Service Manual Manual

ManualsBrandsJLG ManualsSpecial machineryG12-55A

An Oshkosh Corporation Company

Service Manual

Models

G10-55A

G12-55A

S/N 0160045636 & After including

0160045082, 0160045094,

0160045209, 0160045295,

0160045296, 0160045449

31200795

Revised

October 13, 2014

Summary of content (176 pages)

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Service Manual Models G10-55A G12-55A S/N 0160045636 & After including 0160045082, 0160045094, 0160045209, 0160045295, 0160045296, 0160045449 31200795 Revised October 13, 2014 An Oshkosh Corporation Company
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EFFECTIVITY PAGE December 10, 2012 - A - Original Issue Of Manual January 31, 2014 - B - Revise pages ii, 1-4, 2-14, 3-20, 3-30, 3-31, 4-6, 6-2, 6-4, 6-7, 6-8, 7-2, 7-4, 7-6, 7-7, 7-13, 8-3, 8-8, 8-9, 8-21, 8-22, 9-12, 9-17. October 13, 2014 - C - Revise pages 1-4, 2-2 thru 2-12, 2-16, 3-20, 3-25, 7-2, 8-4, 8-7, Add 431 Fault Code 9-26.
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READ THIS FIRST Modifications Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations. Any modification must be approved by JLG. Machine Configuration Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.
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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 . . . . . . . .
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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 5.8 5-1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section Subject Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 G10-55A, G12-55A Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . .
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Section iv Subject Page G10-55A, G12-55A
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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. . . . . . . . . . . . . . . . .
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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.
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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.
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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.
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Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 2.7 G10-55A, G12-55A TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . .
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General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 2.2 THREAD LOCKING COMPOUND JLG P/N Loctite® ND Industries Description 0100011 242TM Vibra-TITETM121 Medium Strength (Blue) 1001095650 243TM Vibra-TITETM122 Medium Strength (Blue) 0100019 271TM Vibra-TITETM140 High Strength (Red) 0100071 262TM Vibra-TITETM131 Medium - High Strength (Red) Loctite® 243TM can be substituted in place of Loctite® 242TM.
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General Information and Specifications 2.3 TORQUE CHARTS 2.3.1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Stress Area Clamp Load Torque (Dry) Torque Lubricated Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 380 8 0.9 6 0.7 6 48 0.1120 0.00661 420 9 1.0 7 0.8 32 0.1380 0.00909 580 16 1.8 12 1.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Stress Clamp Load Area Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 32 0.1380 0.00909 40 0.1380 0.01015 6 8 LB Torque (Dry or Loctite® 263) K=0.20 IN-LB [N.m] Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 IN-LB [N.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque (Dry) K=0.17 Tensile Stress Clamp Load Area Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.16 IN-LB [N.m] Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 IN-LB [N.m] Size TPI Bolt Dia In Sq In LB IN-LB [N.m] 4 40 0.1120 0.00604 380 7 0.8 48 0.1120 0.00661 420 8 0.9 32 0.1380 0.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Stress Clamp Load Area Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 32 0.1380 0.00909 40 0.1380 0.01015 6 8 LB Torque (Dry or Loctite® 263) K=0.17 IN-LB [N.m] Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.16 IN-LB [N.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAP SCREWS Tensile Stress Clamp Load Area See Note 4 Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 32 0.1380 0.00909 40 0.1380 0.01015 6 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 LB Torque (Dry) K=0.17 IN-LB [N.m] Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) or Precoat® 85 K=0.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAP SCREWS Tensile Stress Clamp Load Area See Note 4 Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 32 0.1380 0.00909 40 0.1380 0.01015 6 8 Torque (Dry) K=0.17 LB IN-LB [N.m] Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) or Precoat® 85 K=0.16 IN-LB [N.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Stress Clamp Load Area See Note 4 Torque (Dry or Loctite® 263TM) Torque (Lub) Torque (Loctite® 262TM or 271TM or Vibra-TITETM 131) Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 141) Size Pitch Sq mm KN [N.m] [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size Pitch 3 0.5 Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.20 Torque (Lub or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Sq mm KN [N.m] [N.m] [N.m] 5.03 3.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Stress Area Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.17 Torque (Lub or Loctite® TM 242 or 271TM or Vibra-TITETM 111 or 140) K=0.16 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Size Pitch Sq mm KN [N.m] [N.m] [N.m] 3 0.5 5.03 2.19 1.1 1.1 1.0 3.5 0.6 6.78 2.95 1.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size Pitch 3 0.5 Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.17 Torque (Lub or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Sq mm KN [N.m] [N.m] [N.m] 5.03 3.
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General Information and Specifications 2.3.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Flats Method: 1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm). Size ORFS JIC Flats Method 4 13 lb-ft (18 Nm) 13 lb-ft (18 Nm) 1.5 to 1.75 2. Mark a dot on one of swivel nut flats and another dot in line on hex of adapter it’s connecting to.
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General Information and Specifications 2.4 SPECIFICATIONS 2.4.1 Travel Speeds FUNCTION G10-55A and G12-55A First Gear 3.4 mph (5,47 km/h) Second Gear 6.2 mph (9,97 km/h) Third Gear 14.0 mph (22,5km/h) Fourth Gear 20.0 mph (32,1 km/h) 2.4.2 Hydraulic Cylinder Performance Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature. FUNCTION APPROXIMATE TIMES (seconds) Boom Extend (Boom Level) 16.3–18.
