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3. G10 55A G12 55A Electrical System 9 6 2 anon Constant Power Circuit from Battery Cummins mooom omcr
4. Options Cummins 79 Electrical System 9 5 5 5 140 52 8 QNO 140 x 06 Sg gt A18W3SSV SISSVHO OL z NON 5 SNOL a sO VEE gt M 4 4 gt S 9289 3 383 nnm 5528 8 93 NOOV38 VOL 13 HOM voz 94 CN voz 54 ma 597 amaz noovat Vit HOLMS JYNSSIYd HOLIMS LNOLLdO WS 24 OUVISOWHSHL voz 3504 SNOlLdO E Bagg m la v i mire 140 gas Tv c 3 sa see 5 A i H E z g NOS ONG Bs 8 85 NI NOLLO3NNOO EE NOOvad 2 9 21 le SEO AYTA HOLIM
5. BAT POS BAT POS POWER DIST OPTIONS p GRAYS 4 1 1 1 1 1 Fi gt an gt 1 F2 1 1 gt F5 18 ff ay Fe 1 x t t 1 FB we i 158 8 1 4 5 4 5 uem 5 Fi 15 L gt A gt gt 1 gt 54 f gt 2 gt 5 gt gt i 1 ls gt 4 gt OPTION gt gt 5 gt 5 gt 4 gt 8 1 8 28 t gt 9 58 10 55116 4 H8 5 gt 94 Hrt Y 12 VV i 2 gt n E BLACK 1 GRAY 2 1 i BA 14 HGFEDCBA D gt 182 9 gt gt E 1 1 gt gt E 1 o gt l gt 6 1 gt 19 gt 1 1 5 1 1 1 1 sarapa em Swa e EE ae re a ho de e e ee eee eee E 1 1 1 1 3 1 5 5 5 8 1 CHASSIS HARNESS 1 VVVVVVVVVV VV VV
6. Bai x S lt ND aoe 8 a 3 amp TF ESI x ulii 0 l SS m e 1 e 5 NOS 9 E I SAM ITAVS o SET Sit u PSI NIS gt amawata 5 ELIR 2 mtns 5 NS 5 528200 2202 20250 OPSZ0E PUETE lt 9 902 1H Sidi oQuzOS 2 Oz 5 gt mass af gt or Sig ALANS Za alg HIH ol Zos yavan 2 gt 3551719 lt Luna a 52 uama ono salvar gt gt CN S3IV3H 2715 YMd H31V3H lt o 1 5 20 Ius MOTSSIVSH 95 5 4 amaa IH H3IVSH 5 gt lt NVIG 5 uc ae gt 5 Be 5 95 8 M3HSVM
7. MAIN CONTROL VALVE MY4360 G10 55A G12 55A Hydraulic System Hydraulic Schematic 8 4 3 SANA IOHLNOO OL NOXOIW 01 51 g INSOLLSH 32010 M H3ONITAO W3znigvis 971005 578 dSN3S avol 854 191110 FINI 854 197170 TOYLIGHO ONIN33IS Sayvug 39 338 3ATNA 194145 48815 15 HV3H 15 14033 MY1170H 8 9 G10 55A G12 55A Hydraulic System 8 4 3 Hydraulic Schematic Continued Before S N 0160037877 HOY 1331 15805 dm i d 3NTVA NOLIVNISWOO XOULSAOr ANY 1331 L 4 t AVMS SNI1VSN3dWOOS 0005 0C AVMS 13 M3ONITAO 147 LHI YSOSIMLNO 1431 1180 OL G10 55A G12 55
8. 12345078 901121314 16 1617 18 10 20 21 22 23 24 25 28 27 28 2930 31 5 Hy DASH GND EXC 5OBWLST POWER DIST aws i Nu 1227 BLACKA POWER DISTRIBUTION FUSE BREAKER LEGEND 204 OPTIONS POWER 3 Fi 15A TRANS PARK BRK PWR F4 GAGE INST PANEL PWR F amp SPARE ACCESSORY PWR 10 STEER SWAY PWR Fiz 15A KEY BATTERY PWR HGFEDOCBA MY4730F 9 17 Electrical System 9 5 9 Chassis Schematic Cummins S N 0160039451 and After Including 0160039394 amp 0160039397 lt Webs ma 5 BA na m at ig 3 A18W3SSV OL a ano sasnna SSINUVH S
9. ZETTE 8 5 h lt BAT 022 ENG WARN LT ENG STOP LT 8 THR SGNA15 THR THR RTN STRLY TRANS SOL YZ TRANS SOL YS TRANS SOLYA TRANS SOL YS TRANS SOL YT i5 TO SHIFTER HARNESS TO CAB ASSEMBLY TO DASH PANEL HARNESS TZTURNSPER FOOTTWIST SVIS Yi MANIS Md TTUSVISI MM E lt lt MIT 23 lt lt 12348878 0101112181416 1817 18 19 20 21 22 29 24 2529 27 28 2930 31 8 B zd mU L AVMS vim 1 91 SANIN 3 m H ii mee X805
10. ASSEMBLY 8 HNO o A DASH PANEL HARNESS HD36 24 31PT CHASSIS HARNESS tomi mtis h LEE E 1 n STRVSWAY GND VEG POWER DIST 041 8 212 a HOFEDOBA H FEDOBA POWER DISTRIBUTION FUSE BREAKER LEGEND 20 OPTIONS POWERS Er Fi TRANS PARK BRK PWR Fo 25A ENGINE ECU BAT PWR iz 15A KEY BATTERY PWR Sh pum 1 8 MY459
11. MY3450 7 Install the previously removed wear pad support plates and spacers 25 with existing hardware at the inside top front of the second boom section Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1 78 3 30 mm gap between the boom sections Note Longer bolts 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 Hefer to Section 3 11 2 Wear Pad Installation and Lubrication 8 Install the previously removed wear pads spacers and shims on each side at the front of the second boom section 26 Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1 78 3 30 mm gap between the boom sections JL 27 28 28 29 29 p MY3450 30 30 G10 55A G12 55A 9 Install the wear pad support plate 27 with existing hardware at the inside front of the second boom section 10 Install the previously removed wear pads spacers and shims at the bottom front of the second boom section 28 amp 29 Snug mounting bolts Note Longer bolts 30 may be req
12. No Function Amp Rating F1 Trans Park Brake Power 15 F2 Alternator Excite 5 F3 Engine ECU Ignition Power 10 F4 Gauge Power 10 F5 Spare Accessory Power 15 F6 Auxiliary Electric Power 10 F7 Horn Power 15 F8 Spare Battery Power 25 F9 Engine ECU Battery Power 25 F10 Steer Sway Power 10 F11 Rear Axle Stabilizer Tilt Power 10 F12 Key Battery Power 15 F13 Options Power 3 20 F14 Options Power 4 20 F15 Options Power 1 20 F16 Options Power 2 20 IGN1 Ignition 1 IGN 2 Ignition 2 ACCY1 Accessory 1 ACCY2 Accessory 2 9 8 G10 55A G12 55A Electrical System 9 4 5 Optional Power Distribution Unit VEC F1 R1 R5 F2 F3 R2 R6 R3 R7 F6 R4 z R8 F8 1260 Connector Legend No Function Amp Rating F1 Wiper 20 F2 Option Roof Wiper 5 F3 Option 15 F4 Option 25 F5 Heater 20 F6 Lights 20 F7 Beacon 10 F8 Dash Fan 10 R1 Wiper R2 Heater Blower R3 Aux Elec 1 R4 Aux Elec 2 R5 Option 15 R6 Option 25 R7 Lights R8 Beacon Fan G10 55A G12 55A 9 9 Electrical System 9 5 9 5 1 9 10 ELECTRICAL SYSTEM SCHEMATICS Cab Schematic John Deere WARN LIGHT TEST R
13. 2 19 2 6 Lubrication Schedules 2 20 G10 55A G12 55A 2 1 5 General Information and Specifications 21 REPLACEMENT PARTS AND WARRANTY INFORMATION 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 JLG disclaims liability for any claims or damages whether regarding property damage personal injury or death arising out of the use of unauthorized replacement parts A warranty registration form must be filled out by the JLG distributor signed by the purchaser and returned to JLG when the machine is sold and or put into use Registration activates the warranty period and helps to assure that warranty claims are promptly processed To guarantee full warranty service verify that the distributor has returned the business reply card of the warranty registration form to JLG 2 2 G10 55A G12 55A General Information and Specifications 2 2 TORQUE CHARTS 2 2 1 SAE Fastener Torque Chart Values for Zinc Yellow Chro
14. 48 6 32 40 8 32 36 10 24 32 1 4 20 i 26 02500 00364 3280 6 FB Nm 24 3 8 16 I 24 14 20 1 2 13 20 12 18 5 8 11 __ 20 04375 0 1187 10700 65 90 60 so 6 80 12 13 0 5000 0 1419 12750 90 120 12 916 12 9 16 0 5625 0 1820 16400 130 175 18 0 5625 0 2030 18250 145 195 135 185 58 1 0 6250 0 2260 20850 180 245 170 230 24 03125 0 0580 5220 25 35 20 25 38 16 0 3750 0 0775 7000 35 50 35 50 2 _716 14 0 6060 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED MY4670J G10 55A G12 55A 2 5 General Information and Specifications 2 2 1 SAE Fastener Torque Chart Continued SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Torque Torque TM TM Si TPI Bolt Di Tensile Clamp Load Losic 242 Pu 271 Loctite 2627 gt ola Stress Area 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 K 0 15 K 0
15. 8 19 8 7 8 Steer Select 1 8 20 8 8 Hydraulic 8 21 8 8 1 General Cylinder Removal 5 8 21 8 8 3 Cylinder Pressure Checking 8 23 8 8 4 Steering 5 8 23 8 8 5 Cylinder Torque Specifications 8 24 G10 55A G12 55A 8 1 Hydraulic System 81 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 EXTEND RETRACT HYDRAULIC FLUID LIFT LOWER COMPENSATION CYLINDER RESERVOIR CYLINDER S CYLINDER TILT CYLINDER MALOS81 MAIN CONTROL STEERING STABILIZER VALVE CYLINDER S CYLINDER OUTRIGGER SWAY CYLINDER STEERING CYLINDER S CYLINDER S 8 2 G10 55A G12 55A Hydraulic System n 8 2 SAFETY INFORMATION WARNING DO NOT service the machine without following safety precautions as outlined in Section 1 Safety Practices of this manual Pet
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18. 7 6 7 3 3 Specifications and Maintenance Information 7 6 7 3 4 Component 7 7 7 4 Engine Cooling System 7 8 7 4 1 Radiator Pressure 7 8 7 4 2 Thermostat 7 8 7 4 3 Radiator Oil Cooler and Replacement 7 9 7 5 Engine Electrical 7 10 7 6 ide edem eet dea 7 10 7 6 1 Diesel Fuel erstarrt eee tay eed eee 7 10 7 6 2 Fue TANK PET 7 10 7 6 3 After Fuel System 7 12 7 7 Engine Exhaust 7 12 7 7 1 Exhaust System 7 12 7 7 2 Exhaust System Installation 7 13 7 8 Air Cleaner 7 13 7 8 1 Air Cleaner Assembly Removal John Deere amp Perkins 7 13 7 8 2 Air Cleaner Assembly Installation John Deere amp Perkins 7 13 7 8 3 Air Cleaner Assembly Removal Cummins 7 13 7 8 4 Air Cleaner Assembly Installation 5
19. 3 12 3 5 8 Fourth Boom Section Installation 3 12 3 5 9 Second Boom Section Assembly 3 13 3 5 10 Third amp Fourth Boom Section Installation 3 14 3 5 11 Second Third and Fourth Boom Section Installation 3 15 3 6 Extend Retract Chain Removal Installation 3 16 3 6 1 Retract Chain 3 16 3 6 2 Chain Installation 3 17 3 6 3 Extend Chain 3 17 3 6 4 Extend Chain Installation 3 18 3 7 Boom Section Separation Adjustment 3 18 3 8 Hose Carrier Assembly Removal Installation 3 20 3 8 1 Hose Carrier Assembly Removal 3 20 3 8 2 Assembling the Hose Carrier 3 21 3 8 3 Hose Carrier Assembly 3 21 3 8 4 Boom Hose Adjustment 3 22 3 9 Quick Switch 3 23 3 9 1 Quick Switch Removal 3 23 3 9 2 Quick Switch 3 23 3 9 3 Quick Switch Removal
20. 9 10 9 6 Circuit Breakdowns 9 22 ii G10 55A G12 55A Section Subject Page 9 7 Engine Start CIIGUIL M ORE USE 9 26 9 8 Window Wiper Washer Windshield Wiper 9 28 9 9 Cab Heater and Fan 9 30 9 10 Solenoids Sensors and 5 9 30 9 11 Display Monitor and Gauges 9 37 9 12 Dash Switches ba eet Yu Iu pee ege 9 38 9 13 Troubleshooting John 9 40 9 14 Engine Indicator Lamps Perkins 9 42 9 15 SAE Diagnostic Trouble Codes and Fault Codes Cummins 9 43 G10 55A G12 55A iii Section Subject Page iv G10 55A G12 55A Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1 1 Introduction 1 2 1 2 Disclaimet 1 2 1 3 Operation amp Safety 1 2 1 4 Do Not Operate 1 2 1 5 Safety 1 2 1 5 1 Safety Alert System and Signal
21. Head Nut Cartridge Cartridge Nut G10 55A Before S N 0160033661 107441 um 52 22 Ib ft 30 Nm NS G10 55A S N 0160033661 amp After 122 22 Ib ft 30 Nm G12 55A Before SIN 0160033659 300 325 lb ft 775 825 lb ft 30 Nm 2 5 lb ft excluding 0160033452 407 441 Nm 1050 1119 Nm 3 3 Nm EN Outrigger Cylinder Head Nut Valve Mount 100 400 Ib ft 136 542 Nm 1300 1350 Ib ft 1762 1830 Nm 30 35 Ib ft 41 47 Nm 100 400 Ib ft 136 542 Nm 1100 Ib ft 1491 Nm 30 35 lb ft 41 47 Nm 8 26 G10 55A G12 55A Section 9 Electrical System Contents PARAGRAPH TITLE PAGE 9 1 Electrical Component 9 3 9 1 1 General Overview John 9 3 9 1 2 General Overview Perkins 9 4 9 1 3 General Overview lt 9 5 9 2 Specifications tech ka rue oe ee 9 6 9 3 Safety 9 6 9 4 Fuses and Relays eet Il ee eee eee 9 6 9 4 1 Engine Compartment 9 6 9 4 2 M 9 6 9 4 3 Power Distribution Unit John Deere Perkins 9 7 9 4 4 Power Distribution Unit VEC Cummins
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23. 4391 816 305 YAO 840 YLS HORN LL6 dNS 41110 15410 HIA SH 105 14185 CHECK ENG SHTDN OVR ALLS TRANS TMP WRN HD34 24 31ST MS lt N4 DASH PANEL HARNESS NYOH BLK 18 GAGXL 816 408 YAO 840 415 RED 18 GAGXL 5 MV LS RED 18 GA GXL NYOH AVMS I331S NHOH BEEDE GAUGE Md NYOH 1x9 vo LIN MS dW1 SNVUL NY xo vo 0 6 vo 9uo TAVIS 1 15 90V 12345678 910 1112 1314 15 16 17 18 19 20 21 22 23 24 25 2627 28 29 30 31 NOI AS CXovogi gau S xo vo 817118 0 12345678 65 xo ve ane gt xo vo 81118 0 15910 xo vo TINA NOI AJJ KEY IGN 1V8 199 AIJ MY1060 G10 55A G12 55A Electrical System 9 5 2 Cab Schematic Perkins
24. ow1211 G10 55A G12 55A 2 21 5 General Information and Specifications c 1000 Hour OY2080 2 22 G10 55A G12 55A C C K Section 3 Boom Contents PARAGRAPH TITLE PAGE 3 1 Boom System Component 3 3 3 2 Boom System Four 3 4 3 2 1 Boom System 3 4 3 3 Boom Assembly 3 4 3 4 Complete Boom 3 5 3 4 1 Complete Boom 3 5 3 4 2 Complete Boom Installation 3 5 3 5 Boom Section Removal Installation 3 6 3 5 1 Second Third amp Fourth Boom Section Removal 3 6 3 5 2 Third amp Fourth Boom Section 3 8 3 5 3 Fourth Boom Section 3 9 3 5 4 Hose Carrier 3 10 3 5 5 Fourth Boom Section Assembly 3 10 3 5 6 Hose Carrier 3 11 3 5 7 Third Boom Section Assembly
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27. WILLIAMS SUSPENDED TWIST gt 12 TURNS PER FOOT 105 SNVHL 1234 5 6 7 8 9 10 11121314 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 ZA 105 SNVHL 16 95 ABCDEF VI6 NIH YHL 916 405 YHL HOBBS sw2 sw LATOS SNVHL 105 105 SNVHL 1591 L3IHS e AOS SA 105 12345678 10S TH LATOS swi swa HR MTR TRANSMISSION LEGEND ACTIVATED TRANS SOLENOIDS YA YA YA Y5 Y1 Y3 Y6 Yi Y6 Y2 Y3 Y4 Y6 Y2 Y3 Y5 Y6 Y2 Y3 Y6 Y2 Y6 Y6 ONLY IF PARK BRAKE OFF TO CHASSIS ASSEMBLY Y6 ONLY IF PARK BRAKE OFF Y6 ONLY IF PARK BRAKE OFF Y6 ONLY IF PARK BRAKE OFF GEAR F2 F3 F4 Fi R1 R2 R3 R4 N1 N2 N3 N4 14185 DASH GND 105 ALS 1 4 5 STEER MODE i PK BRK SOL PARK BRAKE ls 5 le om 399119 399119 399119 399119 399119 399119 9 XHBINVHL MESINVEL HIS LINYA
28. 1 2 1 6 Safety Instructions RED EX RIS ee 1 3 1 6 1 Personal 1 3 1 6 2 Equipment Hazards cure datas ey eee sas Gate 1 3 1 6 3 General 5 1 3 1 6 4 Operational 1 4 1 7 Safety Decals uei Sewage ee 1 4 G10 55A G12 55A 1 1 Safety Practices A 11 INTRODUCTION 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 Read understand and follow the information in this manual and obey all locally approved safety practices procedures rules codes regulations and laws These instructions cannot cover all details or variations in the equipment procedures or processes described nor provide directions for meeting every possible contingency during operation maintenance or testing When additional information is desired consult the local distributor Many factors contribute to unsafe conditions carelessness fatigue overload inattentiveness unfamiliarity even drugs and alcohol among others For optimal safety encourage everyone to think and to act safely Appropriate service me
29. 5 6 5 4 Drive anette ea ee 5 9 5 4 1 Drive Shaft Inspection and Service 5 9 5 4 2 Drive Shaft Maintenance 5 9 5 4 3 Drive Shaft 5 9 5 4 4 Drive Shaft Cleaning and Drying 5 9 5 4 5 Drive Shaft 5 9 5 5 Wheels and Tires 5 10 5 5 1 Removing Wheel and Tire Assembly Machine 5 10 5 5 2 Installing Wheel and Tire Assembly onto 5 11 5 6 Brakes 22 9 be ee eee uer ux ne ex E mes 5 11 5 7 Towing a Disabled 5 11 5 7 1 Manually Releasing the Park 5 11 5 7 2 Manually Resetting the Park Brake 5 12 G10 55A G12 55A 5 1 ES Axles Drive Shafts Wheels and Tires 51 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
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31. 3 23 3 9 4 Quick Switch 3 23 G10 55A G12 55A 3 1 oy Boom 3 2 3 10 3 11 3 12 3 13 3 14 Boom Head Mounted Winch 3 24 3 10 1 Boom Head Mounted Winch Removal 3 24 3 10 2 Boom Head Mounted Winch 3 24 Boom Wear 5 uuu uyu ew Gua Sa 3 24 3 11 1 Wear Pad 3 24 3 11 2 Wear Pad Installation and Lubrication 3 24 Boom Extend and Retract 5 3 25 3 12 1 Boom Chain 3 25 3 12 2 Inspection 3 26 3 12 3 Expose Chains for 3 28 3124 Chain LubficatiOn ces a wae S S Qu 3 28 FOLKS re u aus 3 29 Troubleshooting 3 30 G10 55A G12 55A 31 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section EXTEND CHAINS SECTION FOURTH BOOM SECTION SECOND BOOM SECTION 52 m l SECTION AUXI
