel with the previously used hardware (11). T BA 2. Connect the previously labeled wires to the gauge.
Electrical System 9.12.2 Dash Switches a. Switch Removal 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, engage the park brake and shut the engine OFF. 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.
Electrical System 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. Note: When the engine sensor inputs exceed normal operating ranges, the ECU will derate the amount of fuel that is delivered to the engine. A fault code will always accompany a fuel derate.
Electrical System Fault Codes 42 SPN Codes 190 FMI Codes Definition 10 Crank Position Input Pattern Error 0 Engine Overspeed Extreme 16 Engine Overspeed Moderate 54 158 17 ECU Power Down Error 55 639 13 CAN Error 62 110 15 Engine Coolant Temperature High Least Service 63 110 16 Engine Coolant Temperature High Moderately Service 64 100 18 Engine Oil Pressure Moderately Low 65 100 1 Engine Oil Pressure Extremely Low 66 105 16 Manifold Air Temperature Moderately High 68
Electrical System 9.
Electrical System 9.
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 146 110 16 147 91 148 SPN Description Cummins Description Amber Engine Coolant Temperature Coolant Temperature High - Data Valid but Above Normal Operational Range - Moderately Severe Level 1 Red Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period 91 0 Red Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency,
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 212 175 3 Amber Oil Temperature Engine Oil Temperature Sensor 1 Circuit Voltage Above Normal, or Shorted to High Source 213 175 4 Amber Oil Temperature Engine Oil Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low Source 214 175 0 Red Oil Temperature Engine Oil Temperature - Data Valid but Above Normal Operational Range - Most Severe Level 221 108 3 Amber Barometric Pressure Barometric
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 245 647 4 249 171 256 SPN Description Cummins Description Amber Fan Clutch Output Device Driver Fan Control Circuit - Voltage Below Normal, or Shorted to Low Source 3 Amber Ambient Air Temperature Ambient Air Temperature Sensor Circuit Voltage Above Normal, or Shorted to High Source 171 4 Amber Ambient Air Temperature Ambient Air Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low Source 261 174 16 Amber
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 292 441 14 293 441 294 SPN Description Cummins Description Red Auxiliary Temperature 1 Auxiliary Temperature Sensor Input 1 - Special Instructions 3 Amber OEM Temperature Auxiliary Temperature Sensor Input #1 Circuit Voltage Above Normal, or Shorted to High Source 441 4 Amber OEM Temperature Auxiliary Temperature Sensor Input #1 Circuit Voltage Below Normal, or Shorted to Low Source 295 108 2 Amber Barometric Pressure
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 341 630 2 Amber Calibration Memory Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect 342 630 13 Red Calibration Memory Electronic Calibration Code Incompatibility - Out of Calibration 343 629 12 Amber Controller #1 349 191 16 Amber Transmission Output Shaft Speed Transmission Output Shaft Speed - Data Valid but Above Normal Operational Range Moderately Severe
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 442 168 16 449 157 451 SPN Description Cummins Description Amber Electrical Potential (Voltage) Battery #1 Voltage High - Data Valid but Above Normal Operational Range - Moderately Severe Level 0 Red Injector Metering Rail 1 Pressure Fuel Pressure High - Data Valid but Above Normal Operational Range - Moderately Severe Level 157 3 Amber Injector Metering Rail 1 Pressure Injector Metering Rail #1 Pressure Sensor Circuit - Vo
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 554 157 2 Amber Injector Metering Rail 1 Pressure Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect 559 157 18 Amber Injector Metering Rail 1 Pressure Injector Metering Rail #1 Pressure Low - Data Valid but Below Normal Operational Range Moderately Severe Level 584 677 3 Amber Starter Solenoid Lockout Relay Driver Circuit Starter Relay Circuit - Voltage Above Normal, or Shorted to High Source 585 677 4
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 698 1136 4 Amber Sensor Circuit Voltage 719 22 3 Amber Crankcase Pressure AEB15.
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 1241 2623 4 Amber Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Below Normal, or Shorted to Low Source 1242 91 2 Red Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor 1 and 2 - Data Erratic, Intermittent, or Incorrect 1256 1563 2 Amber Control Module Identification Input State Control Module Identification Input State Error Data Erratic, Intermittent, or Incorrec
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 2186 3512 4 Amber System Diagnostic code #1 Sensor Supply Voltage #4 Circuit - Voltage Below Normal, or Shorted to Low Source 2195 703 14 Red Auxiliary Equipment Sensor Auxiliary Equipment Sensor Input 3 Engine Protection Critical - Special Instructions 2215 94 18 Amber Fuel Delivery Pressure Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level 2216 94 1 Amber Fuel Deliver
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 2321 190 2 None Engine Speed Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect 2322 723 2 None Engine Speed Sensor #2 Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect 2345 103 10 Amber Turbocharger 1 Speed Turbocharger speed invalid rate of change detected - Abnormal Rate of Change 2346 2789 15 None System Diagnostic Code #1 Turbocharger Turbine Inl
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 2555 729 3 Amber Inlet Air Heater Driver #1 Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source 2556 729 4 Amber Inlet Air Heater Driver #1 Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source 2557 697 3 Amber Auxiliary PWM Driver #1 Auxiliary PWM Driver #1 - Voltage Above Normal, or Shorted to High Source 2558 697 4 Amber Auxiliary PWM Driver #1 Auxiliary PWM Driver #
Electrical System This Page Intentionally Left Blank 9-56 G10-55A, G12-55A
3126019 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Eng.