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General Information and Specifications 2.4.4 Electrical System Engine Performance Battery Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free Quantity 2 Reserve Capacity Minutes @ 25 Amps 180 Cold Cranking Amps @ 0° F (-18° C) 700 Cranking Amps @ 32° F (-18° C) 840 Group/Series Group 31 Alternator 12V, 100 Amps 2.4.5 Engine Specifications Description G10-55A & G12-55A Engine Make/Model Cummins QSB 4.
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General Information and Specifications 2.5 FLUID AND LUBRICANT CAPACITIES 2.5.
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General Information and Specifications 2.5.
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General Information and Specifications 2.5.3 Capacities Engine Crankcase Oil Capacity with Filter Change 14 quarts (13,3 liters) Fuel Tank Capacity 38 gallons (144 liters) Cooling System System Capacity 20 quarts (18,9 liters) Hydraulic System System Capacity Reservoir Capacity to Middle of Sight Gauge Auxiliary Hydraulic Circuit Max Flow 60.5 gallons (229 liters) 33 gallons (125 liters) 10 gpm (37,9 lpm) Transmission Capacity with Filter Change 22 quarts (20,8 liters) Transfer Case Capacity 1.
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General Information and Specifications 2.6 2.6.
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General Information and Specifications 2.6.
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General Information and Specifications 2.6.
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General Information and Specifications 2.7 LUBRICATION SCHEDULES a.
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General Information and Specifications b.
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General Information and Specifications c.
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Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.11 G10-55A, G12-55A TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Boom 3.12 3.13 3.14 3-2 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . .
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Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section.
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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.
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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 3.8, “Quick Switch Assembly.” 3. Park the machine on a hard, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3. Install the boom pivot pin. 4.
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Boom 3.5 3.5.1 BOOM SECTION REMOVAL/INSTALLATION Second, Third and Fourth Boom Section Removal 9. Remove the tilt cylinder mounting pin (5). 10. Lower tilt cylinder from the boom head. 11. Support the front of the boom by placing a sling behind the boom head. 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 3.8, “Quick Switch Assembly.” 3.
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Boom 21 19 14 24 9 22 23 23 20 MY3540 MY3440 16. 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. 24. Remove the adjusting nut and lock nut (19), retract chain and clevis (20), spring stop (21) and spring (22). Loosen bolts (23) and adjusting block (24). 25. Properly disconnect the batteries. Note: It may be necessary to remove the extend chain rollers to help in the removal of the top wear pads. 17.
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Boom 3.5.2 31. Remove top rear wear pads, spacers, shims and hardware (30) from rear of second boom section. 32. Remove the left (or right) side rear wear pad, spacer, shims and hardware (31) from the rear of the second boom section. 33. Pull each boom section slightly forward to relieve the tension in retract chain (32). Third and Fourth Boom Section Removal 1 1 2 2 34. Remove snap rings and pin connecting rear retract chain (32) from chain clevis at rear of boom.
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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. Remove both wear pads, spacers, shims, blocks and hardware (5) from front top of second boom section.
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Boom 3.5.4 Hose Carrier Removal 3.5.5 Fourth Boom Section Assembly 1. Place fourth boom section onto suitable supports. 1 11 2 C 12 13 13 MY3470 MY3630 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.
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Boom 3.5.6 Hose Carrier Installation 6 14 6 13 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 MY3610 FRONT OF BOOM 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.
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Boom 3.5.7 Third Boom Section Assembly Note: Inspect and lubricate all extend and retract chains before re-assembly. Refer to Section 3.11.1, “Boom Chain Inspection,” for detailed information. Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section. 1. Place the third boom section onto suitable supports. 4 4 2 2 4.
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Boom 3.5.9 Second Boom Section Assembly 1. Place second boom section onto suitable supports. 14 14 15 15 9 13 11 11 MY3510 12 10 10 12 4. Install the previously removed wear pad support (9) at the front inside of the third boom section. Use the previously removed hardened washers and bolts (10). Torque as required. 5. Install the wear pads, spacers and shims on each side and bottom (8 and 11) at the front of the third boom section. Snug mounting bolts.
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Boom . 21 22 17 20 27 18 18 28 28 29 29 19 MY3540 MY3450 2. Install adjusting block (17) using existing hardware (18). Torque as required. 30 30 3. Install chain and clevis (19), spring (20), spring stop (21), adjusting nut and lock nut (22). A 8. Install the wear pad support plate (27) with existing hardware at inside front of second boom section.
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Boom 3.5.11 Second, Third and Fourth Boom Section Installation Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section. 1.
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Boom 3.6 10 11 BOOM SECTION SEPARATION ADJUSTMENT 1. Start the machine and verify the boom is in a horizontal (level) position. 2. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract the boom. 3. Shut machine OFF. MY3440 10. Connect fourth boom section extend chain (10) to clevis at top front of third boom section and adjust to previously measured setting. Do Not tighten lock nut at this time. 11.