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34. 5 MY3580 2 15 At the top front of the boom measure and note the distance from the end of the three extend chain clevises 9 to the face of the lock nut 10 16 Loosen and remove the lock nuts 10 adjusting nuts 11 washers 12 and springs 13 the three extend chain clevises 9 MY3770 7 Label and remove both tilt cylinder hoses 1 3 6 between the tilt cylinder 2 and the hose carrier 3 Label cap and plug the hose carrier tube ends and cylinder ports to prevent dirt and debris from entering the hydraulic system G10 55A G12 55A 14 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 ica 17 18 15 16 20 Remove the extend retract cylinder support 15 from the front of the first boom section 21 Support the extend retract cylinder 16 with a suitable sling 22 Remove the retaining clips 17 from each side of the extend retract cylinder rod 23 Remove the
35. 4 6 4 3 7 Heater Air Conditioning System if equipped 4 6 4 4 Removal uuu l aus t n Ret Gate Hein eee 4 8 4 5 Cab 1 lt 4 9 G10 55A G12 55A 4 1 a Cab and Covers 41 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 FRAME LEVEL INDICATOR HEATER AND A C CONTROLS OPTIONAL BOOM CONTROL STEERING WHEEL JOYSTICK INSTRUMENT PANEL SWAY CONTROL JOYSTICK AUXILIARY CONTROL JOYSTICK TRANSMISSION CONTROL LEVER OUTRIGGER CONTROL JOYSTICK IGNITION SWITCH FUEL TANK SERVICE BRAKE PEDAL ACCELERATOR PEDAL 0930 4 2 G10 55A G12 55A Cab and Covers a A WARNING DO NOT service the machine without following all safety precautions as outlined in the Safety Practices section of this manual 42 OPERATOR S 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
36. 9 8 9 4 5 Optional Power Distribution Unit VEC 9 9 9 5 Electrical System Schematics 9 10 9 5 1 Cab Schematic John Deere 9 10 9 5 2 Cab Schematic 9 11 9 5 3 Cab Schematic lt 9 12 9 5 4 Options Schematic John 9 13 9 5 5 Options 9 14 9 5 6 Chassis Schematic John Deere 9 15 9 5 7 Chassis Schematic Perkins Before S N 0160037186 9 16 9 5 8 Chassis Schematic Perkins S N 0160037186 Thru 0160039397 Excluding 0160039394 amp 0160039397 9 17 9 5 9 Chassis Schematic Cummins S N 0160039451 and After Including 0160039394 amp 0160039397 les eie a RUE 9 18 9 5 10 Power Unit Schematic John 9 19 9 5 11 Power Unit Schematic Perkins 9 20 9 5 12 Power Unit Schematic Cummins 9 21 9 6 Circuit 9 22 9 6 1 Constant Power Circuit from Battery John Deere amp Perkins 9 22 9 6 2 Constant Power Circuit from Battery C
37. 6 Install the previously removed wear pads spacers and shims at the bottom front of the third boom section 11 Snug mounting bolts alt Note Longer bolts 12 may be required to fully engage the threaded inserts in the wear pads without allowing 8 8 bolts to protrude past the chamfer on wear pads Refer to 6 Wear Pad Installation and Lubrication for detailed information 3 5 9 Second Boom Section Assembly 1 Place the second boom section onto suitable n 8 supports 14 y M ss ss MY3510 15 gt 3 Install the previously removed wear pad support plates and spacers 7 with existing hardware at the inside top front of the third boom section Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 13 0 070 0 130 in 1 78 3 30 mm gap between the boom sections 4 Install the previously removed wear pads spacers D and shims on each side at the front of the third boom H B section 8 Snug mounting bolts Shim as needed i 5 AFTER boom section is installed to maintain 0 070 0 130 in 1 78 3 30 mm gap between the boom section
38. 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 6 4 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 Remove the transmission to axle drive shafts Refer to Section 5 4 3 Drive Shaft Removal Remove air cleaner unit and intake tubes Remove the hydraulic pump Refer to Section 8 6 1 Implement Pump Replacement Label and disconnect the transmission temperature switch connector and shift solenoid wiring harness connectors Label disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission Remove the access plug from side of the engine bell housing This will allow access to remove the four bolts holding the torque convertor diaphragm to the engine flywheel 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 Wipe up any spilled hydraulic and transmission oil Connect a lifting strap or chain to the lifting eye at the top of the transmission and to a suitable hoist or overhead crane Operate the hoist or crane to remove slack from the chain but DO NOT raise the transmission at this time Place blocks under rear of engine for support BEFORE transmission moun
39. ALTERNATOR RELAY OIL PRESSURE STARTER RELAY SENDER ENGINE CONTRO MODULE ECM G10 55A G12 55A Electrical System 9 2 SPECIFICATIONS 9 4 2 Electrical system specifications are listed in Section 2 General Information and Specifications 9 3 SAFETY INFORMATION A 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 JOHN DEERE PERKINS MY0410 The optional power distribution unit is located in the cab 2 2 For access remove the screws securing the load chart panel 3 to the dash KO q 1 J MY1800 CUMMINS 10 o MY4550 The starter relay 1 and power distribution unit 2 is located on the power distribution unit bracket in the engine compartment 9 6 G10 55A G12 55A Elect
40. Rail 1 Pressure Valid but Above Normal Operational Range Moderately Severe Level G10 55A G12 55A 9 49 Electrical System Fault SPN FMI Lamp m Codes Codes Codes Color SPN Description Cummins Description 554 157 2 Amber Injector Metering Fuel Pressure Sensor Error Data Erratic Rail 1 Pressure Intermittent or Incorrect 559 157 18 Amber Injector Metering Injector Metering Rail 1 Pressure Low Data Rail 1 Pressure Valid but Below Normal Operational Range Moderately Severe Level 584 677 3 Amber Starter Solenoid Starter Relay Circuit Voltage Above Normal Lockout Relay Driver Shorted to High Source Circuit 585 677 4 Amber Starter Solenoid Starter Relay Circuit Voltage Below Normal or Lockout Relay Driver Shorted to Low Source Circuit 595 103 16 Amber Turbocharger 1 Turbocharger 1 Speed High Data Valid but Speed Above Normal Operational Range Moderately Severe Level 596 167 16 Amber Alternate Potential Electrical Charging System Voltage High Data voltage Valid but Above Normal Operational Range Moderately Severe Level 597 167 18 Amber Alternate Potential Electrical Charging System Voltage Low Data voltage Valid but Below Normal Operational Range Moderately Severe Level 598 167 1 Red Alternate Potential Electrical Charging System Voltage Low Data voltage Valid but Below Normal Operational Range Most Severe
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43. Contents PARAGRAPH TITLE PAGE 8 1 Hydraulic Component 8 2 8 2 Safety 8 3 8 3 Hydraulic Pressure 8 3 8 3 1 Pressure Checks and 8 4 8 4 Hydraulic 8 4 8 4 1 Hydraulic 5 5 8 4 8 4 2 Tilt Circuit Port Relief 8 5 8 4 3 Hydraulic Schematic 8 9 8 5 Hydraulic Reservoir 8 13 8 5 1 Hydraulic Oil Reservoir 8 13 8 5 2 Hydraulic Oil Reservoir 8 13 8 5 3 Hydraulic Oil Reservoir Removal Installation 8 13 8 6 Implement PUMP a 8 14 8 6 1 Implement Pump 8 14 8 7 Control 6 1 ee ee cee le 8 15 8 7 1 Main Control Valve 8 15 8 7 3 Service Brake Valve 8 17 8 7 4 Service Brake 0 8 18 8 7 7 Steering Orbitrol Valve
44. Head Nut G10 55A Before S N 0160033659 excluding 0160033452 550 600 Ib ft 745 813 Nm 2050 2100 Ib ft 2779 2847 Nm G10 55A S N 0160033659 thru 0160037689 including 0160033452 2200 2400 Ib ft 2982 3254 Nm G10 55A S N 0160037689 amp After 2200 2400 Ib ft 2982 3254 Nm G12 55A Before S N 0160033659 excluding 0160033452 600 Ib ft 813 Nm 2250 2300 Ib ft 3050 3118 Nm G12 55A S N 0160033659 thru 0160037689 including 0160033452 1600 2000 Ib ft 2169 2712 Nm G12 55A S N 0160037689 amp After 1600 2000 Ib ft 2169 2712 Nm G10 55A G12 55A 8 25 Hydraulic System n e Sway Cylinder Head Nut Check Valve G10 55A Before S N 0160033661 300 325 Ib ft 407 441 Nm 750 800 Ib ft 1016 1085 Nm 15 lb ft 20 Nm G10 55A S N 0160033661 thru 0160037690 1125 1375 Ib ft 1525 1864 Nm 33 Ib ft 45 Nm G10 55A S N 0160037690 amp After 1125 1375 Ib ft 1525 1864 Nm 33 Ib ft 45 Nm G12 55A Before S N 0160033659 excluding 0160033452 300 325 lb ft 407 441 Nm 750 800 Ib ft 1016 1085 Nm 15 lb ft 20 Nm G12 55A S N 0160033659 thru 0160035879 including 0160033452 1125 1375 Ib ft 1525 1864 Nm 33 Ib ft 45 Nm G12 55A S N 0160035879 amp After 1125 1375 lb ft 1525 1864 Nm 33 Ib ft 45 Nm Stabilizer Cylinder
45. Section 6 Transmission Contents PARAGRAPH TITLE PAGE 6 1 Transmission Assembly Component Terminology 6 2 6 2 Transmission Serial 6 3 6 3 Transmission Specifications And Maintenance Information 6 3 6 4 Transmission 6 3 6 4 1 Transmission 6 3 6 4 2 Transmission Inspection and Internal Repair 6 4 6 4 3 Transmission 5 8 6 5 6 4 4 After Transmission Service or 6 5 6 5 Torque Convertor Diaphragm 6 6 6 5 1 Torque Convertor Diaphragm 6 6 6 5 2 Torque Convertor Diaphragm Installation 6 6 6 6 Troubleshooting 6 7 G10 55A G12 55A 6 1 Transmission gt gt 9 zo os oz zr 2 2 lt 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 referr
46. 9 22 9 6 CIRCUIT BREAKDOWNS 9 6 1 KEY BAT POS BAT POS NEGATIVE CABLE BATTERY E 3 0 AWG BLACK lt c POWER DIST TO ENGINE ECU TO CAB FIREWALL POSITIVE CABLE 3 0 AWG RED BLACKS GRAYS VEC TO BATTERY N STARTER A RELAY F2 5 2 B 2 x 2 IGNITION 2 ST RLY PWR gt lt gt STRT SOL 2 D 212 STR 25 2 kevace 3 lt 4 gt 311 5 2 5 Fi 15 G TRAN BRK PW 5 3 4 3 0 AWG RED 12 IGNITION 1 1 gt 8 lt gt BATTERY E lt gt 3 0 AWG BLACK Akk 9 gt gt POSITIVE CABLE lt 5 TO STARTER gt gt e n gt STARTER AND ALTERNATOR gt gt siqy gt NEGATIVE CABLE gt gt 13 TO ENG BLOCK 3 lt 5 NEGATIVE CABLE P BE E gt gt STRTSOL gt gt lt gt FEAGTO 86 565 8568 5 gt gt lt gt gt gt 5 H 2 ST RLY PWR lt gt vvvvvvvv iv vY v V v gt BLACK 1 GRAY 2 lt gt HGFEDCBA HGFEDCBA n vyvy v vyvyv 2 ALTERNATOR lt 7 5 4 AWG RED SP PWR 21 5 ECU BATA lt gt NT ALTEXCA j T T I I B E 25 Be x x xr xr E 9 x 8 HHE 83 5 5 2 H 5 6 6 gy
47. Adjust the sling s around the fourth boom section for stability Balance the fourth boom section and slowly pull the fourth boom section out of the third boom section being careful not to damage any surrounding components Lower the fourth boom section onto a suitable support 3 9 P Boom 3 5 4 Hose Carrier Removal 13 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 When the hose carrier is approximately 25 free of the fourth boom section fasten the two hose carriers together using nylon tie wraps or nylon straps to prevent separation 5 Continue to remove the hose carrier fastening the hose carriers together as they are being removed 6 When the hose carrier is approximately 75 tied together pull the assembly free of the boom section 7 Lower the hose carrier onto a suitable support per iu 14 4 FRONT OF BOOM eee 8 Remove the hose carrier guide bracket from the inside of the fourth boom section 14 3 5 5 Fourth Boom Section Assembly
48. Ignition Key Switch a Ignition 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 Remove the screws securing the dash panel 6 Remove the hex nut securing the ignition key switch to the dash 7 Label and disconnect the ignition switch wires and remove the switch from the machine 9 38 b Disassembly DO NOT disassemble the ignition switch Replace a defective switch with a new part c Inspection and Replacement To determine the proper operation of the ignition key switch test the terminals on the back of the switch for continuity with an ohmmeter MY0830 Test the ignition key switch for continuity by checking from the BAT terminal 13 to each of the remaining terminals in their corresponding switch position If all terminals do not show proper continuity replace the ignition switch d Ignition Switch Installation 1 Connect the ignition key switch to the previously labeled wires 2 Align the ignition switch in the dash so that when it is in the OFF position the key slot is positioned vertically
49. M HEE m 12345678 PARK BRAKE OFF 8 7 3 1 4 5 SHIFTER HARNESS 3 n ON LEFT DASH PANEL DASH PANEL HARNESS MY1111 G10 55A G12 55A Electrical System 9 6 4 Start amp Charge Circuit Cummins 1 u 1 x d BOE p ye 1 g I l WAIT TO START WHT 18AWG i m ENG STOP LT ORG 18AWG i 5 taki P gt oT ENG WARN LT VIO 18AWG af gt gt AE ms ESBO SHE ALTERNATOR BUG ww POWER DIST EO eT A See LIN BATT POSITIVE VEC 5 gt F
50. Pg gsm 5ssszeszeds Fa vd GNO iva ag ama va as B 5 5 j ES EE 22 35 5 tial dIHS T 5888558888888 fe cel s be al d rid rl id rl md a MY1080 G10 55A G12 55A 9 15 Chassis Schematic Perkins Before S N 0160037186 Electrical System
51. S N 0160039451 amp After including 0160039394 amp 0160039397 2 5 quarts 2 4 liters Type of Coolant 0 to 104 F 20 to 40 C 50 50 ethylene glycol amp water 40 to 0 F 40 to 20 C 60 40 ethylene glycol amp water Coolant Conditioner Before S N 0160039451 excluding 0160039394 amp 0160039397 0 5 quarts 0 47 liters S N 0160039451 amp After including 0160039394 amp 0160039397 Not Required G10 55A G12 55A 2 15 5 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 4249 Tractor Hydraulic Fluid 40 to 0 F 40 to 20 C Exon Univis HVI All Season Hyd Fluid Auxiliary Hydraulic Circuit Max Flow 10 gpm 37 9 Transmission Capacity with Filter Change 4 gallons 16 liters Type of Fluid 0 to 104 F 20 to 40 C Mobilfluid 4249 Tractor Hydraulic Fluid 40 to 0 F 40 to 20 C Mobilfluid LT Hydraulic Fluid 75W 80 Transfer Case Capacity 1 5 quarts 1 4 liters Type of Fluid 0 to 104 F 20 to 40 C Mobilfluid 4249 Tractor Hydraulic Fluid 40 to 0 F 40 to 20 C Mobilfluid LT Hydrauli
52. 6 10 11 12 13 14 15 16 17 Uncap and reconnect the previously labeled hydraulic hoses to the extend retract cylinder Uncap and connect any remaining hydraulic fittings to their appropriate locations Recheck the wear pad gaps to ensure they meet the minimum gap requirement Shim if necessary Ensure that the boom chains are properly adjusted Refer to Section 3 7 Boom Section Separation Adjustment Properly connect the battery Start the engine and operate all boom functions several times Check for leaks and check the hydraulic fluid level in the reservoir add fluid if required Install the quick switch assembly Refer to Section 3 9 2 Quick Switch Installation If equipped install the Boom Head Mounted Winch Refer to Section 3 10 2 Boom Head Mounted Winch Installation Clean up all debris hydraulic fluid etc in on near and around the machine Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Install the previously remove attachment to the quick switch assembly Refer to the appropriate operation and safety manual 3 5 ade Boom 3 5 BOOM SECTION REMOVAL 8 Using a suitable lift
53. 8 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A 9 10 2 Park Brake Solenoid Valve a Park Brake Solenoid Valve 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 Disconnect the wiring connector at the park brake solenoid lead Ne Pea ELS MY1140 6 Remove the nut on the end of the park brake coil 7 7 Remove the park brake coil 8 Remove the park brake solenoid 8 Remove only if the 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 1 with new parts to
