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JLG G10-55A G12-55A Service Manual and Parts List Manual
0160045082, 0160045094,
0160045209, 0160045295,
0160045296, 0160045449
Content for Service Manual:
Section 1. SAFETY PRACTICES
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Safety Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.6 Safety Instructions
1.7 Safety Decals
Section 2. GENERAL INFORMATION AND SPECIFICATIONS
2.1 Replacement Parts and Warranty Information
2.2 Thread Locking Compound
2.3 Torque Charts
2.4 Specifications
2.5 Fluid and Lubricant Capacities
2.6 Service and Maintenance Schedules
2.7 Lubrication Schedules
Section 3. BOOM
3.1 Boom System Component Terminology
3.2 Boom System - Four Section
3.3 Boom Assembly Maintenance
3.4 Complete Boom Removal/Installation
3.5 Boom Section Removal/Installation
3.6 Boom Section Separation Adjustment
3.7 Hose Carrier Assembly Removal/Installation
3.8 Boom Hose Take-up Adjustment
3.9 Boom Hose Adjustment
3.10 Quick Switch Assembly
3.11 Boom Wear Pads
3.12 Boom Extend/Retract Chain Removal/Installation
3.13 Boom Chain Inspection and Lubrication
3.14 Forks
3.15 Emergency Boom Lowering Procedure
3.16 Troubleshooting
Section 4. CAB AND COVERS
4.1 Operators Cab and Covers Component Terminology
4.2 Operator Cab
4.3 Cab Components
4.4 Cab Removal
4.5 Cab Installation
Section 5. AXLES, DRIVE SHAFTS, WHEELS AND TIRES
5.1 Axle, Drive Shaft and Wheel Component Terminology
5.2 Axle Serial Number
5.3 Axle Specifications And Maintenance Information
5.4 Axle Replacement
5.5 Drive Shafts
5.6 Wheels and Tires
5.7 Brakes
5.8 Towing a Disabled Machine
Section 6. TRANSMISSION
6.1 Transmission Assembly Component Terminology
6.2 Transmission Serial Number
6.3 Transmission Specifications And Maintenance Information
6.4 Transmission Replacement
6.5 Transmission Cooler Thermal By-Pass Valve
6.6 Torque Convertor Diaphragm
6.7 Troubleshooting
Section 7. ENGINE
7.1 Introduction
7.2 Engine Cooling System
7.3 Engine Electrical System
7.4 Fuel System
7.5 Engine Exhaust System
7.6 Air Cleaner Assembly
7.7 Engine Replacement
7.8 Troubleshooting
Section 8. HYDRAULIC SYSTEM
8.1 Hydraulic Component Terminology
8.2 Safety Information
8.3 Hydraulic Pressure Diagnosis
8.4 Hydraulic Circuits
8.5 Hydraulic Reservoir
8.6 Implement Pump
8.7 Control Valves
8.8 Hydraulic Cylinders
Section 9. ELECTRICAL SYSTEM
9.1 Electrical Component Terminology
9.2 Specifications
9.3 Safety Information
9.4 Fuses and Relays
9.5 Electrical System Schematics
9.6 Engine Start Circuit
9.7 Window Wiper/Washer Windshield Wiper Motor
9.8 Cab Heater and Fan
9.9 Solenoids, Sensors and Senders
9.10 Display Monitor and Gauges
9.11 Dash Switches
9.12 SAE Diagnostic Trouble and Fault Codes
----------------
Content for Parts List Manual:
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-1. FRAME AND ATTACHING PARTS
FIGURE 1-2. COVERS
FIGURE 1-3. OUTRIGGER INSTALLATION
FIGURE 1-4. PINTLE HOOK