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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: 1. Fully retract the boom. 3. Loosen second to third boom section retract chain lock nut and adjusting nut (3) as far as possible. 4.
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Boom 3.7 HOSE CARRIER ASSEMBLY REMOVAL/INSTALLATION 3 Hose carrier assembly locates primarily in fourth boom section. It is fastened at bottom front of fourth boom section and at rear of third boom section. 3.7.1 Hose Carrier Assembly Removal 1 1. Remove any attachment from the quick coupler assembly. Refer to Operation & Safety Manual. Note: Allow adequate room in front of the machine when removing and installing the hose carrier assembly. 2.
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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 hose carrier since it will not prevent two hydraulic carriers from moving apart sideways. 14. Continue withdrawing the hose carrier, fastening the two hydraulic carriers together. 15. With two hose assemblies tied together, remove hose carrier and set on ground or proper supports. 3.7.
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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 4 3. Verify any trapped hydraulic pressure in the auxiliary circuit and the tilt circuit is relieved. 4. Open the engine cover. Allow the system fluids to cool. 10 MY9310 5 13.
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Boom 13. Cycle the auxiliary circuit and/or the tilt circuit, verifying the auxiliary hoses and the tilt hoses are NOT touching the bottom of the second boom section and the proper slack, 4 in (101,6 mm) is maintained. 14. Retract the boom and shut engine OFF. 15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 3.8 3.8.1 7. Remove the head pin (13) and the quick switch assembly (10) 8. Inspect above pins for nicks or surface corrosion.
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Boom 3. Inspect above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired pin must be replaced. 3.8.4 Manual Quick Switch Installation 1. Assemble quick switch assembly (10) to boom head (14). Line up quick switch between mounts on boom head. The quick switch should be centered in the boom head. 2. Coat head pin (13) with an anti-seize compound. Insert head pin through the quick switch assembly and boom head.
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Boom 5 3.10 5 3.10.1 BOOM EXTEND/RETRACT CHAIN REMOVAL/INSTALLATION Boom Retract Chain Removal The following section explains the removal of the retract chains without removing the boom assemblies. Note: The retract chain on the bottom of the boom must be removed to gain access to the inner retract chain. To remove retract chain from third to first boom sections: 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 2.
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Boom To remove the retract chain from the fourth to second boom sections: 1. Remove the jam nut (4) from the chain clevis installed in the chain adjustment block. 2. Back off the adjusting nut fully on the chain clevis. Do not remove the nut from the clevis. 3. Remove the chain from the clevis, install a nylon tiewrap through the holes in the chain, making a loop with the tie-wrap and tie a rope to the loop. 4. Move to the back of the boom and pull the chain to the rear to allow slack for removal. 5.
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Boom 3.10.4 Boom Extend Chain Installation BOOM CHAIN INSPECTION AND LUBRICATION 3.11 The following section explains the installation of the retract chains without removing the boom assemblies. Inspect and lubricate the chains thoroughly before the installation. 1. Fasten the previously used rope to the end of the extend chain. 2. Carefully pull the chain into the boom to the chain clevis anchor. 3. Fasten the chain to clevis with a pin and cotter pin. 4.
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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. • 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. It is therefore necessary to conduct frequent inspections until replacement life can be predicted.
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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. The types of cracks are: MZ1466 Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing.
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Boom 3.11.3 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.
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Boom 3.12 FORKS 3.13 EMERGENCY BOOM LOWERING PROCEDURE 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. WARNING Daily Inspection To avoid instability of the machine, the extend/retract cylinder MUST BE fully retracted prior to retracting the lift cylinders.
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Boom Hoses: • Two Hydraulic Hoses - Approximately 10 ft (3,0 m) each, with a minimum I.D. of 0.375 in (9,5 mm) and a minimum rating of 4000 psi (275,8 bar). 1 3 G10-55A or G12-55A - Fittings: • Two -12 ORFS Caps • Two -12 ORFS Plugs Adaptors: • Two -12 ORFS 90° Adaptors Note: The adaptor size may vary depending on the hose ends of the auxiliary hydraulic power supply. 3.13.2 Lowering Procedure a. Retract the boom as follows: 1.
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Boom 3. Using the hoses and fittings specified, connect the hoses between the auxiliary hydraulic power supply and the tubes removed from the main control valve lift/lower section of the affected machine. Lift tube (3) is the return and lower tube (4) is the supply. Connect the hoses in the proper order to ensure that the boom is lowered, not raised. 4. Remove the previously installed boom support. 5. Use the auxiliary power supply to slowly lower the boom. 6.
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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.
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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 3.6, “Boom Section Separation Adjustment.” 3. Wear pads loose, contaminated, excessively worn or damaged. 3. Replace wear pad. Refer to Section 3.
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Boom Problem 8. Rapid boom pad wear. 9. Auxiliary hydraulics will not operate. 10. Excessive chain wear. 3-34 Cause Remedy 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.9, “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.