54. 9 34 9 10 8 Fuel Level 9 35 9 10 9 Inclinometer 9 36 9 10 10 Front and Rear Axle Proximity Sensors 9 37 Display Monitor and 9 37 9 11 1 Analog 9 37 Dash Be 9 38 9 12 1 Ignition Key Switch 9 38 9 12 2 Dash Switches 9 39 Troubleshooting John 9 40 9 13 1 Engine Fault Codes 9 40 9 13 2 Engine Fault Codes 9 40 Engine Indicator Lamps 5 9 42 SAE Diagnostic Trouble Codes and Fault Codes Cummins 9 43 G10 55A G12 55A 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 John Deere 4 1 GAUGE DASH SWITCHES OPTIONAL POWER DISTRIBUTION UNIT
55. 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 14 1 mph 22 7 km h Fourth Gear 13 8 mph 22 2 km h 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 APPROXIMATE TIMES seconds FUNCTION G10 55A G12 55A Boom Extend Boom Level 17 3 16 5 Boom Retract Boom Level 16 8 16 0 Boom Lift 14 6 15 8 Boom Lower 15 8 18 3 Attachment Tilt Forward 6 0 8 0 Attachment Tilt Rearward 7 1 6 4 Sway Full Right to Left 10 4 9 8 Sway Full Left to Right 12 2 10 0 Outrigger Down 5 0 4 9 Outrigger Up 4 1 4 1 G10 55A G12 55A 5 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 4 Engine Performance Specifications John Deere Description G10 55A G12 55A Engine Make Model John Deere PE 4045HF275 John Deere PE 4045HF275 Displacement 276 in 4 5 liters 276 in 4 5 liters Low Idle 900 rpm 900 rpm
56. x 1 7 EE I E E enm Jew EDT Isdooiy doose TT al v Vad aj iv Vad Wad a v al Vad oodd s dns T Lt FATWA NOISS3HdWOO3 TY L 1 335 OL 1noo ao z z L ej z Fu 8 Imm Hs d Lk L z 13 1 511 XOLLSAOf 1HOIH ONY 1331 5 5 1 xnv ame SNLVSN3dWOO m 4 z EE T lt E eX r3 15 1 1 MONTO LIN H3ODIHLAO 1HOIH 1431 G10 55A G12 55A Hydraulic System 8 4 3 Hydraulic Schematic Continued SWAY CYLINDER 050 SWAY AUX JOYSTICKS AUXILIARY HYDRAULICS PORTS DECOMPRESSION VALVE SWAY AUX AUXILIARY HYDRAULICS OPTION MY1190H 8 12 G10 55A G12 55A Hydraulic System 8 5 HYDRAULIC RESERVOIR JOHN DEERE PERKINS MY1150 MY5300 The hydraulic reservoir 1 is located on the frame between the engine compartment and the cab 8 5 1 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control
57. 16 17 18 19 20 G10 55A G12 55A Key to Possible Causes Blocked fuel tank vent Incorrect grade of fuel Sticking throttle or restricted movement Exhaust pipe restriction Leaking cylinder head gasket Overheating Cold running Incorrect tappet adjustment Sticking valves Incorrect high pressure pipes Worn cylinder bores Pitted valves and seats Broken worn or sticking piston ring s Worn valve stems and guides Restricted air cleaner Worn or damaged bearings Insufficient oil in sump Inaccurate gauge Oil pump worn Pressure relief valve sticking open Pressure relief valve sticking closed Broken relief valve spring Faulty suction pipe Restricted oil filter Piston seizure pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors if fitted Coolant level too low Blocked sump strainer Broken valve spring Exhauster or vacuum pipe leak Turbo impeller damaged or dirty Turbo lubricating oil seal leak Induction system leaks Engine 7 18 This Page Intentionally Left Blank G10 55A G12 55A Section 8 Hydraulic System
58. 9 Close and secure the engine cover 10 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A Electrical System 9 8 1 Windshield Rear Window Washer Reservoir MY1220 The windshield washer motor and reservoir 4 is located in the cab behind the seat It is labeled as a unit and cannot be serviced separately a 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 Remove the nuts and the lock washers from the washer mounting bolts 6 Pull the washer reservoir out and away from the mounting bracket 7 Rotate the washer reservoir label and remove the cab harness connectors from the washer reservoir connectors 8 Remove the windshield washer hoses from the reservoir b Disassembly DO NOT disassemble the pump The pump is not serviceable Replace pump if found to be defective c Installation and Testing 1 Connect the windshield washer hoses to the reservoir G10 55A G12 55A Connect cab wiring harness
59. High Idle 2 400 to 2 650 rpm 2 400 to 2 650 rpm Horsepower 125 HP 93 kW 2400 rpm 140 HP 104 kW 2400 rpm Peak Torque 341 Ib ft 483 Nm 1400 rpm 367 lb ft 497 Nm 1400 rpm Fuel Delivery Fuel Injection Fuel Injection Average Fuel Consumption depending on load duty 4 1 gal hr 15 5 l hr 4 3 gal hr 16 2 l hr Air Cleaner Dry Type Replaceable Primary and Dry Type Replaceable Primary and Safety Elements Safety Elements 2 3 5 Engine Performance Specifications Perkins Description G10 55A G12 55A Engine Make Model Perkins 1104D 125HP Perkins 1104D 142HP Displacement 276 in 4 5 liters 276 in 4 5 liters Low Idle 1000 rpm 900 rpm High Idle 2 400 to 2 650 rpm 2 400 to 2 650 rpm Horsepower 125 HP 93 kW 2400 rpm 142 HP 104 kW 2400 rpm Peak Torque Not Available at Publication 410 Ib ft 556 Nm 1400 rpm Fuel Delivery Fuel Injection Fuel Injection Air Cleaner Dry Type Replaceable Primary and Dry Type Replaceable Primary and Safety Elements Safety Elements 2 12 G10 55A G12 55A General Information and Specifications 5 2 3 6 Engine Performance Specifications Cummins Description G10 55A amp G12 55A Engine Make Model Cummins QSB 130HP Displacement 276 in 4 5 liters Low Idle 900 rpm High Idle 2 500 to 2 700 rpm Horsepower 130 HP 97 kW 2500 rpm Peak Torque 459 Ib ft
60. ZA ZA E 9A w AMALIVE OL 31850 3AUISOd v AMALIVE OL 31950 3AUVOSN za SA PA 1 QN3931 NOISSIASNVH L MY1820 55A G10 55A G12 9 20 Electrical System Power Unit Schematic Cummins 9 5 12 318VO SALUSOd 1818 OL cv nus ow nus miss l 2 a Qnis GND OL 44 GN9 1H1S OL 1H1S OL OL GND OL 9 21 MY4720A NOISSINSNVU L BSANENL NOISSINSNVUL JZ anavo QNO mavo GIT SON OT OT TR MG dL VL mnsa amp 5 5 ORT NU EL TOF CRT TS ORO UG ORT HUT VEL Sanavo SRT OTS 5 PI rp 3NION3 NO 3 10LLd393H Nid 09 OL SL03NNOO ia EPUM
61. 1 Place the fourth boom section onto suitable supports 3 10 1 2 es W d B o Mam MY3630 Install the previously removed extend chain assembly and clevis 1 at the top rear of the fourth boom section Allow 0 250 in 6 35 mm C between the end of the clevis 1 and the face of the lock nut 2 Torque lock nut to 100 Ib ft 135 Nm 5 5 4 4 O oo 3 E 3 MY3490 Install the previously removed wear pads spacers and shims at the bottom rear of the fourth boom section 3 Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1 78 3 30 mm gap between the boom sections Install the previously removed wear pads and spacers at the top rear of the fourth boom section 4 Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1 78 3 30 mm gap between the boom sections Install the previously removed wear pad and spacer on each side of the fourth boom section 5 Snug mounting bolts Shim as needed AFTER boom section is installed G10 55A G12 55A gt 3 5 6 Hose Carrie
62. 12 or enlarged holes 12 can vum occur If either of these failures occurs the chain should be replaced immediately MZ1470 Tight Joints All joints in the chain should flex ooi freely Tight 13 joints 13 MEI resist flexing If the problem is caused by dirt or foreign substance packed in the joints clean and lubricate thoroughly before re installing the chain If the problem is caused by corrosion and rust or bent pins replace the chain 3 27 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 While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain If during the inspection any chain is found to be damaged or stretched the chain must be replaced It is recommended that when any chain is replaced that all the chains and clevises be replaced at the same time e Retract Chains The three retract chains are only partially visible through the rear of the boom with all the sections retracted It is possible to see a section of the
63. 15 Connect the transmission temperature switch connector and shift solenoid wiring harness connectors Secure the wiring harness to the transmission housing Connect the transmission oil cooler inlet and outlet hoses at the transmission Install the hydraulic pump Refer to Section 8 6 1 Implement Pump Replacement Install the transmission to axle drive shafts Refer to Section 5 4 5 Drive Shaft Installation Install the air cleaner and tubing Clean the transmission oil filter mounting surface Apply a thin film of clean hydraulic oil to the new transmission filter gasket Install the new filter and torque to 20 25 Ib ft 27 34 Nm G10 55A G12 55A 16 17 0990 Transmission oil be added through the dipstick tube 5 Remove the dipstick and add hydraulic oil Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation amp Safety Manual DO NOT overfill Reinstall the dipstick when finished 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 18 Properly connect the battery 19 Install the engine cover 20 Close and secure the engine cover 21 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6 4 4 After Transmission Service or Replacement In general
64. 3 18 3 8 Hose Carrier Assembly 1 3 20 3 9 Quick Switch Assembly 3 23 3 10 Boom Head Mounted Winch 3 24 3 11 Boom Wear 3 24 312 Boom Extend and Retract 5 3 25 3 13 haces riter rui a 3 29 3 14 Troubleshooting uec snae Ete eene 3 30 Section 4 Gab and Covers issus sae e ee E ERA 4 1 4 1 Operator s Cab and Covers Component Terminology 4 2 4 2 Operator s oe rb eer dte sah aed eed Seder 4 3 4 3 Cab 5 4 3 4 4 Gab Removal vecti vue Hi Eee d dau eee Mas 4 8 4 5 Gab Installation 4 9 G10 55A G12 55A i Section Subject Page Section 5 Axles Drive Shafts Wheels and 5 1 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 2 General 5 3 5 3 Axle oat SEV be Cam Mea Seas Sa ee 5 3 5 4 Drive S
65. 4 Properly disconnect the battery 5 Label disconnect and cap all hose attached to the service brake valve 6 Remove the service brake pedal Refer to Section 4 3 2 Service Brake Pedal 10740 7 Remove the four capscrews four nuts and four lockwashers 3 mounting the service brake valve 4 to the service brake bracket 5 Note DO NOT disassemble the service brake valve The service brake valve is not serviceable and must be replaced in its entirety if defective 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 2 Install the service brake pedal Refer to Section 4 3 2 Service Brake Pedal Note ALWAYS replace seals o rings gaskets 1 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 Uncap and connect the previously labeled hoses to the service brake valve 4 Check the routing of all hoses and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 5 Properly connect the battery 6 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any
66. 7 8 9 10 12 13 14 15 16 17 18 19 20 22 31 32 33 5 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 24 29 31 32 33 61 63 8 9 10 11 12 13 14 18 19 20 21 22 23 24 25 26 27 31 32 33 61 63 8 9 10 12 13 14 16 18 19 20 25 26 28 29 30 32 11 13 14 16 18 19 20 22 23 24 25 27 28 29 31 32 33 63 11 13 14 16 18 19 20 22 24 25 27 28 29 31 32 33 61 63 4 16 18 19 20 25 27 31 33 34 35 45 56 62 4 36 37 38 39 40 42 43 44 58 9 14 16 18 19 22 26 28 29 31 33 35 36 45 46 59 7 8 9 10 11 12 13 14 16 20 21 23 26 28 29 30 33 35 45 59 13 14 20 23 25 26 29 30 33 45 47 48 49 4 38 41 11 13 14 16 18 19 24 25 45 50 51 52 53 54 57 25 11 19 25 28 29 31 32 33 34 46 59 10 31 33 34 45 55 60 11 12 1 Battery charge low 2 Bad electrical connection 3 Faulty starter motor 4 Incorrect grade of lubricating oil 5 Low cranking speed 6 Fuel tank empty 7 Faulty stop control operation 8 Fuel inlet restricted 9 Faulty fuel lift pump Clogged fuel filter 11 Restricted air cleaner Air in fuel system Faulty fuel injection pump Faulty fuel injectors or incorrect type Incorrect use of cold start equipment Faulty cold start equipment Broken fuel injection pump drive Incorrect fuel pump timing Incorrect valve timing Poor compression
67. Flats Method will contain some variance Use the Flats Method only when accessibility with a torque wrench is not possible Torque Wrench 1 Identify the appropriate application and refer to the above chart for the correct torque value 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 Ib ft 4 Nm Use the double wrench method while tightening to avoid hose twist Torque wrench must be held at the center of the grip Apply constant force until it clicks After the connection has been properly tightened mark a straight line across the connecting parts indicating that the connection has been properly tightened 2 10 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 Ib ft 4 Nm Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it s connecting to Use the double wrench method while tightening to avoid hose twist After the connection has been properly tightened mark a straight line across the connecting parts not covering the dots indicating that the connection has been properly tightened G10 55A G12 55A General Information and Specifications 2 3 SPECIFICATIONS 2 3 1 Travel Speeds FUNCTION
68. Label disconnect and cap the steering and brake lines at the axle Wipe up any spilled oil 8 Block the front and rear of both tires on the axle that is not being removed Ensure that the machine will remain in place during axle removal before proceeding 5 4 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 Ensure that the machine will remain in place during axle removal 10 Support the axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 11 Remove both wheel and tire assemblies from the axle that is being removed Refer to Section 5 5 1 Removing Wheel and Tire Assembly from Machine Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing the direction of forward travel 12 Remove the drive shaft assembly Refer to Section 5 4 3 Drive Shaft Removal 13 On the front axle remove the capscrew and locknuts securing the lower position cylinder mount pin to the front cylinder Tap the cylinder mount pin out and move the cylinder to prevent it from interfering with axle removal 14 Remove the bolts and locknuts securing the axle to the frame 15 Remove the axles from the machine using the jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise distu
69. NO SOLENOIDS INGAUGED E5 ES E6 E3 EA EI 3121 ACTIVATED TRANS SOLENOIDS SHEET2 SEE AC CLUTCH 111 duis i I SPEED TILT 1234 ONO H3LdIHS SHIFTER HARNESS TO TILT ON JOYSTICK ROLLER OPTION WARN LIGHT TEST RELAY SHIFTER HARNESS REVERSE RELAY THROTTLE 8 Y RO TIZUWIERWITIIWE ZZ H 262528 2823 90 37 277212 ABCDEF vive vi Ys Ye Y2 vs e YY V4 Ye Yi Y3 Y5 Ye Y2 Ya Y4 Ye Yz Ya Y5 Y6 12345973 8 TRANSMISSION SHIFTER ZF Y6 ONLY IF PARK BRAKE OFF Y6 ONLY IF PARK BRAKE OFF TO CHASSIS ASSEMBLY Y6 ONLY IF PARK BRAKE OFF Ye ONLY IF PARK BRAKE OFF TRANSMISSION LEGEND ZF GEAR ACTIVATED TRANS SOLENOIDS MAIN DASH PANEL WAIT TO START RED 1