SECTION 2 - BOOM
FIGURE 2-1. BOOM INSTALLATION
FIGURE 2-2. FIRST BOOM SECTION G10-55A
FIGURE 2-3. FIRST BOOM SECTION G12-55A
FIGURE 2-4. SECOND BOOM SECTION G10-55A
FIGURE 2-5. SECOND BOOM SECTION G12-55A
FIGURE 2-6. THIRD BOOM SECTION G10-55A
FIGURE 2-7. THIRD BOOM SECTION G12-55A
FIGURE 2-8. FOURTH BOOM SECTION G10-55A
FIGURE 2-9. FOURTH BOOM SECTION G12-55A
FIGURE 2-10. EXTEND CHAINS G10-55A
FIGURE 2-11. EXTEND CHAINS G12-55A
FIGURE 2-12. RETRACT CHAINS G10-55A
FIGURE 2-13. RETRACT CHAINS G12-55A
FIGURE 2-14. MANUAL QUICK ATTACH
SECTION 3 - ATTACHMENTS
FIGURE 3-1. STANDARD CARRIAGE (Prior to SN 0160052000)
FIGURE 3-2. STANDARD CARRIAGE (SN 0160052000 to Present)
FIGURE 3-3. SIDE TILT CARRIAGE
FIGURE 3-4. 50 IN SIDE SHIFT CARRIAGE
FIGURE 3-5. DUAL FORK POSITIONING CARRIAGE
FIGURE 3-6. 90, SWING CARRIAGE
FIGURE 3-7. 180, SWING CARRIAGE
FIGURE 3-8. SHEET HANDLER CARRIAGE
FIGURE 3-9. FORKS AND ATTACHING PARTS
FIGURE 3-10. FORK MOUNTED PLATFORM
FIGURE 3-11. FORK MOUNTED HOOK
FIGURE 3-12. GENERAL PURPOSE BUCKET
FIGURE 3-13. GRAPPLE BUCKET
FIGURE 3-14. TRUSS BOOM
FIGURE 3-15. TRUSS BOOM WITH WINCH
FIGURE 3-16. ADJUSTABLE TRUSS BOOM
FIGURE 3-17. 8 FOOT STANDARD MAST
FIGURE 3-18. 8 FT SIDE TILT ELECTRIC MAST
SECTION 4 - ENGINE AND ATTACHING PARTS
FIGURE 4-1. ENGINE INSTALLATION
FIGURE 4-2. ENGINE
FIGURE 4-3. ENGINE
FIGURE 4-4. FUEL TANK AND LINES
FIGURE 4-5. RADIATOR INSTALLATION
FIGURE 4-6. AIR CLEANER INSTALLATION
FIGURE 4-7. AIR CLEANER INSTALLATION
FIGURE 4-8. EXHAUST INSTALLATION
FIGURE 4-9. EXHAUST INSTALLATION
SECTION 5 - DRIVE TRAIN
FIGURE 5-1. DRIVETRAIN COMPONENTS (Prior to SN 0160054609)
FIGURE 5-2. DRIVETRAIN COMPONENTS (SN 0160054609 to Present)
FIGURE 5-3. FRONT AXLE
FIGURE 5-4. FRONT AXLE (SN 0160063540 to Present)
FIGURE 5-5. FRONT AXLE - CENTRAL HOUSING AND STEERING (Prior to SN 0160046229, SN 0160046235 through 0160063539, Excluding 0160045209, 0160045296, 0160045449 and 0160045636)
FIGURE 5-6. FRONT AXLE - CENTRAL HOUSING AND STEERING (SN 0160046229 through 0160046235, Including 0160045209, 0160045296, 0160045449 and 0160045636)
FIGURE 5-7. FRONT AXLE - CENTRAL HOUSING (SN 0160063540 to Present)
FIGURE 5-8. FRONT AXLE - DIFFERENTIAL
FIGURE 5-9. FRONT AXLE - DIFFERENTIAL (SN 0160063540 to Present)
FIGURE 5-10. FRONT AXLE - HUB REDUCTION (Prior to SN 0160046229, SN 0160046235 through 0160063539, Excluding 0160045209, 0160045296, 0160045449 and 0160045636)
FIGURE 5-11. FRONT AXLE - HUB REDUCTION (SN 0160046229 through 0160046235, Including 0160045209, 0160045296, 0160045449 and 0160045636)
FIGURE 5-12. FRONT AXLE - HUB REDUCTION (SN 0160063540 to Present)
FIGURE 5-13. FRONT AXLE - BRAKES (Prior to SN 0160046229, SN 0160046235 through 0160063539, Excluding 0160045209, 0160045296, 0160045449 and 0160045636)
FIGURE 5-14. FRONT AXLE - BRAKES (SN 0160046229 through 0160046235, Including 0160045209, 0160045296, 0160045449 and 0160045636)
FIGURE 5-15. FRONT AXLE - BRAKES (SN 0160063540 to Present)