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Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 G10-55A, G12-55A TITLE Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Cab and Covers 4.1 OPERATORS 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.
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Cab and Covers 4.2 OPERATOR CAB 2 WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2.1 Cab Safety 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.
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Cab and Covers b. Orbitrol Valve Installation 1. Secure steering valve to steering column with four hex-flange capscrews and four lockwashers. 2. Install steering column through dash panel opening. Position steering valve to its original orientation in the cab. 3. Install the transmission control lever and connect the lever 4. Install steering wheel assembly. Torque steering wheel nut to 29–34 lb-ft (39–46 Nm). c. Service Brake Pedal Removal 1.
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Cab and Covers 4.3.3 4.3.4 Throttle Pedal a. Throttle Pedal Removal Boom and Tilt Joystick Assembly a. Joystick Assembly Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn engine OFF. 1.
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Cab and Covers b. Joystick Assembly Installation 1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 2. Connect the tilt function electronic connector. 3. Install the bolts securing the joystick to the cab. 3. Install the dash panel to its original position with the previously used hardware. 4. Properly connect the batteries. 5. Test the complete range of the joystick functions per control decal in cab or Operation & Safety manual. 6.
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Cab and Covers HEATER WITH AIR CONDITIONING SHOWN 14 15 MY4390 16 11 10 14 16 13 13. Loose hose clamps securing heater hoses (13). 14. Label and remove both heater hoses. 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. 15. Label and disconnect any electrical connections (14). 16. Label and disconnect both air conditioning hoses (15). 17.
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Cab and Covers Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing. 10. Wait for the engine to cool and check the coolant level. Add coolant as required to bring the coolant to the proper level. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 4.
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Cab and Covers 13 21. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed. 14 22. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift cab and remove it from frame. Readjust position of sling as needed to help balance cab during removal. 23. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall.
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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.
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Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4.1 5.5 5.6 5.7 5.8 G10-55A, G12-55A TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . ................................................................. Axle Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . Axle Removal .
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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.
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Axles, Drive Shafts, Wheels and Tires WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in the (N) NEUTRAL position, engage parking brake, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel. 3. Open engine cover.
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Axles, Drive Shafts, Wheels and Tires 15. Remove axles from machine using jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb machine while removing axle. Balance axle and prevent it from tipping, turning or falling while removing it from beneath machine. Place axle on a suitable support or holding stand. 5.4.2 10. Tighten axle oil drain plug, loosen and remove axle oil fill plug (1). (Refer to Section 2.
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Axles, Drive Shafts, Wheels and Tires 5.4.3 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. G10-55A, G12-55A Cause Remedy 1. Oil level too low. 1. Fill oil to correct level. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.” 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 2.
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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. 5-6 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. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.
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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. G10-55A, G12-55A Cause Remedy 1. Oil level too high. 1. Fill oil to correct level with hydraulic oil. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.” 2.
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Axles, Drive Shafts, Wheels and Tires 5.5 DRIVE SHAFTS 7 5.5.1 8 Drive Shaft Inspection and Service Inspect areas where drive shaft flange yokes and slip yokes mount to drive shafts. Attempt to turn each drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise.
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Axles, Drive Shafts, Wheels and Tires Note: The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. 5.6 2. Apply Loctite® 243TM to all mounting bolts. 3. Install two straps and four new bolts (1) securing front axle (3) bearing crosses to transmission. Torque bolts to 55-60 lb-ft (75-81 Nm). 4. Install two straps and four new bolts (2) securing front axle (3) bearing crosses to axle. Torque bolts to 55-60 lb-ft (75-81 Nm). 5.
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Axles, Drive Shafts, Wheels and Tires 4. Place a suitable jack under axle pad closest to wheel being removed. Raise machine and position a suitable support beneath axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly. 1 8 6 3 5. Lower the machine onto the support. 6. Remove lug nuts and lug washers in an alternating pattern. 9 10 7. Remove wheel and tire assembly from machine. 5.6.
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Axles, Drive Shafts, Wheels and Tires 5.8 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power, before using the emergency towing procedures outlined below. Note: Block the wheels of the machine BEFORE attempting to release the park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable. 5.8.