70. 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 Drain the hydraulic oil reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 6 Label disconnect and cap all hydraulic hoses attached to the hydraulic oil reservoir Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system 7 Remove the bolts securing the hydraulic oil reservoir to the frame 8 Remove the hydraulic oil reservoir b Disassembly The hydraulic oil reservoir is a one piece unit and cannot be disassembled The hydraulic oil level sight glass and hydraulic oil filler cap can be removed and reused on the new replacement reservoir Dispose of the old reservoir according to local regulations concerning hazardous materials disposal 8 13 n Hydraulic System 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 che
71. straight up and down Install the hex nut securing the ignition switch to the dash DO NOT overtighten 3 Install the dash panel with the previously used hardware 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 Note If further information is needed refer to Section 9 5 Electrical System Schematics G10 55A G12 55A Electrical System 9 12 2 Dash Switches b Switch Removal 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Properly disconnect the battery There are three frames with three switches in each frame Pull the frame out of the dash disconnect the harness connector to the switch in question and push the switch out of the frame Disassembly DO NOT disassemble the dash switch Replace a defective switch with a new part Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions Replace a defective or faulty switch with a new
72. that moves over the sheaves because it receives the most frequent articulation Measuring the chain near its clevis terminals could give an inaccurate reading The ends of the chains near the clevis terminal will not have flexed as frequently if at all as the middle of the chains It is best to measure in 12 pin increments from pin center to pin center For example if the links are one inch from pin center to pin center the distance should be 12 in 305 mm If the links are 3 4 in 19 0 mm apart the distance after 12 pins should be 9 in 228 6 mm MY1360 If the distance measured 3 is 3 greater than the normal length 4 discard and replace the chain G10 55A G12 55A C x Distorted or Battered Link Plates MZ1466 Distorted or battered link plates 5 on a leaf chain can cause tight joints and prevent flexing Turning or Protruding Pins Highly loaded chain operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates When chain is allowed to operate in this condition a pin or series of pins can begin to twist out of a chain resulting in failure 0205 8 MZ1465 Examine the pin head rivets to determine if the VEE flats are still in correct alignment 6 Chain with rotated displaced heads 7 or abnormal pin protrusion 8 should be replaced
73. the appropriate lifting points 1 Use a suitable hoist or overhead crane Note Apply Loctite 242 to the engine mount bracket capscrew threads before installation 2 3 10 11 12 13 14 15 16 Install two guide studs in the bell housing holes Lift the engine and slowly push and lower into the engine bay Have an assistant ensure that the engine clears the frame hose and harness components during engine installation Position engine brackets over the front frame mounts Push the engine towards the transmission aligning the guide studs and the torque convertor shaft with the corresponding holes Push the engine against the transmission and install eight of the ten bolts and washers Remove both guide studs and replace with the remaining two bolts and washers Torque bolts to 53 58 lb ft 72 79 Nm Remove the support from under the transmission and lower the engine the remainder of the way onto the frame Align the motor mount holes and install the bolts Apply Loctite 242 to the motor mount bolts and torque to 125 140 Ib ft 169 190 Nm Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts through the access plug in the bell housing Install them one at a time DO NOT fully tighten until all of the capscrews and locknuts are in place Torque to 26 39 Ib ft 35 59 Nm Replace access plug Install the exhaust pipe Refer to Section 7 7 2 Exhaust System Insta
74. 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 6 Remove the chain clevis pin and retaining ring to free the chain 7 Install the nylon tie wrap through the holes in the chain making a loop with the tie wrap and tie a rope to the loop 8 Pull the slack to the chain clevis at the front of the boom 9 Remove the clevis pin and the retaining ring from the chain and chain clevis 10 Install a nylon tie wrap through the chain holes forming a loop and tie a rope to the loop 11 Carefully pull the chain out of the boom 12 Untie the rope and leave it in place for reinstallation of the chain 3 6 4 Extend Chain Installation The following section explains the installation of the retract chains without removing the boom assemblies Inspect and lubricate chains thoroughly before 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 Atthe other end of the chain connect the chain to the clevis fastening the chain to the clevis with a pin and retaining ring 5 Install the chain clevis fastening and adjusting hardware on both ends 6 Remove any clampi
75. 0160030644 MAIN CONTROL VALVE HYDRAULIC MANIFOLD G10 55A S N 0160031864 amp After G12 55A S N 0160030644 amp After 1301 G10 55A G12 55A 8 7 n Hydraulic System b Pressure Specifications S N 0160037877 amp After Hydraulic Circuit Test Port Function Used to Adjustment Pressure Range Test Location Main P1 A Bottom Tilt Down 1 Pilot JS1 B No Function 2 2 Standby P1 A No Function 3 525 Service Brake BV1 C Bottom Steering 4 1050 1150 psi Supply Any Mode 72 79 Bar Steering GLS 0 5 169 176 Bar Load Sense LS2 E Bottom Tilt Down 6 Ge Ps Boom Extend LS2 E 7 unn Boom Retract LS2 E sig 8 Lift LS2 E Bottom Lift Down 9 22 Auxiliary Hydraulic 82 E Bonom Auxiliary No Adjustment 3179 9429 psi Function 219 229 Bar HYDRAULIC MANIFOLD 8 8
76. 110 16 Amber Engine Coolant Coolant Temperature High Data Valid but Temperature Above Normal Operational Range Moderately Severe Level 147 91 1 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor Position Circuit Abnormal Frequency Pulse Width or Period 148 91 0 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor Position Circuit Abnormal Frequency Pulse Width or Period 151 110 0 Red Engine Coolant Coolant Temperature Low Data Valid but Temperature Above Normal Operational Range Most Severe Level 153 105 3 Amber Intake Manifold 1 Intake Manifold Air Temperature Sensor Circuit Temp Voltage Above Normal or Shorted to High Source 154 105 4 Amber Intake Manifold 1 Intake Manifold Air Temperature Sensor Circuit Temp Voltage Below Normal or Shorted to Low Source 155 105 0 Red Intake Manifold 1 Intake Manifold Air Temperature High Data Temp Valid but Above Normal Operational Range Most Severe Level 187 3510 4 Amber 5 Volts DC Supply Sensor Supply Voltage 2 Circuit Voltage Below Normal or Shorted to Low Source 193 520199 3 Amber Cruise Control Cruise Control Resistive Signal Circuit Voltage Above Normal or Shorted to High Source 194 520199 4 Amber Cruise Control Cruise Control Resistive Signal Circuit Voltage Below Normal or Shorted to Low Source 195 111 3 Amber Coolant Level Coolant Level Sensor Circuit Voltage Above Normal or Shorted to High Source 196 111 4 Amber Coolant Level
77. 3 mm G12 55A 18 5 18 75 in 469 9 476 7 mm Tighten the retract chain adjusting nut 4 until the proper distance F is obtained and proper access hole alignment 2 is obtained Torque the lock nuts to 100 Ib ft 135 Nm Re adjust the extend chains as needed 3 19 3 8 HOSE CARRIER ASSEMBLY REMOVAL INSTALLATION 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 1 Remove any attachment from the quick switch assembly Refer to the appropriate operation and safety manual Hose Carrier Assembly Removal Note Allow adequate room in front of the machine when removing and installing the hose carrier assembly 2 Park the machine on a hard level surface level the machine fully retract the boom level the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the engine cover Allow the system fluids to cool 5 Properly disconnect the battery MY2690 6 Loosen and remove both compression springs 1 from the hose take up weldment at the bottom of the first boom section 7 Label and disconnect the tilt and auxiliary hydraulic hoses attached to th
78. 3730 33600 420 570 78 9 0 8750 0 4620 41600 605 85 55 740 45 620 14 0 8750 0 5090 45800 60 910 _ 8 1 0000 06060 51500 860 1170 12 1 0000 0 6630 5970 95 1355 85 115 745 1015 290 12 1445 11 4 7 12 1 3 8 6 12 112 6 1 5000 14050 126500 3165 4305 2845 3870 2370 3225 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4660 2 4 G10 55A G12 55A General Information and Specifications 2 2 1 SAE Fastener Torque Chart Continued SOCKET HEAD CAP SCREWS Loctit DONE 271m Tensile Clamp Load Torque OR 4 Dry K 17 Vibra TITE 111 or 140 OR Precoat 858 K 0 15 K 0 1 0 Sq In N m IN LB N m 4 40 0 00604 0 00661 0 00909 _ Size Bolt Dia L 49 1 3E T1 1 8 omw oomo T 36 oi oo L 24 0190 oor 1 1 o1 0000 O L TL i4 0 0250 0018 12 4 14 313
79. 4 Amber Electric LiftPump for Fuel Priming Pump Control Signal Circuit Engine Fuel Voltage Below Normal or Shorted to Low Source 2292 611 16 Amber Fuel Inlet Meter Fuel Inlet Meter Device Data Valid but Above Device Normal Operational Range Moderately Severe Level 2293 611 18 Amber Fuel Inlet Meter Fuel Inlet Meter Device flow demand lower than Device expected Data Valid but Below Normal Operational Range Moderately Severe Level 2311 633 31 Amber Fuel Control Fueling Actuator 1 Circuit Error Condition 1 Exists G10 55A G12 55A 9 53 Electrical System Fault SPN FMI Lamp m Codes Codes Codes Color SPN Description Cummins Description 2321 190 2 None Engine Speed Engine Speed Position Sensor 1 Data Erratic Intermittent or Incorrect 2322 723 2 None Engine Speed Engine Speed Position Sensor 2 Data Sensor 2 Erratic Intermittent or Incorrect 2345 103 10 Amber Turbocharger 1 Turbocharger speed invalid rate of change Speed detected Abnormal Rate of Change 2346 2789 15 None System Diagnostic Turbocharger Turbine Inlet Temperature Code 1 Calculated Data Valid but Above Normal Operational Range Least Severe Level 2347 2790 15 None System Diagnostic Turbocharger Compressor Outlet Temperature Code 1 Calculated Data Valid but Above Normal Operational Range Least Seve
80. 5 Nm 5 Tighten capscrews to 34 Ib ft 46 Nm 6 Replace o rings and or tighten capscrews to 85 lb ft 115 Nm 7 Replace converter and or input shaft seal 8 Replace output shaft seal 9 Transmission may be under full Ensure transmission is at operating temperature 185 F 85 C and fill to upper mark on transmission dip stick 10 Replace housing as needed 6 10 G10 55A G12 55A Section 7 Contents PARAGRAPH TITLE PAGE 7 1 Introduction John 7 2 7 1 1 Disclaimer and 7 2 7 1 2 Engine Serial 7 2 7 1 3 Specifications and Maintenance Information 7 2 7 1 4 Component 7 3 7 2 Introduction 5 7 4 7 2 1 Disclaimer and 7 4 7 2 2 Engine Serial 7 4 7 2 3 Specifications and Maintenance Information 7 4 7 2 4 Component 7 5 7 3 Introduction Cummins 7 6 7 3 1 Disclaimer and 7 6 7 3 2 Engine Serial
81. 622 Nm 1500 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements G10 55A G12 55A 2 13 General Information and Specifications 2 3 7 Tires Note Standard wheel lug nut torque is 350 400 Ib ft 475 542 Nm Note Pressure for foam filled tires are for initial fill ONLY a G10 55A Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 65 psi 4 5 bar 14 00 x 24 G 2 L 2 Bias Ply Traction 12 Ply Foam Approx 720 Ib 327 kg 62 psi 4 3 bar Pneumatic 65 psi 4 5 bar 14 00 x 24 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 720 Ib 327 kg 62 psi 4 3 bar Pneumatic 70 psi 4 8 bar 14 00 x 24 G 2 L 2 Radial 1 Star Foam Approx 720 Ib 327 kg 70 psi 4 8 bar 14 00 x 24 Solid 1038 Ib 470 kg Pneumatic 65 psi 4 5 bar 17 50 x 25 G 2 L 2 Bias Ply Traction 12 Ply Foam Approx 785 Ib 356 kg 51 psi 3 5 bar Pneumatic 65 psi 4 5 bar 17 50 x 25 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 785 Ib 356 kg 51 psi 3 5 bar Pneumatic 70 psi 4 8 bar 17 50 x 25 G 2 L 2 Radial 1 Star Foam Approx 785 Ib 356 kg 73 psi 5 0 bar Pneumatic 76 psi 5 2 bar 400 75 28 Duraforce 16 Ply Foam Approx 570 Ib 259 kg 73 psi 5 0 bar b G12 55A Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 65 psi 4 5 bar 17 50 x
82. 78 3 30 mm gap between the boom sections 3 Install the previously removed wear pads spacers and shims on each side at the front of the first boom section 2 Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1 78 3 30 mm gap between the boom sections 4 Install the previously removed wear pads spacers and shims at the top front of the first boom section 3 Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1 78 3 30 mm gap between the boom sections 5 Re adjust the sling s and push the second third and fourth boom assembly the remainder of the way into the first boom section 3 15 11 Install both hose sheave covers 9 mounting e bolts as required 5 la 4 Len 590 N 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 Pull hose carrier from the rear as far as possible to access the hydraulic and if equipped the electrical connections If equipped connect the electrical cable 5 to the fitting on
83. CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED MY4680J G10 55A G12 55A 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 Torque Torque Loctite Torque Sio Loctite 262 242 or 2717 OR OR Area 2637 Vibra TITE 131 Vibra TITE 111 or 140 os 35 06 4 or 5 os 1420 616 6 874 7 so is 8 10 12 2 2 18 ms 25 26 1065 22 25 1320 24 3 27 3 30 3 5 33 3 5 36 42 as um j SE SR N NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED MVASSOH G10 55A G12 55A 2 7 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 H
84. Coolant Level Sensor Circuit Voltage Below Normal or Shorted to Low Source 197 111 18 Amber Coolant Level Coolant Level Data Valid but Below Normal Operational Range Moderately Severe Level 199 1661 4 Amber Engine Automatic Engine Automatic Start Lamp Driver Circuit Start Lamp Voltage Above Normal or Shorted to High Source 211 1484 31 None J1939 Error Additional Auxiliary Diagnostic Codes logged Condition Exists 9 44 G10 55A G12 55A Electrical System Fault SPN FMI Lamp E A E Codes Codes Codes Color SPN Description Cummins 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 Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 222 108 4 Amber Barometric Pressure Barometric Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 227 3510 3 Amber 5 Volts DC Supply Sensor Supply Voltage 2 Circuit Voltage Above Normal or Shorted to High Source 231 109 3 Amber Coolant Pressure Coolant Pressure Sensor Circuit Voltage
85. GVO dS T ju Md ADVIS 2 Eis WWdivads gt VISINIS zx SVENOS EHI z HL z h OND H3LJIHS 58 Ud s ER EJEN 2 9 ZA 105 SNVEL TOS UB yd 2 ux 7 Tavis 33 ds59md gt SX IOS SNVEL z TA IOS SNVEL SA TOS 2 ZA IOS SNVHL 2 TOS SNVEL 89 ips BER e E 38 G355md SN Teas f I PIENIN BHL U SIENOS gt 2 a z 8 5 51515165 ui Nd 21 E 5 2 3 3 8 lt 5 9 2 2 z slal z p L3IHS 105 SNVHI lt 105 SNVHI 2 s gt gt 2 SNVEL TOS SNVEL 2 9 2 5 5 Fle 5 z E 2 E COS Did AHS SIRS il KNIS INVI HNVO 8 n I E 0395119 48 exoma lt 8 8 9355119 Ua SAM 8 ITdOIS SNS 515 E ONS 5 ITIBVIS OF 8 IE E z 110 28