FIGURE 5-16. FRONT AXLE - STEERING (SN 0160063540 to Present)
FIGURE 5-17. FRONT AXLE - TRUNION (SN 0160063540 to Present)
FIGURE 5-18. REAR AXLE
FIGURE 5-19. REAR AXLE (SN 0160063541 to Present)
FIGURE 5-20. REAR AXLE - CENTRAL HOUSING AND STEERING (Prior to SN 0160054609)
FIGURE 5-21. REAR AXLE - CENTRAL HOUSING AND STEERING (SN 0160054609 through 0160063540)
FIGURE 5-22. REAR AXLE - CENTRAL HOUSING (SN 0160063541 to Present)
FIGURE 5-23. REAR AXLE - DIFFERENTIAL (Prior to SN 0160054609)
FIGURE 5-24. REAR AXLE - DIFFERENTIAL (SN 0160054609 through 0160063540)
FIGURE 5-25. REAR AXLE - DIFFERENTIAL (SN 0160063541 to Present)
FIGURE 5-26. REAR AXLE - HUB REDUCTION (Prior to SN 0160054609)
FIGURE 5-27. REAR AXLE - HUB REDUCTION (SN 0160054609 through 0160063540)
FIGURE 5-28. REAR AXLE - HUB REDUCTION (SN 0160063541 to Present)
FIGURE 5-29. REAR AXLE - BRAKES (Prior to SN 0160054609)
FIGURE 5-30. REAR AXLE - BRAKES (SN 0160054609 through 0160063540)
FIGURE 5-31. REAR AXLE - BRAKES (SN 0160063541 to Present)
FIGURE 5-32. REAR AXLE - STEERING (SN 0160063541 to Present)
FIGURE 5-33. REAR AXLE - TRUNION (SN 0160063541 to Present)
FIGURE 5-34. REAR AXLE - DIFFERENTIAL ASSEMBLY (SN 0160063541 to Present)
FIGURE 5-35. REAR AXLE - RING GEAR SUPPORT KIT (SN 0160063541 to Present)
FIGURE 5-36. REAR AXLE - PLANET GEAR CARRIER KIT (SN 0160063541 to Present)
FIGURE 5-37. REAR AXLE - SUPPORT ASSEMBLY (SN 0160063541 to Present)
FIGURE 5-38. TRANSMISSION
FIGURE 5-39. TRANSMISSION - CONVERTER AND INPUT
FIGURE 5-40. TRANSMISSION - GEARBOX HOUSING
FIGURE 5-41. TRANSMISSION - FORWARD GEAR GROUP
FIGURE 5-42. TRANSMISSION - REVERSE GEAR GROUP
FIGURE 5-43. TRANSMISSION - 1ST SHAFT GROUP
FIGURE 5-44. TRANSMISSION - 2ND SHAFT GROUP
FIGURE 5-45. TRANSMISSION - 3RD SHAFT GROUP
FIGURE 5-46. TRANSMISSION - 4TH SHAFT GROUP
FIGURE 5-47. TRANSMISSION - POWER TAKE-OFF
FIGURE 5-48. TRANSMISSION - CONTROL UNIT AND PRESSURE REGULATOR
FIGURE 5-49. TRANSMISSION - GEARSHIFT SYSTEM
FIGURE 5-50. TRANSMISSION - OIL PUMP, FILTER AND DIPSTICK
FIGURE 5-51. TRANSMISSION - TRANSFER BOX
FIGURE 5-52. WHEEL ASSEMBLY
FIGURE 5-53. FENDER INSTALLATION (Prior to SN 0160052014, SN 0160058370 to Present)
FIGURE 5-54. FENDER INSTALLATION (SN 0160052014 through 0160058369)
SECTION 6 - CAB
FIGURE 6-1. CAB INSTALLATION
FIGURE 6-2. CAB ASSEMBLY
FIGURE 6-3. CAB DOOR
FIGURE 6-4. CAB INTERIOR
FIGURE 6-5. WIPERS
FIGURE 6-6. SEATS
FIGURE 6-7. HEATER INSTALLATION
FIGURE 6-8. AIR CONDITIONING INSTALLATION
SECTION 7 - CONTROLS
FIGURE 7-1. BRAKE
FIGURE 7-2. ACCELERATOR
FIGURE 7-3. STEERING COLUMN
FIGURE 7-4. BOOM JOYSTICK
FIGURE 7-5. OUTRIGGER AND FRAME LEVEL/AUXILIARY CONTROLLER
SECTION 8 - HYDRAULIC CIRCUITS
FIGURE 8-1. SUPPLY CIRCUIT
FIGURE 8-2. DUMP CIRCUIT
FIGURE 8-3. STEER SELECT CIRCUIT
FIGURE 8-4. SERVICE BRAKE CIRCUIT
FIGURE 8-5. BOOM JOYSTICK CIRCUIT
FIGURE 8-6. FRAME LEVEL/AUXILIARY CONTROLLER
FIGURE 8-7. OUTRIGGER CONTROLLER