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Axles, Drive Shafts, Wheels and Tires This Page Intentionally Left Blank 5-12 G10-55A, G12-55A
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Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.6 6.7 G10-55A, G12-55A TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.
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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.
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Transmission 6.4 WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of transmission. Refer to local distributor and applicable Transmission Service Manual for assistance with comprehensive transmission diagnosis, repair and component replacement. 6.
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Transmission 14. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission. 15. Remove access cover from bottom of engine bell housing. This will allow access to remove four bolts holding the torque convertor diaphragm to the engine flywheel. 16. Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts to be accessed. Remove them one at a time. 3 17. Wipe up any spilled hydraulic and transmission oil. 18.
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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. 4 1. Install two guide studs near the top of the bell housing holes. 2. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis. 3.
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Transmission 6.4.4 5 After Transmission Service or Replacement In general: 1. Check transmission oil level and add oil as required. 2. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning. 3. Drain and flush entire transmission cooling system. 4. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements. 6 MY6990 16. Fill the transmission. Refer to Section 2.
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Transmission 6.5 TRANSMISSION COOLER THERMAL BY-PASS VALVE 6.5.1 Thermal By-Pass Valve Cartridge Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel. 3. Open engine cover. Allow system fluids to cool. 4. Properly disconnect the batteries. 5.
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Transmission 6.5.2 Thermal By-Pass Valve Cartridge Installation 1. Remove the plug and install the new cartridge (12) in the thermal by-pass valve (11). 2. Uncap and connect previously labeled transmission oil cooler hoses (10) to thermal by-pass valve. 3. Clean transmission oil filter mounting surface. 4. Apply a thin film of clean hydraulic oil to new transmission filter gasket. Install new filter and torque to 20-25 lb-ft (27-34 Nm). 5. Fill the transmission. Refer to Section 2.
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Transmission 6.7 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact local distributor if internal transmission repair is required during the warranty period. Problem 1. Transmission will not engage or will not shift properly. 2. Low or no pump flow or pressure.
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Transmission Problem 3. Low clutch pressure. 4. Lack of power. 5. Transmission overheating (oil above 248° F (120° C)). 6-10 Cause Remedy 1. Incorrect oil level. 1. Fill transmission to correct level with hydraulic oil. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.” 2. Main pressure valve stuck open. 2. Clean the valve spool and housing. 3. Broken or worn coupling shaft or piston o-rings. 3. Replace coupling and/or o-rings. 4.
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Transmission Problem 6. Grinding or “clunking” noise from transmission. Cause 1. Oil level too low. Remedy 1. Fill oil to correct level. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.” 2. Repair or replace parts as needed. G10-55A, G12-55A 2. Transmission filled with incorrect oil. 3. Drain transmission and fill to correct level with hydraulic oil. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.
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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 Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.” Replace orings 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.
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Section 7 Engine Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 G10-55A, G12-55A TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3 Specifications and Maintenance Information . . . . . . . . . . . . .
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Engine 7.1 7.1.1 INTRODUCTION 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.
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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.
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Engine 7.2 ENGINE COOLING SYSTEM TYPICAL THERMOSTAT 7.2.1 Surge Tank Cap A 17.4 psi (1,2 Bar) cap is used on the surge tank. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. 7.2.2 Thermostat Replacement Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator. • If engine seems to take a long time to warm up, thermostat may be stuck in open position and requires replacement.
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Engine 7.2.3 Radiator/Oil Cooler and Replacement Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator. • If the engine runs hot, check the temperature of the upper radiator hose. 7. Place a funnel at base of radiator to channel drained coolant into a container. Loosen drain cock (1) to allow coolant to drain.
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Engine 18. Label, disconnect and cap both transmission cooler hoses at radiator (10). Cap fittings and openings to prevent dirt and debris from entering transmission. IF EQUIPPED FOR LS 19. Remove fan guard (11). 7 20. Loosen and remove bolts from radiator fan shroud (12). Pull fan shroud back and over fan assembly. 21. Carefully lift and remove radiator assembly. 9 Note: If more clearance is needed to remove radiator, engine fan may be removed for easier access. 8 b.
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Engine 7.3 ENGINE ELECTRICAL SYSTEM The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9.5, “Electrical System Schematics.” 6 7.4 5 7.4.1 FUEL SYSTEM Diesel Fuel Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair.
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Engine 7.4.2 Fuel Tank 10. Remove bolts on the fuel tank hold down bar (6). Note: The fuel tank is a one piece unit. It is located on the rear of the cab. If it is determined that the fuel tank must be removed, the fuel must be drained before tank removal. Always dispose of fuel properly. a. Fuel Tank Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake, and shut engine OFF. 11.