86. 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 Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 193 295 0407 Fax 55 193 295 1025 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland Phone 44 0 141 781 6700 Fax 44 0 141 773 1907 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Barcelona Spain Phone 34 93 772 4 700 Fax 34 93 771 1762 www jlg com JLG France SAS 2 1 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Europe B
87. Lift Lower Cylinder Cylinder Torque Specifications Head Nut CB Valve CB Cap Screw G10 55A Before S N 0160033659 550 600 lb ft 2125 2175 lb ft 45 50 lb ft 28 30 lb ft excluding 0160033452 745 813 Nm 2881 2949 Nm 54 61 Nm 38 41 Nm G10 55A S N 0160033659 thru 1600 2000 Ib ft 30 35 Ib ft 24 27 lb ft 0160035822 including 0160033452 2169 2711 Nm 40 47 32 36 Nm 755 923 lb ft 1600 2000 lb ft 30 35 lb ft 24 27 lb ft 910 55 S N 0160035822 amp After 1024 1251 Nm 2169 2711 Nm 40 47 32 36 G12 55A Before S N 0160033659 550 600 lb ft 2850 2900 lb ft 45 50 lb ft 28 30 lb ft excluding 0160033452 745 813 Nm 3864 3932 Nm 54 61 28 41 Nm G12 55A S N 0160033659 thru 1600 2000 b ft 45 50 Ib ft 24 27 Ib ft 0160035879 including 0160033452 2169 2711 Nm 54 61 32 36 Nm 755 923 lb ft 1600 2000 Ib ft 45 50 lb ft 24 27 lb ft 912 55 SIN 0160035879 amp After 1024 1251 Nm 2169 2711 Nm 54 61 Nm 32 36 Nm b Extend Retract Cylinder CB Valve CB Valve Large Small 500 550 lb ft 1325 1375 Ib ft 110 Ib ft 35 Ib ft 910 55 Before S N 0160033661 7 745 1796 1864 Nm 149 Nm 47 Nm G10 55A S N 0160033661 thru 1400 1700 Ib ft 110 Ib ft 33 Ib ft 0160035822 1796 1864 Nm 149 Nm 44 Nm 1400 1700 Ib ft 110 Ib ft 33 lb ft G10 55A S N 016003582
88. Not 05 Responding Properly or Out of Adjustment 1145 656 7 Amber Injector Cylinder Injector Cylinder 6 Mechanical System Not 06 Responding Properly or Out of Adjustment 1239 2623 3 Amber Accelerator Pedal Accelerator Pedal or Lever Position Sensor 2 Position Circuit Voltage Above Normal or Shorted to High Source G10 55A G12 55A 9 51 Electrical System Fault SPN FMI Lamp S Codes Codes Codes Color SPN Description Cummins Description 1241 2623 4 Amber Accelerator Pedal Accelerator Pedal or Lever Position Sensor 2 Position Circuit Voltage Below Normal or Shorted to Low Source 1242 91 2 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor 1 Position and 2 Data Erratic Intermittent or Incorrect 1256 1563 2 Amber Control Module Control Module Identification Input State Error Identification Input Data Erratic Intermittent or Incorrect State 1257 1563 2 Red Control Module Control Module Identification Input State Error Identification Input Data Erratic Intermittent or Incorrect State 1852 97 16 Amber Water in Fuel Water in Fuel Indicator Data Valid but Above Indicator Normal Operational Range Moderately Severe Level 1911 157 0 Amber Injector Metering Injector Metering Rail 1 Pressure Data Valid Rail but Above Normal Operational Range Most Severe Level 2111 52 3 Amber Coolant Temperature Coolant Temperature 2 Sensor C
89. Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 2 Open the engine cover Allow the system fluids to cool 3 Properly disconnect the battery G10 55A G12 55A Install a drive ratchet into the square hole in the serpentine belt tensioner bracket While lifting the automatic belt tensioner away from the belt remove the fan serpentine belt Note Record how the alternator is installed to ensure correct installation later 6 Label and disconnect the wire leads attached to the alternator Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine While supporting the alternator with one hand remove the upper longer mounting hardware from the upper alternator mount Remove the alternator from the machine Alternator Installation Position the alternator and align with the upper alternator mount on the engine bracket Insert the upper longer mounting hardware through the alternator mount Thread the longer capscrew into the alternator front mount DO NOT tighten completely at this time Align the lower alternator mount hole with the lower mounting bracket on the engine and insert the lower mounting capscrew Tighten the lower capscrew and upper capscrew securely Place a drive ratchet into the square hole on the serpentine belt tensioner bracket Apply pressure against the tensioner bracket an
90. Number The John Deere 4045HF275 serial number Is stamped on a plate which is secured to the engine block near the fuel injector pump Information contained in the serial number is required in correspondence with the engine manufacturer 7 1 3 Specifications and Maintenance Information For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Detailed John Deere engine service instructions covering disassembly inspection internal repair assembly adjustment and troubleshooting information are provided in the appropriate John Deere engine service manual For engine electrical related issues refer to the John Deere Engine Troubleshooting Manual P N 31200371 G10 55A G12 55A 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 THERMOSTAT TURBOCHARGER FUEL INJECTOR PUMP ENGINE CONTROL MODULE ECM MY1011 ALTERNATOR we STARTER IN LINE FUEL FILTER ne OIL FILTER MY4500 G10 55A G12 55A Engine 7 2 INTRODUCTION PERKINS 7 2 1 These instructions are written for worldwide u
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92. Sensor Circuit Voltage Above Indicator Normal or Shorted to High Source 429 97 4 Amber Water in Fuel Water in Fuel Sensor Circuit Voltage Below Indicator Normal or Shorted to Low Source 431 558 2 Amber Accelerator Pedal Accelerator Pedal or Lever Idle Validation Low Idle Switch Circuit Data Erratic Intermittent or Incorrect 432 558 13 Red Accelerator Pedal Accelerator Pedal or Lever Idle Validation Low Idle Switch Circuit Out of Calibration 435 100 2 Amber Engine Oil Pressure Oil Pressure Sensor Circuit Data Erratic Intermittent or Incorrect 441 168 18 Amber Electrical Potential Battery 1 Voltage Low Data Valid but Below Voltage Normal Operational Range Moderately Severe Level 9 48 G10 55A G12 55A Electrical System Fault SPN FMI Lamp E EE Codes Codes Codes Color SPN Description Cummins Description 442 168 16 Amber Electrical Potential Battery 1 Voltage High Data Valid but Above Voltage Normal Operational Range Moderately Severe Level 449 157 0 Red Injector Metering Fuel Pressure High Data Valid but Above Rail 1 Pressure Normal Operational Range Moderately Severe Level 451 157 3 Amber Injector Metering Injector Metering Rail 1 Pressure Sensor Rail 1 Pressure Circuit Voltage Above Normal or Shorted to High Source 452 157 4 Amber Injector Metering Injector Metering Rail 1 Pressure Sensor Rail 1 Pressure Cir
93. 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 d Move the joystick handle to the left activating the boom retract function The boom should RETRACT e Depress the left side of the switch optional to activate the tilt up function The attachment should TILT UP Depress the right side of the switch optional to activate the tilt down function The attachment should TILT DOWN 6 Close and secure the engine cover 4 3 5 Frame Sway Auxiliary and Outrigger Control Joysticks a Joystick 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 NEUTRAL position engage the parking brake and turn the engine OFF 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 Properly disconnect the battery 0960 4 Remove screws 8 securing the dash panel 9 to the cab Remove the dash panel 5 Remove any hardware securing the joystick to the cab 6 Label disconnect and cap the hydraulic fittings attached to the joystick 7 Remove the joystick from the cab 4 6 b Joystick Installation 1 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations 2 Install the bolts
94. and hoses MZ1460 Contact JLG Parts Department Toll Free at 1 877 554 5438 or 717 485 6472 for ordering information CHER 70000652 Dial iios E i0lbs Consult Factory 70000101 Digital 73 _ Consult Factory 70027911 01918 7166 _ Consult Factory 8 3 Hydraulic System n 8 3 1 When diagnosing trouble in the hydraulic system use the hydraulic testing information in Section 8 4 1 Hydraulic Pressures Pressure Checks and Adjustments 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 The test port is located at the top right corner of the main control valve Install a pressure gauge capable of measuring at least 1096 more pressure than that which the circuit being checked operates under 3 Start the engine Operate machine functions several times to allow hydraulic oil to reach operating temperature The hydraulic oil temperature should be between 100 120 F 38 49 C If a temperature gauge or thermometer is unavailable the hydraulic oil reservoir should be warm to the touch 4 Refer to Section 8 4 1 Hydraulic Pressures for testing procedures 5 Fully depress the accelerator
95. 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 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 Fa lo 4480 3 22 boom section 11 MY4470 5 Verify that 4 in 101 6 mm of slack 11 is present between the hose take up bracket 5 and the first hose clamp 12 Verify the hose take up bracket 5 is not bent and is at an 85 angle to the hose Note Replace both auxiliary hoses and or tilt hoses if the hoses are touching the bottom of the second boom section AND 4 in 101 6 mm of slack is present between the hose take up bracket and the first hose clamp 8 11 14 15 Refer to Section 3 8 3 Hose Carrier Assembly Installation step 13 and 14 for hose take up bracket adjustment Measure the slack 11 at the lowest point between the hose take up bracket 5 and the first hose clamp 12 The 4 in 101 6 mm measurement is from the bottom of the first boom section to the top of the hose If necessary loosen the hose clamp 12 pull the auxiliary hoses and or the tilt hoses tighten the hose clamp for additional clearance Replace the auxiliary hoses and or the tilt hoses if the proper slack 4 in 101 6 mm 1
96. connectors to the reservoir connectors Install the reservoir tank onto the mounting bracket Install the lock washers and nuts and secure Fill the washer fluid reservoir with washer fluid Properly connect the battery 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 Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 29 Electrical System 9 9 CAB HEATER AND FAN 9 9 1 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 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 MY1230 5 Remove the screws securing the right cab dash panel 5 6 Pull out the panel to gain access to the heater control electrical connections Disconnect the harnesses 7 Remove the heater control knobs 8 Remove the necessar
97. effects can be as follows Moisture Corrosive rusting reduces chain strength by pitting and cracking Temperature Low temperature reduces chain strength by embrittlement Going in and out of cold storage results in moisture from condensation Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time Abrasives Accelerated wearing and scoring of the articulating members of the chain pins an d plates with a corresponding reduction in chain strength Due to the inaccessibility of the bearing surfaces pin surfaces and plate apertures wear and scoring are not readily noticeable to the naked eye 3 25 Eds Boom Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain 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 It is therefore necessary to conduct frequent inspections until r
98. end pin Lower the lift lower cylinder onto the frame rails Repeat this step for the right side lift lower cylinder Support the compensation cylinder Remove the lock bolt and rod end pin Lower the compensation cylinder onto the frame rails Lower the boom to a level position and place a suitable support under the boom head Reposition the slings to each end of the boom Remove the bolt securing the boom pivot pin Pull out the boom pivot pin Lift the complete boom off machine and set on level ground or supports Complete Boom Installation Park the machine on a hard level surface place the transmission control lever in NEUTRAL engage G10 55A G12 55A the park brake chock the wheels and shut the engine OFF Using suitable slings balance the boom assembly lift and carefully guide the boom into place Align the frame pivot bore with the boom assembly pivot bore Install the boom pivot pin With the sling still in place install the compensation cylinder pins and bolts With the sling still in place install the rod end of the left lift lower cylinder pin and lock bolt Repeat for the right side lift lower cylinder Note Raising the boom up or down with the sling may be necessary so the boom compensation and lift lower cylinder bores can be aligned for easier pin installation Note Grease the boom pivot bore compensation cylinder rod ends lift lower cylinder rod end and pins before installing
99. extend retract cylinder rod mounting pin 18 24 Lower the front of the extend retract cylinder to a secured block on top of the frame Do Not use the engine hood for support G10 55A G12 55A MY3540 25 Remove the adjusting nut and lock nut 19 retract chain amp clevis 20 spring stop 21 and spring 22 Loosen bolts 23 and adjusting block 24 26 Properly disconnect the battery 27 At the rear of the boom remove both hose sheave covers 25 MY3420 28 Unbolt the hose carrier bracket 26 from the rear of the second boom section and the hose carrier 29 Pull the hose carrier 27 back to gain access to the tilt hose 28 and the auxiliary hose 29 connections 30 Disconnect the tilt hoses auxiliary hoses and if equipped the electrical connector at the rear of the hose carrier Label plug and cap all hydraulic connections to prevent dirt and debris from entering the hydraulic system 31 Push hose carrier 27 as far forward as possible Note Tag each wear pad spacer shim and hardware from each location Note the location of any grease fitting if equipped on each wear pad 3 7 aid Boom 32 Remove the top rear wear pads spacers shims and 3 5 2 Third amp Fourth Boom Section 33 34 35
100. faulty sender with a new part Engine Coolant Temperature Sender Installation and Testing Thread the engine coolant temperature sender into the engine block snugly then connect the sender connector to the wiring harness connector 2 Properly connect the battery 3 Check for proper coolant level G10 55A G12 55A 4 Start the engine allow it to reach operating temperature and observe the operator s instrument cluster for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine improper or low coolant obstructed or faulty radiator coolant pump loose fan belt defective instrument display etc Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 33 Electrical System 9 10 6 Air Manifold Temperature Sensor John Deere Air Manifold Temperature Sensor Removal 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool 4 Properly disconnect the battery Unplug the engine coolan