FIGURE 8-8. LIFT CYLINDER CIRCUIT
FIGURE 8-9. EXTEND/RETRACT CYLINDER CIRCUIT
FIGURE 8-10. TILT CYLINDER AND COMPENSATION CYLINDER CIRCUIT
FIGURE 8-11. BOOM HYDRAULIC ASSEMBLY
FIGURE 8-12. AUXILIARY HYDRAULIC CIRCUIT
FIGURE 8-13. FRAME LEVEL CIRCUIT
FIGURE 8-14. OUTRIGGER CIRCUIT
FIGURE 8-15. QUICK ATTACH INSTALLATION
SECTION 9 - HYDRAULIC COMPONENTS
FIGURE 9-1. LIFT CYLINDER AND HARDWARE
FIGURE 9-2. LIFT CYLINDER AND HARDWARE
FIGURE 9-3. EXTEND/RETRACT CYLINDER AND HARDWARE
FIGURE 9-4. TILT CYLINDER AND HARDWARE
FIGURE 9-5. COMPENSATION CYLINDER AND HARDWARE
FIGURE 9-6. FRAME LEVEL CYLINDER AND HARDWARE
FIGURE 9-7. OUTRIGGER CYLINDER AND HARDWARE
FIGURE 9-8. STABILIZER CYLINDER AND HARDWARE
FIGURE 9-9. SIDE TILT CARRIAGE CYLINDER (Prior to SN 0160066379)
FIGURE 9-10. SIDE TILT CARRIAGE CYLINDER (SN 0160066379 to Present)
FIGURE 9-11. 50 IN SIDE SHIFT CARRIAGE CYLINDER
FIGURE 9-12. SWING CARRIAGE CYLINDER
FIGURE 9-13. GRAPPLE BUCKET CYLINDER
FIGURE 9-14. MAIN CONTROL VALVE
FIGURE 9-15. PISTON PUMP
FIGURE 9-16. HYDRAULIC TANK
FIGURE 9-17. STEER SELECT VALVE
FIGURE 9-18. BRAKE VALVE
FIGURE 9-19. HYDRAULIC MANIFOLD VALVE
FIGURE 9-20. DECOMPRESSION VALVE
FIGURE 9-21. QUICK ATTACH VAVLE
FIGURE 9-22. QUICK ATTACH INSTALLATION, G SERIES
FIGURE 9-23. CYLINDER - QUICK ATTACH ASSEMBLY
FIGURE 9-24. QUICK COUPLER CYLINDER
FIGURE 9-25. DIVERTOR VALVE
SECTION 10 - ELECTRICAL
FIGURE 10-1. ENGINE COMPARTMENT ELECTRICAL INSTALLATION
FIGURE 10-2. ENGINE COMPARTMENT ELECTRICAL INSTALLATION
FIGURE 10-3. ARCTIC PACKAGE INSTALLATION
FIGURE 10-4. BOOM AND FRAME ELECTRICAL INSTALLATION
FIGURE 10-5. CAB ELECTRICAL INSTALLATION
FIGURE 10-6. CAB SWITCHES
FIGURE 10-7. CLEARSKY INSTALLATION
FIGURE 10-8. WORK LIGHTS (Prior to SN 0160059446)
FIGURE 10-9. WORK LIGHTS (SN 0160059446 to Present)
FIGURE 10-10. REVERSE SENSING SYSTEM INSTALLATION
FIGURE 10-11. DRIVE LIGHTS
FIGURE 10-12. ENGINE HARNESS
FIGURE 10-13. ENGINE HARNESS
FIGURE 10-14. TRANSMISSION HARNESS
FIGURE 10-15. FRAME HARNESS
FIGURE 10-16. VEC OPTIONS HARNESS
FIGURE 10-17. TRANSMISSION RELAY HARNESS
FIGURE 10-18. ENCLOSED CAB OPTIONS HARNESS
FIGURE 10-19. DASH HARNESS
FIGURE 10-20. INSTRUMENT PANEL HARNESS
FIGURE 10-21. FRAME ROAD LIGHT HARNESS
FIGURE 10-22. BOOM WORK LIGHT HARNESS
FIGURE 10-23. CAB ROAD LIGHT HARNESS
FIGURE 10-24. CAB WORK LIGHT HARNESS (Prior to SN 0160059446)
FIGURE 10-25. CAB WORK LIGHT HARNESS (SN 0160059446 to Present)
FIGURE 10-26. CAB WORK LIGHT HARNESS
FIGURE 10-27. A/C HARNESS
FIGURE 10-28. VEC HARNESS
FIGURE 10-29. TELEMATICS INSTALLATION, UNITED RENTALS, (WITH SHORT JUMPER HARNESS)
FIGURE 10-30. TELEMATICS INSTALLATION, UNITED RENTALS, (WITH LONG JUMPER HARNESS)
FIGURE 10-31. REVERSE SENSOR HARNESS
SECTION 11 - DECALS
FIGURE 11-1. CAB AND FRAME DECALS
FIGURE 11-2. BOOM DECALS
SECTION 12 - RECOMMENDED SPARE PARTS
FIGURE 12-1. RECOMMENDED SPARE PARTS
PART NUMBER INDEX
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