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Engine e. Inspection Note: If a leak is suspected in the fuel tank, contact a JLG Service Department. 1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage. 2. With the fuel tank removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 1-1.5 psi (7-10 kPa) of air pressure through the elbow.
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Engine 7.5 ENGINE EXHAUST SYSTEM 7.5.1 7.5.2 Exhaust System Removal—ULS 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel. 3. Open engine cover. Allow system fluids and exhaust system to cool. 4. Properly disconnect the batteries.
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Engine 7.5.3 7.5.4 Exhaust System Removal—LS 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel. Exhaust System Installation—LS Note: Keep all clamps loosened until entire exhaust system is in place. 1. Install exhaust outlet pipe (26) to turbo charger (27) and secure with clamp (25).
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Engine 7.6 AIR CLEANER ASSEMBLY 7.6.2 Air Cleaner Assembly Installation —ULS Note: Apply Loctite® 242™to the capscrew threads before installation. WARNING NEVER run the engine with only the inner safety element installed. 1. Install the air cleaner assembly (3) to mounting bracket (6) with previously removed hardware (5). Note: Refer to the appropriate Operation & Safety Manual for your machine for the correct element change procedure. 2.
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Engine 7.6.3 Air Cleaner Assembly Removal—LS 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel. 3. Open engine cover. Allow system fluids to cool. 4. Properly disconnect battery. 7.6.
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Engine 7.7 7.7.1 ENGINE REPLACEMENT Engine Removal Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section 7.2, “Engine Cooling System.” Several additional components must be removed before engine removal. They will be addressed in the following procedures. 16. Remove access plug from bottom of engine bell housing. This will allow access to remove bolts holding the torque convertor diaphragm to the engine flywheel. 17.
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Engine 7.7.2 Engine Installation 1. Secure engine with a lifting strap or chain from the appropriate lifting points (1). Use a suitable hoist or overhead crane. Note: Apply Loctite® 242™to engine mount bracket capscrew threads before installation. 2. Install two guide studs in bell housing holes. 3. Lift engine and slowly push and lower into engine bay. Have an assistant ensure that engine clears frame, hose and harness components during engine installation.
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Engine 7.
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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 . . . . . . . . . . . . . . . . . .
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Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that operator/mechanic be familiar with name and location of hydraulic components of the machine. The following illustration identifies components that are referred to throughout this section.
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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 operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present.
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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 machine on a firm, level surface. Engage park brake, place transmission control lever in (N) NEUTRAL, level boom and turn engine OFF. 2. Locate proper test port.
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Hydraulic System 3. Tighten jam nut and recheck pressure at full throttle. If reading is within specification, shut machine off, install safety cap and remove gauge from test port. A 4. If proper pressure cannot be set, use accompanying hydraulic schematic and/or electrical schematic to help troubleshoot and correct problem. 8.4.
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Hydraulic System B MY7060 21. The relief on the (B) port of the main control valve is non-adjustable and must be replaced. Replace and repeat steps 17 and 18. 22. Verify pressure is correct. 23. Shut engine OFF. 24. Slowly remove the gauge, line and tee fitting from the compensation cylinder (1 and 2). Reinstall each hose and torque as required. 25. Install any previously removed attachment.
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Hydraulic System 8.4.3 Pressure Specifications Note: 1. All pressures must be checked in numerical order. Note: 2. Connect gauge to P1 port, adjust Standby Pressure down to 300 psi (step 2). Adjust Main Compensator Pressure to 3800 psi (step 3). Connect additional gauge to GLS (A) port, stall lift down, adjust Load Sense relief to the setting noted below.
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Hydraulic System 8.4.
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Hydraulic System Hydraulic Schematic (Continued) 8.4.
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Hydraulic System 8.5 HYDRAULIC RESERVOIR 8.5.2 Hydraulic Oil Reservoir Filling 1. Be sure reservoir is clean and free of all debris. 1 2. Install a new hydraulic oil filter. 3. Fill the reservoir with hydraulic oil. Refer to Section 2.5, “Fluid and Lubricant Capacities.” 2 4. Properly connect the batteries. 5. Close and secure the engine cover. 6. Remove Do Not Operate Tags from both ignition key switch and steering wheel. 8.5.
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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 JLG 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.
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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 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. 8.7 8.7.
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Hydraulic System 2. Remove the o-rings from between the two sections. 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 1 5. Remove any check valves, compensator valves, anti-cavitation valves or shock valves from individual valve section if equipped. 6. Keep all parts being removed from individual valve sections tagged and kept together. 1 c.
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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.