101. help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 1 If necessary install the park brake solenoid in its original orientation 9 31 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 Note If the transmission is not shifting properly the transmission shift control switch travel select lever wiring harness or transmission shift solenoids 9 should be checked in order to determine which component is defective Specific information to determine which travel position and corresponding component is not responding can be found in the detailed transmission service instructions covering repair disassembly reassembly and adjustment information are provided in the ZF Powershift Transmission 4WG 92 98 TSC Repair Manual JLG P N 31200241 and can be obtained by calling your local JLG dealer or ZF Service Center The transmission should be checked serviced and repaired only by experienced service technicians who a
102. hydraulic functions 7 Inspect the service brake valve and connections 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 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 9 Close and secure the engine cover 10 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 8 7 4 Service Brake Bleeding Carefully bleed the brake lines as soon as the brake valve is installed in the machine Air in the system will not allow the brakes to apply properly There are four brake bleeder located on the front axle two inner service brake bleeders and two outer park brake bleeders and two service brake bleeders on the rear axle Work with an assistant to perform this procedure 1 Place the travel select lever in N NEUTRAL engage the park brake and start the engine 8 18 0750 Remove the plastic from one service brake bleeder 6 Attach one end of a length of transparent tubing over the brake bleeder Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil The end of the tubing must be below the oi
103. hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 2 Transmission filled withincorrect 2 Drain transmission and fill to oil or oil contaminated correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 3 Pump suction pipe screen 3 Clean repair and or replace clogged suction pipe 4 Central shaft damaged 4 Replace central shaft 5 Pump worn or damaged 5 Repair or replace pump assembly 3 Low clutch pressure 1 Incorrect oil level 1 Fill transmission to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 2 Main pressure valve stuck open 2 Clean the valve spool and housing 3 Broken or worn coupling shaftor 3 Replace coupling and or o rings piston o rings 4 Pressure reducing valve stuck 4 Clean the valve spool and open housing 4 Lack of power 1 Park or service brake dragging 1 Refer to Section 8 4 Hydraulic Circuits 2 Low engine rpm causes 2 Adjust the engine rpm to converter stall specifications Refer to Engine Service Manual 3 Pump output pressure is low 3 Referto Section Note Contact the local distributor if internal transmission repair is required during the warranty period Problem 2 Low or no pump flow or pressure 4 Clutch discs worn or damaged 4 Replace clutch discs 5 Transmission overheating 5 Referto Section Note Contact the local distributor if internal
104. hydraulic system Remove the frame level and attachment tilt and auxiliary control joystick Refer to Section 4 3 5 Frame Sway Auxiliary and Outrigger Control Joysticks Label disconnect and cap all hydraulic hoses attached to the joystick Cap all fittings and openings to keep dirt and debris from entering the hydraulic system Label disconnect and cap all hydraulic hoses attached to the steering orbitrol valve Cap all fittings and openings to keep dirt and debris from entering the hydraulic system Label disconnect and cap all hydraulic hoses attached to the steering orbitrol valve Cap all fittings and openings to keep dirt and debris from entering the hydraulic system Label disconnect and cap all hydraulic hoses attached to the service brake valve Cap all fittings and openings to keep dirt and debris from entering the hydraulic system Push all the hydraulic hoses through the opening in the cab Disconnect the throttle cable from the throttle assembly Refer to Section 4 3 3 Throttle Pedal Disconnect the engine air filter and hydraulic oil reservoir breather from their brackets at the top of the cab Move the air filter and breather clear from the cab so they do not become damaged during cab removal Remove the fuel tank from the cab Refer to Section 7 6 2 Fuel Tank G10 55A G12 55A Cab and Covers a 19 G10 MY0610 Ope
105. immediately DO NOT attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system This condition damages the chain as well as increases frictional loading and should be corrected G10 55A G12 55A Cracked 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 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 Fatigue Cracking Fatigue cracks 9 are a result of repeated cyclic loading beyond MZ1467 the chain s endurance limit Cracking The LEO outside link plates 10 are particularly MZ1468 susceptible to stress corrosion cracking 10 Stress Corrosion Corrosion Fatigue Cracking Corrosion fatigue cracks are very similar to fatigue cracks in appearance Corrosion fatigue is the combined action of an aggressive environment and cyclic stress Other Modes of Failure Ultimate Strength Failure These types of failures are PM caused by overloads farin 11 excess of the design load MZ1469 Either fractured plates 11
106. in N NEUTRAL engage the parking brake switch level the boom 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 Properly disconnect the battery G10 55A G12 55A C i 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 0555555555555 555555555 MX0510 1 3 6 Remove tension from the chain by backing off the jam nut and adjusting nut 1 7 Remove the four bolts 2 from the chain adjustment block 8 Remove the chain from the clevis 3 at the block 9 Install a nylon tie wrap through the holes of the removed chain making a loop with a tie wrap and tie a rope to the loop 10 At the rear of the boom pull the chain to the rear to allow slack for removal 11 Remove the chain from the clevis and drop it free from the boom 12 Holding a rope at the front adjustment block carefully pull the chain out through the back of the boom 13 Untie the rope and leave it in place for reinstallation of th
107. lever in N NEUTRAL engage the park brake and shut the engine OFF Hydraulic Oil Reservoir Draining 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 Open the filler cap on the hydraulic oil reservoir Remove the drain plug on the side of the hydraulic oil reservoir 6 Transfer the used hydraulic oil into a suitable covered container and label as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the drain plug 7 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area G10 55A G12 55A n 1 Be sure the reservoir is clean and free of all debris Hydraulic Oil Reservoir Filling 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 8 5 3 Hydraulic Oil Reservoir Removal Installation If itis determined that the hydraulic oil reservoir must be removed the hydraulic oil must be drained before the reservoir is removed Always dispose of hydraulic oil properly a Reservoir Removal 1 Park the machine on a firm
108. 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 4 Secure the pump to the transmission with the four bolts and washers Torque as required 5 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations 6 Fill the hydraulic reservoir Refer to Section 8 5 2 Hydraulic Oil Reservoir Filling 7 Prime the pump by filling the case drain port with fresh filtered hydraulic oil from a clean container before installing the case drain connector and hose 8 Check all routing of hoses and tubing for sharp bends or interference with any rotating members tube and hose clamps must be tight 9 Remove the 10 amp fuse from location F3 in power distribution unit located in the engine compartment This will allow the engine to crank but not start while air is worked out of the new pump 10 Connect a hose to the P1 port on the pump Direct the open end of the hose into a fluid drip pan 11 Properly connect the battery 12 Turn the machine ignition switch to START and back OFF in 3 to 5 second intervals Monitor the open end of the drain hose for a constant f
109. pedal if required Place and hold the joystick in the position needed to operate the particular machine function being checked Continue holding the joystick in position until pressure readings are taken 6 Check the pressure gauge reading It should read as specified in the Pressure Readings column of the charts found in Section 8 4 1 Hydraulic Pressures If the reading is not as specified turn the engine OFF and check other components in the system Verify that all related hydraulic components and electrical switches sensors solenoids etc are operating correctly 7 Adjust the relief valve by turning the adjustment screw Turning clockwise will increase the pressure turning the screw counterclockwise will decrease the pressure 8 Start the engine and check the pressure again Turn the engine OFF If there is pressure reading in the gauge bleed it off then disconnect or remove the pressure gauge from the machine 8 4 8 4 HYDRAULIC CIRCUITS This section covers the hydraulic circuits and includes listings for all hydraulic function pressures where and how to check those pressures and a hydraulic schematic Electrical and hydraulic functions are often related Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit Always check the following before beginning to troubleshoot a circuit that is not functioning correctly 1 Check the hydraulic oi
110. position engage the parking brake and shut the engine OFF 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 5 Slowly turn the radiator cap to the first stop and allow any pressure to escape Remove the radiator cap 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain plug and slowly remove to allow the coolant to drain Transfer the coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Replace the radiator drain plug TYPICAL A THERMOSTAT 3 7 Disconnect the engine water temperature sender 1 if connected to the thermostat housing 8 Remove the two capscrews 2 securing the thermostat housing 3 to the engine 9 Remove the thermostat housing old gasket and thermostat Clean all gasket surfaces DO NOT let any debris into the thermostat opening Note ALWAYS use the correct thermostat and install a new gasket NEVER operate the engine without a thermostat or engine damage will result G10 55A G12 55A 7 4 3 Thermostat Installation Install the engine thermostat thermostat gasket and thermostat housing Secure with the two capscrews and torque as required Connect the e
111. sections 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 6 Shims may be required to maintain a 0 070 0 130 in 1 78 3 30 mm gap at the top rear of the third boom section c 5 6 H c zm H 6 MY3630 7 Install the previously removed extend chain assemblies and clevises 5 at the top rear of the third boom section Allow 0 250 in 6 35 mm between the end of the clevis 5 and the face of the lock nut 6 Torque lock nut to 100 Ib ft 135 Nm 3 5 8 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 Clean and lubricate the bottom of the fourth boom section where the wear pads of the third boom section contact the fourth boom section 2 Place the sling or two slings for better stability around the fourth boom section and slowly insert the fourth boom section into the third boom section being careful not to damage any surrounding components G10 55A G12 55A N VU VU
112. select lever in third gear forward 4 Smoothly and controllably depress the throttle pedal Note Do Not hold the accelerator pedal in the fully depressed position for more than ten seconds Damage to the power train could occur 5 Smoothly and controllably fully release the throttle pedal 6 The machine should remain stationary during the test 7 the machine does not remain stationary during this test contact the local distributor for proper service 8 Engage the park brake place the travel select lever in N NEUTRAL lower the boom and shut engine OFF 8 7 6 Park Brake Test This procedure is used in order to determine if the parking 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 ata 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 Conduct the following parking brake test on a dry level surface clear of any personnel and or obstacles 1 Place the travel select lever in N NEUTRAL engage the park brake and start the engine 2 Raise the boom to a travel position 3 Depress the service brake disengage and place the travel select lever in first gear forward G10 55A G12 55A 4 Smoothly and controllably release the service brake 5 Smoothly and c
113. set screw G10 55A G12 55A 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 Carefully insert the cylinder rod assembly into the cylinder barrel 7 Screw the head gland into the cylinder barrel and tighten with a spanner wrench Refer to Section 8 8 5 Cylinder Torque Specifications for torque specifications for the head gland 8 If applicable install new counter balance valve into block on the cylinder barrel d General Cylinder Installation 1 Grease the bushings at the ends of the hydraulic cylinder Using an appropriate sling lift the cylinder into it s mounting position 2 Align cylinder bushing and install pin lock bolt or retaining clip 3 Connect the hydraulic hoses in relation to the labels or markings made during removal 4 Before starting the machine check fluid level of the hydraulic fluid reservoir and if necessary fill to full mark with hydraulic oil 5 Properly connect the battery 6 Start the machine and run
114. switch d 1 2 Switch Installation Connect the switch to the cab harness connector Position the switch over the rectangular switch bezel and snap into position Properly connect the battery Start the machine and check the replaced switch for proper function 5 Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A 9 39 Electrical System 913 TROUBLESHOOTING JOHN DEERE 9 13 1 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 Engine Fault Codes Retrieval 2 Turn the ignition switch to 3 Push down and hold the Reset button on the dash for 3 5 seconds The fault lamp will begin to flash a code number The light will flash the first digit then pause for a short time and then flash the second digit If there are active codes the system will first flash code 32 If there are no active codes the system will flash code 88 The system will then flash code 33 if there are any stored fault codes If there are no stored codes the system will flash code 88 4 Once the code is retrieved turn the ignition OFF Note When the engine sensor inputs exceed normal operating ranges the ECU will derate the amount of fuel that is d
115. teeth on the flywheel can also prevent the starter from cranking the engine If the starter only clicks it may indicate that the battery is discharged or that there is a loose or corroded battery cable connection Check the battery state of charge and battery condition first then check the cables and cable connections For additional information on the starting circuit refer to Section 9 5 Electrical System Schematics Starter Removal Remove the starter only if it fails To remove the starter 1 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 2 Open the engine cover Properly disconnect the battery Remove the wires from the solenoid stud Remove the positive battery cable from the starter Label and disconnect the wire from the starter solenoid housing stud Record how the wires are installed to ensure correct installation later Loosen but DO NOT remove the three fasteners securing the starter to the flywheel housing Support the starter securely as it is relatively heavy and will fall if not supported Support the starter and remove the fasteners securing the starter to the engine Remove the negative ground cable from its starter mounting bolt Remove the starter from the machine Starter Installation Position the starter in its mounting opening on the flywheel housing Positio
116. the hose carrier MY3420 Remove any caps and plugs from the tilt and auxiliary hoses at the rear of the boom assembly Connect and tighten the tilt 6 and auxiliary hoses 7 to their proper fitting locations on the hose carrier Torque as required Install the hose carrier bracket 8 at the rear of the third boom section and the hose carrier Torque mounting bolts as required 3 16 MY3440 12 Connect the fourth boom section extend chain 10 to the clevis at the top front of the third boom section and adjust to the previously measured setting Do Not tighten the lock nut at this time 13 Connect the third boom section extend chains 11 to the clevises at the top front of the second boom section and adjust to the previously measured setting Do Not tighten the lock nut at this time 14 Grease all wear pad at the rear of the boom using the zerk fittings 15 Refer to Section 3 7 Boom Section Separation Adjustment for proper boom section adjustments 3 6 EXTEND RETRACT CHAIN REMOVAL INSTALLATION 3 6 1 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 the retract chain from the third to first boom sections 1 Park the machine on level ground Place the transmission control lever
117. the previously labeled heater hoses to their appropriate locations 4 Connect the previously labeled air conditioning hoses to their appropriate locations Install the seat riser weldment Install the front plate to the seat riser weldment Install the cab seat ONDA Fill the cooling system completely with coolant allowing time for the coolant to fill the engine block The cooling system capacity is listed in Section 2 4 Fluid and Lubricant Capacities 9 Properly connect the battery 4 7 Cab and Covers a 4 8 CAB REMOVAL A 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 If modification damage a cracked weld and or fatigued metal is discovered replace the cab Contact the local distributor with any questions about the suitability or condition of a cab Note Remove and label cab components as needed before removing the cab from the machine Label disconnect and cap hydraulic hoses Transfer cab parts to the replacement cab after the replacement cab is secure
118. the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Properly disconnect the battery Remove the inclinometer switch protective cover 9 36 0 MY1311 Unplug and label the inclinometer switch connector 9 from the wiring harness connector Remove the hardware securing the inclinometer Switch 10 to the machine frame Inclinometer Switch Installation Install the inclinometer switch to the machine frame with the previously used hardware Connect the previously labeled wires to the inclinometer switch Install the inclinometer switch protective cover Properly connect the battery Close and secure the engine cover Start the engine Fully retract and level the boom and level the frame Locate a 12 curb and drive the left front and left rear tires onto the curb Sway the machine to the right When the frame is out of level by 15 the machine will automatically sway back to 14 7 Repeat step 7 for the right side of the machine Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A Electrical System 9 10 10 Front and Rear Axle Proximity Sensors The sensors used on each axle allow the ste
119. tire and wheel assembly 5 10 The wheel and tire assemblies must be installed with the directional tread pattern arrows 5 facing in the direc tion of forward travel 5 5 1 Removing Wheel and Tire Assembly from Machine 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed 4 Place a suitable jack under the axle pad closest to the wheel being removed Raise the machine and position a suitable support beneath the axle Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly 5 Lower the machine onto the support 6 Remove lug nuts and lug washers in an alternating pattern 7 Remove the wheel and tire assembly from the machine G10 55A G12 55A Axles Drive Shafts Wheels and Tires hs 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 Install tires onto wheels to rotate in proper direction 460 1 Posit
120. to Section 9 5 Electrical System Schematics and Section 9 11 Display Monitor and Gauges The housing of the steer select valve is not serviceable and must be replaced if defective a Steer Select Manifold and Valve 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 Label disconnect and cap the hydraulic hoses and the electrical plugs connected to the steering select valve 6 Remove the bolts holding the steer select valve to the mounting plate on the frame 7 Remove the steer select manifold with the attached steer select valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine 8 20 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 3 Remove the solenoid valves and cartridges from the steer select housing 4 Clean all components with a suitable cleaner
121. transmission repair is required during the warranty period Problem 5 Transmission overheating oil above 248 F 120 C 6 8 G10 55A G12 55A Transmission 6 Problem Cause Remedy 5 Transmission overheating oil above 248 F 120 C 1 Low oil level 2 Clogged radiator 3 Transmission filled with incorrect oil or oil contaminated 4 Excessive roading 5 Restriction in oil cooler hoses 6 Pump worn or damaged 7 Engine thermostat stuck 1 Fill transmission to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 2 Remove debris from the radiator 3 Drain transmission and fill to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 4 Stop and idle the engine 5 Replace cooler hoses 6 Repair or replace pump assembly 7 Replace engine thermostat Refer to Section 7 4 2 Thermostat Replacement 6 Grinding or clunking noise from transmission 1 Oil level too low 2 Transmission filled with incorrect oil 3 Incorrect clutch engagement 4 Internal damage 5 Broken diaphragm torque convertor 6 Loose diaphragm torque convertor mounting capscrews 1 Fill oil to correct level Refer to Section 2 4 Fluid and Lubricant Capacities 2 Repair or replace parts as needed 3 Drain transmission and f
122. wheel before attempting to perform any service or maintenance Remove key and disconnect battery leads 1 5 SAFETY INFORMATION To avoid possible death or injury carefully read understand and comply with all safety messages In the event of an accident know where to obtain medical assistance and how to use a first aid kit and fire extinguisher fire suppression system Keep emergency telephone numbers fire department ambulance rescue squad paramedics police department etc nearby If working alone check with another person routinely to help assure personal safety 1 5 1 Safety Alert System and Signal Words DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury G10 55A G12 55A 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 safe
123. 0A 9 18 G10 55A G12 55A Electrical System Power Unit Schematic John Deere 9 5 10 NOISSINSNVH L SA lea N93 ANION 3433A a NN e el e Ejs z a VVVVVVVVVVVVVVVVVVVVVVVVVVVVVV 55548556 Vv BS555t88z28892220R8mHg90QOBRSERX RE 1 M Im sm oos solo zzz SEE 5559066 996 assa EISE oe Jese manas eS zo s ses ima m3 lola ma ma SP 399895 d9s a gs zz 2 zz 2 25 zz ga B B E
124. 1 Check the 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 the entire transmission cooling system 4 Thoroughly clean transmission filter screens and cases and replace transmission filter elements 5 Reassemble all components and fill the transmission with clean fresh hydraulic oil through the dipstick tube opening 5 Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation amp Safety Manual DO NOT overfill Reinstall the dipstick when finished 6 5 6 Transmission 10 6 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 Run the engine for two minutes at idle to help prime the torque converter and the transmission oil lines Recheck the level of the fluid in the transmission with the engine running at idle Add hydraulic oil as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick Recheck the oil level when it reaches operating temperature 180 200 F 83 94 C Recheck all drain plugs lines connections etc for leaks and tighten where necessary 65 TORQUE CONVERTOR DIAPHRAGM 6 5 1 Torque Convertor Diaphragm Removal 1 Park t
125. 1 cannot be achieved Start the machine raise the boom to level cycle the extend retract cylinder fully extend the boom 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 Retract the boom and shut engine OFF Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A C e 3 9 QUICK SWITCH ASSEMBLY 3 9 1 Quick Switch Removal Before S N 0160037689 3 9 1 G10 MY5080 Remove the lock bolt 1 holding the tilt cylinder rod end pin 2 to the quick switch assembly 3 Remove the Tilt Cylinder pin Support the quick switch assembly 3 Remove the capscrew 4 and locknut 5 securing the head pin 6 to the boom head 7 Inspect the 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 the pin must be replaced 2 Quick Switch Installation Assemble the quick switch assembly 3 to the boom head 7 Line up the quick switch between the mounts on the boom head The quick switch should be centered in the boom head Coat the quick switch head pin 6 with an anti seize compound Insert the quick switch head pin through the quick switch and boom head Secure with th
126. 12 55A 9 25 Electrical System 9 7 ENGINE START CIRCUIT 9 7 1 Starter MY4600 The starter 1 is located on the left side of the engine the right side of the machine John Deere The starter 1 is located on the right side of the engine the right side of the machine Perkins amp Cummins a Testing the Starter on the Engine If the starter does not engage when the ignition key switch is turned check the following 1 The main fuse may be blown requiring replacement Check for the cause of the blown fuse 2 There may be a defect in the ignition key switch ignition wiring or starter solenoid 3 Check battery condition Clean the battery posts and the connectors at each end of the battery cables 4 Check for broken wiring and damaged insulation on the wiring Replace all broken or damaged wiring 5 Check all connections at the starter solenoid key switch and wiring harness plugs Clean and tighten all connections 6 Ifthe starter still does not operate after these checks have been performed check the starting circuit b Starter Circuit Checks 1 Check wires and connections for looseness corrosion damage etc 9 26 whirring noise is heard the engine does 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
127. 18 Sq In 4 0 00604 6 8 0 1900 0 02000 1 4 __ __ ___ 0 2500 0 0318 2860 129 5 J 0 2500 0 0364 3280 148 J Sq In 5 16 lU FT LB FT LB N m FT LB N m 0 3125 0 0524 4720 20 25 20 25 0 3125 0 0580 5220 25 35 20 25 3 8 0 3750 0 0775 7000 45 6 40 55 35 50 0 3750 0 0878 7900 45 60 35 50 716 0 4375 0 1063 9550 65 90 50 70 0 4375 0 1187 10700 80 10 70 95 60 80 1 2 0 5000 0 1419 12750 95 130 80 110 0 5000 0 1599 14400 110 150 90 120 9 16 5 8 T 3 4 10 7 8 0 8750 0 5090 45800 600 815 500 680 1 8 10000 0 6060 51500 1170 775 1055 645 875 1 0000 0 6630 59700 1355 895 1215 745 1015 11 8 1 1250 0 7630 68700 1290 1755 1160 1580 965 1310 1 1250 0 8560 77000 1445 1965 1300 1770 1085 1475 11 4 1 2500 0 9690 87200 1815 2470 1635 2225 1365 1855 1 2500 1 0730 96600 2015 2740 1810 2460 1510 2055 13 8 6 13750 1 1550 104000 2385 3245 2145 2915 1785 2430 1 3750 1 3150 118100 2705 3680 2435 3310 2030 2760 11 2 6 15000 1 4050 126500 3165 4305 2845 3870 2370 3225 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR
128. 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 4 Install the muffler 4 to the exhaust pipe 6 5 Install the tail pipe 10 to the muffler 4 6 Install the clamps 3 securing the tail pipe muffler exhaust pipe to the frame mounted brackets 7 Adjust the muffler exhaust and tail pipes for proper clearance then tighten all clamps 8 Install the exhaust heat shield 2 9 Install the muffler heat shield 1 10 Properly connect the battery 11 Start engine and check for exhaust leaks at all exhaust connections Adjust as needed 12 Close and secure the engine cover 13 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 8 AIR CLEANER ASSEMBLY A WARNING NEVER run the engine with only the inner safety element installed Note Refer to the appropriate Operation amp Safety Manual for your machine for the correct element change procedure 7 8 1 Air Cleaner Assembly Removal John Deere amp Perkins 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 NEUTRAL position engage the parking brake and shut the engine OFF 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 th
129. 2 amp After E e Nm G12 55A Before S N 0160033659 500 550 lb ft 1325 1375 lb ft 11015 8 149 35 lb ft 47 excluding 0160033452 678 745 Nm 1796 1864 Nm Nm Nm G12 55A S N 0160033659 thru 1400 1700 Ib ft 110 lb ft 33 lb ft 0160035879 including 0160033452 1796 1864 Nm 149 Nm 44 Nm 1400 1700 Ib ft 110 lb ft 33 lb ft G12 55A S N 0160035879 amp After 1140 8 24 G10 55A G12 55A Hydraulic System Tilt Cylinder Head Nut CB Valve 10 55 Before S N 0160033661 550 600 Ib ft 745 813 Nm 2050 2100 6 2779 2847 Nm 44 lb ft 60 Nm G10 55A S N 0160033661 thru 2200 2400 Ib ft 44 lb ft 60 Nm 0160035822 2982 3254 Nm G10 55A S N 0160035822 thru 2200 2400 Ib ft 0160037689 2982 3254 Nm a 500 600 Ib ft 2200 2500 Ib ft G10 55A S N 0160037689 amp After 2982 3389 Nm 40 45 lb ft 54 61 Nm G12 55A Before S N 0160033659 550 600 lb ft 2250 2300 Ib ft excluding 0160033452 745 813 Nm 3050 3118 Nm 44 Ib ft 60 Nm G12 55A S N 0160033659 thru 0160035879 including 0160033452 2400 2600 Ib ft 3254 3525 Nm 44 lb ft 60 Nm G12 55A S N 0160035879 thru 0160037689 2400 2600 Ib ft 3254 3525 Nm 44 lb ft 60 Nm G12 55A S N 0160037689 amp After 500 600 Ib ft 678 813 Nm 2200 2500 lb ft 2982 3389 Nm 4045 lb ft 54 61 Nm Compensation Cylinder