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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.
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Hydraulic System 8.7.5 Service Brake Test 8.7.6 Steering Orbitrol Valve This procedure is used in order to determine if service brake is functional. This procedure is not intended to measure maximum brake performance. Brake holding torque that is required to sustain an engine torque at a specific engine rpm varies depending on machine configuration. Variations are differences in engine settings, power train efficiency and in brake holding ability, etc.
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Hydraulic System 8.7.7 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 steer select valve from manifold by removing four socket head capscrews. Discard four o-rings. 8 3. Remove solenoid valves and cartridges from steer select housing. 4. Clean all components with a suitable cleaner before inspection. MY4290 Machine can be used in front-wheel, four-wheel or crab steering mode.
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Hydraulic System 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. 8. Close and secure the engine cover. a. General Cylinder Disassembly 1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder. 2.
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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.
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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.
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Hydraulic System 8.8.5 Cylinder Torque Specifications a. Lift/Lower Cylinder G10-55A, G12-55A Head Nut CB Valve CB Cap Screw 120 lb-ft (163 Nm) 2682 lb-ft (3636 Nm) 45-50 lb-ft (61-67 Nm) 35 lb-ft (47 Nm) Head Nut CB Valve (Large) CB Valve (Small) 100 lb-ft (135 Nm) 1376 lb-ft (1866 Nm) 110 lb-ft (149 Nm) 33 lb-ft (45 Nm) b. Extend/Retract CylinderTilt Cylinder G10-55A, G12-55A c.
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Hydraulic System This Page Intentionally Left Blank 8-22 G10-55A, G12-55A
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Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 G10-55A, G12-55A TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . .
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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. 9.1.1 General Overview a.
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Electrical System b.
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Electrical System 9.2 SPECIFICATIONS 9.4.2 Cab Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 4 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 9.4 FUSES AND RELAYS 9.4.1 Engine Compartment MY7420 The optional power distribution unit is located in the cab.
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Electrical System 9.4.3 Power Distribution Unit (VEC) F8 F3 F15 F4 F16 F14 F9 F7 F10 F11 F12 IGN1 F13 F1 IGN3 ACCY1 F2 F5 F6 ACCY2 MY4610 Connector Legend No.
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Electrical System 9.4.4 Optional Power Distribution Unit (VEC) R1 R2 R3 R4 F1 R5 F2 F3 R6 F4 F5 R7 F6 F7 R8 F8 MY1260 Connector Legend 9-6 No.
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Electrical System 9.5.
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Electrical System 2 AUX ELECTRICS 1 2 5 WIPER LIGHTS OPTION (15A) F8 10 F7 10 F5 20 F1 20 F6 30 AUX ELEC1 A B C D E F G H A B C D E F G H WIPER PWR HEATER PWR KEY ACC BCN PWR D FAN PWR DOME LT CAB LT PWR S/W LT PWR SW1 86 HEATER GND CAB LT GND DOME/BCN GND AUX ELEC PWR SW1 87A SW2 86 SW2 87A 30 87 86 85 87 30 OPTIONS WORKLIGHT/ BEACON OPTION STOP LT BCN PWR 8 4 6 2 1 3 WORK LT DOME LT CAB LT PWR S/W LT PWR STOP LT BCN PWR WORK LT 7 5 2 M 3 BEACON HEATER VALVE M H B 4 3
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Electrical System 9.5.
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Electrical System 2 1 3 WHT KEW SW SIG RED DIAG PWR BLK DIAG GND - ORG ENG STOP LT - VIO ENG WARN LT - VIO PK BRK SOL - BLK ENG GND - RED ALT EXC - BLOCK GROUND 14 4 9 8 7 15 6 YEL CAN H/904 - ORN ST RLY - GRN THR SGN/915 YEL THR RTN/914 - BRN THR SUP/911 - GRN CAN L/905 DBL TRANS TMP SW VIO SEN SUP 2 - 20 5 14 13 12 11 10 15 18 17 WHT WAIT TO START LT BRN TRANS SOL Y2 - BRN TRANS SOL Y1 - S21 X22 4 3 2 1 9 8 7 6 5 CAN SPLICE S18 BLK ENG GND - BRN TRANS SOL Y1
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Electrical System 9.5.
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Electrical System 9.6 9.6.1 ENGINE START CIRCUIT Starter 1 3. If starter only “clicks” it may indicate that battery is discharged, or that there is a loose or corroded battery cable connection. Check battery state of charge and battery condition first, then check cables and cable connections. 4. For additional information on the starting circuit, refer to Section 9.5, “Electrical System Schematics.” c. Starter Removal 1.
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Electrical System 9.6.2 Charging Circuit 4. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket (3). 5. While lifting the automatic belt tensioner away from the belt, remove the fan serpentine belt. 2 Note: Record how the alternator is installed to ensure correct installation later. 6. Label and disconnect the wire leads attached to the alternator assembly. 7. Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine. 8.
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Electrical System 9.7 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.
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Electrical System 9.7.1 Windshield/Rear Window Washer Reservoir c. Installation and Testing 1. Connect windshield washer hoses to reservoir. 2. Connect the cab wiring harness connectors to the reservoir connectors. 5 3. Install reservoir tank onto mounting bracket. 4. Install lock washers and nuts and secure. 5. Fill the washer fluid reservoir with washer fluid. 6. Properly connect the batteries. 7. Turn ignition key switch to RUN position and press washer switch.
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Electrical System 9.8 9.8.1 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.
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Electrical System 9.9.2 Transmission Solenoid Valves 7 9 (Y3) 9 (Y1) 9 (Y6) 9 (Y4) 9 (Y5) 10 9 (Y2) 8 MY7330 MY7320 6. Remove nut on end of park brake coil (7). 7. Remove park brake coil. 8. Remove park brake solenoid (8). (Remove only if electrical coil is found to not be faulty.) b. Disassembly DO NOT disassemble the solenoid. The solenoid is not serviceable. Replace solenoid if found to be defective. c. Park Brake Solenoid Valve Installation Note: ALWAYS replace seals, o-rings, gaskets, etc.
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Electrical System 9.9.3 Transmission Temperature Sender a. Transmission Temperature Sender Removal 9.9.4 Engine Coolant Temperature Sender a. Engine Coolant Temperature Sender Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF. 1.
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Electrical System c. Engine Coolant Temperature Sender Installation and Testing 1. Thread engine coolant temperature sender into engine block snugly, then connect sender connector to wiring harness connector. 2. Properly connect the batteries. 3. Check for proper coolant level. 4. Start engine, allow it to reach operating temperature and observe the operator’s instrument cluster for warning indication.
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Electrical System 9.10 9.10.1 DISPLAY MONITOR AND GAUGES b. Disassembly DO NOT disassemble the gauge. The gauge is not serviceable. Replace the gauge if found to be defective. Gauges c. Gauge Installation and Testing 11 1. Install gauge (13) in dash. Install gauge bracket. 2. Connect previously labeled wires to the gauge. P 1/2 13 E F 12 P 250 150 50 1 3 3. Install panel with previously used hardware (12). 4. Properly connect the batteries. 5.
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Electrical System 9.11 9.11.1 DASH SWITCHES b. Disassembly DO NOT disassemble the ignition switch. Replace a defective switch with a new part. Ignition Key Switch Note: For information on the front windshield wiper, rear window wiper and washer systems, refer to Section 9.7, “Window Wiper/Washer Windshield Wiper Motor.” c. Inspection and Replacement To determine proper operation of ignition key switch, test terminals on back of switch for continuity with ohmmeter. a.
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Electrical System 9.11.2 Dash Switches c. Inspection and Replacement a. Switch Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. 3. Open engine cover. Allow system fluids to cool. 4. Properly disconnect the batteries.
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Electrical System 9.
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 148 91 0 Red Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor Circuit— Abnormal Frequency, Pulse Width, or Period 151 110 0 Red Engine Coolant Temperature Coolant Temperature High—Data Valid but Above Normal Operational Range—Most Severe Level 153 105 3 Amber Temp—Intake Manifold #1 Intake Manifold Air Temperature Sensor Circuit— Voltage Above Normal, or Shorted to Hi
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 239 3511 3 Amber System code #2 Diagnostic 241 84 2 Amber Wheel-based Vehicle Speed Vehicle Speed Sensor Circuit—Data Erratic, Intermittent, or Incorrect 242 84 10 Amber Wheel-based Vehicle Speed Vehicle Speed Sensor Circuit tampering has been detected—Abnormal Rate of Change 244 623 4 Amber Red Stop Lamp Red Stop Lamp Driver Circuit—Voltage Below Normal, or Shorted to Low Source 245 647 4 Amber Fan
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 324 653 5 Amber Injector Cylinder #03 Injector Solenoid Cylinder #3 Circuit—Current Below Normal, or Open Circuit 331 652 5 Amber Injector Cylinder #02 Injector Solenoid Cylinder #2 Circuit—Current Below Normal, or Open Circuit 332 654 5 Amber Injector Cylinder #04 Injector Solenoid Cylinder #4 Circuit—Current Below Normal, or Open Circuit 343 629 12 Amber Controller #1 Engine Contr
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 441 168 18 Amber Electrical Potential (Voltage) Battery #1 Voltage Low—Data Valid but Below Normal Operational Range—Moderately Severe Level 442 168 16 Amber Electrical Potential (Voltage) Battery #1 Voltage High—Data Valid but Above Normal Operational Range—Moderately Severe Level 449 157 0 Red Injector Metering Rail 1 Fuel Pressure High—Data Valid but Above Normal Operational Range—Moderately Severe Level
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 555 101 16 Amber Not Available Crankcase Pressure—Data Valid But Above Normal Operating Range—Moderately Severe Level 556 101 0 Red Not Available Crankcase Pressure—Data Valid But Above Normal Operating Range—Moderately Severe Level 559 157 18 Amber Injector Metering Rail 1 Pressure Injector Metering Rail #1 Pressure Low—Data Valid but Below Normal Operational Range—Moderately Severe Leve
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 953 524286 31 Amber Not Available Reserved for temporary use—Condition Exists 1117 627 2 None Power Supply Power Lost With Ignition On—Data Erratic, Intermittent, or Incorrect 1239 2623 3 Amber Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor 2 Circuit —Voltage Above Normal, or Shorted to High Source 1241 2623 4 Amber Not Available Accelerator Pedal or Lever Position Sensor 2 Circui
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 1974 101 15 Amber/ Blinking Not Available Crankcase Pressure—Data Valid But Above Normal Operating Range—Least Severe Level 2185 3512 3 2186 611 4 2195 703 14 2249 157 1 Amber Injector Metering Rail 1 Pressure Injector Metering Rail 1 Pressure—Data Valid but Below Normal Operational Range—Most Severe Level 2272 27 4 Amber Not Available EGR Valve Position Circuit—Voltage Below Nor
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 2374 1209 4 Amber Exhaust Gas Pressure Exhaust Gas Pressure Sensor Circuit—Voltage Below Normal, or Shorted to Low Source Amber Exhaust Gas Recirculation (EGR) Temperature Exhaust Gas Recirculation (EGR) Temperature Sensor Circuit—Voltage Above Normal, or Shorted to High Source Exhaust Gas Recirculation (EGR) Temperature Sensor Circuit—Voltage Below Normal, or Shorted to Low Source 2375 412 3 Cummins Description
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Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 3141 3667 4 Amber Engine Air Shutoff Circuit—Voltage below normal, or shorted to low source 3186 1623 9 Amber Tachograph Output Shaft Speed—Abnormal update rate 3213 1623 2 Amber Tachograph Output Shaft Speed—Received Network Data In Error 3222 520435 12 Amber Glow Plug Module—Bad intelligent device or component 3326 91 9 Red Multiplexed Accelerator Pedal or Lever Sensor System—Abnormal update rate 3328 191 9 Amber
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31200795 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 2 65811111 Fax: +61 2 65813058 JLG Latino Americana Ltda.