130. 25 G 2 L 2 Bias Ply Traction 12 Ply Foam Approx 785 Ib 356 kg 51 psi 3 5 bar Pneumatic 65 psi 4 5 bar 17 50 x 25 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 785 Ib 356 kg 51 psi 3 5 bar Pneumatic 70 psi 4 8 bar 17 50 x 25 G 2 L 2 Radial 1 Star Foam Approx 785 Ib 356 kg 73 psi 5 0 bar Pneumatic 76 psi 5 2 bar 400 75 28 Duraforce 16 Ply Foam Approx 570 Ib 259 kg 73 psi 5 0 bar G10 55A G12 55A 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 7 quarts 6 5 liters Cummins 13 5 quarts 12 8 liters Type of Oil 0 to 104 F 20 to 409 C 15W 40 CH 40 to 0 F 40 to 20 C OW 40 CH Fuel Tank Capacity 38 gallons 144 liters Type of Fuel 0 to 104 F 20 to 40 C 2 Diesel 40 to 0 F 40 to 20 C 1 Diesel Anti Gel Fluid 40 to 0 F 40 to 20 C 16 oz 0 5 liters Cooling System System Capacity John Deere 20 5 quarts 19 4 liters Perkins 22 25 quarts 21 liters Cummins No Heater 22 8 quarts 21 6 liters With Heater 24 3 quart 23 liters Overflow Bottle Capacity Before S N 0160039451 excluding 0160039394 amp 0160039397 3 quarts 2 8 liters
131. 3 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 1569 31 Fuel Derate 69 110 0 Engine Coolant Temperature High Most Severe 71 1076 0 Pump Control Valve Closure Too Long 72 1076 1 Pump Control Valve Closure Too Short 73 1076 5 Pump Solenoid Circuit Open 74 1076 6 Pump Solenoid Circuit Severely Shorted 75 1076 7 Pump Control Valve Closure Not Detected 76 1076 10 Pump Solenoid Circuit Moderately Shorted 77 1076 3 Pump Solenoid Current High 78 200 13 Security Violation 79 2000 6 Internal ECU Error 81 174 16 Fuel Temperature Moderately High 82 1110 31 Engine Protection Shutdown 83 970 31 Auxiliary Engine Shutdown Switch Active 84 158 17 ECU Power Down Error 971 31 External Derate Switch Active 88 N A N A Signifies No Fault Codes Are In Buffer G10 55A G12 55A 9 41 Electrical System 9 14 ENGINE INDICATOR LAMPS PERKINS SG Lamp State Lamp Indication Engine State Lamp Lamp ON ON Bulb Check When the ignition is turned on the Key on but engine has EMS shall illuminate each bulb for yet to be cranked 2 seconds and extinguish them afterwards OFF OFF No Faults Present With both lamps off whilst engine is Engine is running with no running then are
132. 36 29 28 28 30 37 38 39 40 41 3 8 hardware 30 from the rear of the second boom section Remove the left or right side rear wear pad spacer shims and hardware 31 from the rear of the second boom section Pull each boom section slightly forward to relieve the tension in retract chain 32 Remove the snap rings and pin connecting the rear retract chain 32 from the chain clevis at the rear of the boom Allow chain to hang out over the rear of the boom Place a sling around the second boom section With a suitable lifting device slowly pull the second third and fourth boom sections approximately 25 out of the first boom section MY4140 With the second third and fourth boom section still connected to a suitable lifting device remove all wear pads spacers shims and hardware 28 from the front sides of the first boom section Remove both wear pads spacers shims blocks and hardware 29 from the front top of the first boom section Remove both wear pads spacers shims and hardware 30 from the front bottom of the first boom section Adjust sling s around the second boom section to help balance the second third and fourth boom sections Remove the remainder of the second third and fourth boom sections from the first boom section and set on suitable supports Removal
133. 4 from the front sides of the second boom section 8 Remove both wear pads spacers shims blocks and hardware 5 from the front top of the second boom section 9 Remove both wear pads spacers shims and hardware 6 from the front bottom of the second boom section 10 Loosen and remove the wear pad support plate 7 from the bottom front of the second boom section 11 Adjust sling s around the third boom section to help balance the third and fourth boom sections 12 Remove the remainder of the third and fourth boom sections from the second boom section and set on suitable supports G10 55A G12 55A 3 5 3 1 Fourth Boom Section Removal Place a sling around the fourth boom section and slowly pull the fourth boom section approximately 25 out of the third boom section Lower the fourth section boom head onto a suitable support 9 Al ral 9 8 s8 8 8 ee 510 With the fourth boom section still connected to suitable lifting device remove all wear pads spacers shims and hardware 8 from the front sides of the third boom section Remove top and bottom front wear pads shims and blocks 9 from the third boom section Loosen and remove the wear pad support plate 10 from the bottom front of the third boom section
134. 5 1 1 lt 4 zg E B 3 1 ale 3 o UU 1 2 2989 oe Ee e 83 3 5 HE CHASSIS HARNESS i E nues 1 1 Er ETT T MONE JAAAAAA A AAAAAAAAAAAAAAAAAAAA A 1234567 8 91011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 123456 7 8 910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 vvvv VVVVVVVV AAAAAA AAAAAAAAAAAAAAAAAAAA par 88 E n EE TRAN BRK PWR REVERSE B E i 8 gt 6 lt 7 1 T m ip Nas BATTERY 4 POSITIVE CABLE KEY IGN PARK BRAKE 87984321 TO STARTER T ALTERNATOR H WAIT TO START u STONERIDGE RED 18 GAGXL i 5 GAUGE 5 n TRANS TMP WRN EE i RED 18 GAGXL n sm L ENG WARN g E RED 18GAGXL A Sy 8 83242 5 2 ig g zs ENG STOP E Ela RED 18 GAGXL WARN LIGHT REVERSE iB TEST RELAY RELAY 1 gt gt ta gt gt n HOBBS 1 ORG 18 GA GXL gt i ORG 18 GAGXL 5 WHT 18 GA GXL gt gt MANIDASHPANEL I MY5050 G10 55A G
135. 55A G12 55A Engine 14 15 16 17 18 19 20 21 22 23 Remove the exhaust pipe from the exhaust manifold Refer to Section 7 7 1 Exhaust System Removal Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe Remove the air cleaner tube assembly Refer to Section 7 8 1 Air Cleaner Assembly Removal John Deere amp Perkins or Section 7 8 3 Air Cleaner Assembly Removal Cummins Remove the access plug from bottom of the engine bell housing This will allow access to remove the bolts holding the torque convertor diaphragm to the engine flywheel Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts to be accessed Remove them one at atime Secure the engine with a lifting strap or chain from the appropriate lifting points 1 Use a suitable hoist or overhead crane Place a support or jack under the transmission to hold the transmission in place while engine is being removed Remove the bolts and washer securing the engine mounts Remove the ten bolts holding the transmission to the engine Slightly lift and pull the engine out of the machine Have an assistant ensure that the engine clears all frame components during removal Place engine on a flat level surface G10 55A G12 55A 7 9 2 1 Engine Installation Secure the engine with a lifting strap or chain from
136. 7 1 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 Exhaust System Removal 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 and the exhaust system to cool 4 Properly disconnect the battery iud E 8 w d T 3 73 22 9s Ew gt 1 um Ec je a MY4240 e Remove the muffler heat shield 1 Remove the exhaust heat shield 2 N Loosen and remove both clamps 3 securing the muffler 4 to the frame mounted brackets Remove the muffler 8 Loosen and remove the clamp 5 securing the exhaust pipe 6 to the frame at the bottom rear corner of the engine pod Remove the exhaust pipe Note Removal of the turbo charger heat shields may be required to access exhaust pipe bolts 9 Disconnect and remove the three bolts 7 securing the exhaust pipe flex pipe 8 to the turbo charger Remove the exhaust pipe flex pipe from under machine G10 55A G12 55A 7 7 2 Note Keep all clamps loosened until entire exhaust system is in place Exhaust System Installation 1 Install the exhaust pipe flex pipe 8 with a new seal 9 to the turbo charger
137. 7 14 7 9 Engine 7 14 7 9 1 Engine 7 14 7 9 2 Engine Installation nee dae ee eee ERES 7 15 7 10 Troubleshooting 7 17 G10 55A G12 55A 7 1 Engine O 7 1 INTRODUCTION JOHN DEERE 7 1 1 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 Disclaimer and Scope Note These instructions cover only the routine maintenance removal installation and troubleshooting of the engine Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis repair and component replacement A gradual running in break in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F 60 C Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds DO NOT apply an overload to the engine 7 2 7 1 2 Engine Serial
138. 8 GA GXL atv N GAN YELLOW 12346078 120 OHM CAN TERMINATOR MY4570A G10 55A G12 55A Electrical System 9 5 4 G10 55A G12 55A WINDSHIELD Options Schematic John Deere Perkins
139. A 8 10 Hydraulic System 8 4 3 Hydraulic Schematic Continued S N 0160037877 amp After 8 11 l al gl fal Tu xnv AVMS WO 1431 ALIHOlHd x 1 k movo ITNI pG lt y y x Y x 3 E E Ic E EJ x i I I tore i k
140. Above Normal or Shorted to High Source 232 109 4 Amber Coolant Pressure Coolant Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 233 109 18 Amber Coolant Pressure Coolant Pressure Data Valid but Below Normal Operational Range Moderately Severe Level 234 190 0 Red Engine Speed Engine Speed High Data Valid but Above Normal Operational Range Most Severe Level 235 111 1 Red Coolant Level Coolant Level Low Data Valid but Below Normal Operational Range Most Severe Level 237 644 2 Amber External Speed Input External Speed Input Multiple Unit Synchronization Data Erratic Intermittent or Incorrect 238 3511 4 Amber System Diagnostic Sensor Supply Voltage 3 Circuit Voltage code 1 Below Normal or Shorted to Low Source 239 3511 3 Amber System Diagnostic Sensor Supply Voltage 3 Circuit Voltage code 2 Above Normal or Shorted to High Source 241 84 2 Amber Wheel based Vehicle Vehicle Speed Sensor Circuit Data Erratic Speed Intermittent or Incorrect 242 84 10 Amber Wheel based Vehicle Vehicle Speed Sensor Circuit tampering has Speed 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 G10 55A G12 55A 9 45 Electrical System Fault SPN FMI Lamp Codes Codes Codes Color SPN Description Cummins
141. Circuits 3 Faulty lift lower cylinder 3 Repair cylinder Refer toSection 8 8 Hydraulic Cylinders 4 Seized boom pivot pin bearing 4 Replace bearing 7 Excessive Lift Lower cylinder 1 Insufficient lubrication 1 Lubricate at regular intervals pivot pin noise and or wear Refer to Section 2 5 Service and Maintenance Schedules Replace worn pins as needed Refer to Section 8 8 Hydraulic Cylinders 2 Worn self aligning bushing s 2 Replace bushing s and lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules G10 55A G12 55A 3 31 gt Boom N D i Problem Cause Remedy 8 Rapid boom pad wear 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 2 Reduce cycle times loads 3 Contaminated corroded or 3 Remove contamination and or rusted wear pad sliding corrosion from wear pad sliding surfaces surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s 4 Operating in extremely dusty 4 Clean equipment frequently abrasive conditions 9 Auxiliary hydraulics will not 1 Auxiliary hydraulic system not 1 Refer to Section 8 4 Hydraulic operate operating properly Circuits 10 Excessive chain wear 1 Improper chain adjustment 1 Adjust to correct tension R
142. Description 245 647 4 Amber Fan Clutch Output Fan Control Circuit Voltage Below Normal or Device Driver Shorted to Low Source 249 171 3 Amber Ambient Air Ambient Air Temperature Sensor Circuit Temperature Voltage Above Normal or Shorted to High Source 256 171 4 Amber Ambient Air Ambient Air Temperature Sensor Circuit Temperature Voltage Below Normal or Shorted to Low Source 261 174 16 Amber Fuel Temperature Engine Fuel Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 263 174 3 Amber Fuel Temperature AEB15 60 Page 149 of 157 Engine Fuel Temperature Sensor 1 Circuit Voltage Above Normal or Shorted to High Source 265 174 4 Amber Fuel Temperature Engine Fuel Temperature Sensor 1 Circuit Voltage Below Normal or Shorted to Low Source 268 94 2 Amber Fuel Delivery Fuel Pressure Sensor Circuit Data Erratic Pressure Intermittent or Incorrect 271 1347 4 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit Pressurizing Voltage Below Normal or Shorted to Low Assembly 1 Source 272 1347 3 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit Pressurizing Voltage Above Normal or Shorted to High Assembly 1 Source 281 1347 7 Amber Fuel Pump High Fuel Pressure Solenoid Valve 1 Pressurizing Mechanical System Not Responding Properly Assembly 1 or Out of Adjustment 284 1043 4 Amber Internal Sensor Engine Speed Position Sensor Crankshaft Voltage Supply Supply Voltage Circuit Voltage Belo
143. Diagnostic Sensor Supply Voltage 4 Circuit Voltage code 1 Below Normal or Shorted to Low Source 2195 703 14 Red Auxiliary Equipment Auxiliary Equipment Sensor Input 3 Engine Sensor Protection Critical Special Instructions 2215 94 18 Amber Fuel Delivery Fuel Pump Delivery Pressure Data Valid but Pressure Below Normal Operational Range Moderately Severe Level 2216 94 1 Amber Fuel Delivery Fuel Pump Delivery Pressure Data Valid but Pressure Above Normal Operational Range Moderately Severe Level 2217 630 31 Amber Calibration Memory ECM Program Memory RAM Corruption Condition Exists 2249 157 1 Amber Injector Metering Injector Metering Rail 1 Pressure Data Valid Rail 1 Pressure but Below Normal Operational Range Most Severe Level 2261 94 15 Maint Fuel Delivery Fuel Pump Delivery Pressure Data Valid but Pressure Above Normal Operational Range Least Severe Level 2262 94 17 Maint Fuel Delivery Fuel Pump Delivery Pressure Data Valid but Pressure Below Normal Operational Range Least Severe Level 2263 1800 16 Amber Battery Temperature Battery Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 2264 1800 18 Amber Battery Temperature Battery Temperature Data Valid but Below Normal Operational Range Moderately Severe Level 2265 1075 3 Amber Electric Lift Pump for Fuel Priming Pump Control Signal Circuit Engine Fuel Voltage Above Normal or Shorted to High Source 2266 1075
144. EAD CAP SCREWS 5 Torque Lube OR Loctite Torque c Loctite 262 Loctite 263 OR T Vibra TITE Vibra TITE 131 111 140 K 0 20 K 0 18 K 0 15 Tensile Stress Area Sq mm KN N m N m N m 3 0 5 3 35 az oz eve 547 os 1420 ea 125 125 5 03 A m o 2 2 361 59 j 6 s 5 20 83 175 0 ol 1 2 2 I 0 2 2 0 0 1890 0 2220 990 3 1 1 5 5 5 5 i 55 95 235 325 460 625 800 m m t 3 3 27 3 5 561 349 5 2095 1885 1575 3 5 432 5 2855 2570 2140 509 0 698 0 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED MY4700J 2 8 G10 55A G12 55A General Information and Specifications 2 2 2 Metric Fastener Torque Chart Continued Magni CLASS 12 9 SOCKET HEAD SCREWS 6 AND ABOVE Torque Lube OR Loctit
145. ELAY REVERSE RELAY THROTTLE TRANSMISSION SHIFTER LEFT DASH PANEL STANDARD JOYSTICK TILT SPEED ema et 5119 nr ma ALS UP DOWN 123456 AOF ALS 9 1 om Md ALS lt RED YEL Md 111 8 15 z QNO H3lIHS SHEET 2 SP BAT PWR SP ACCY PWR SP GND 1 SP CAB GND 2 AC CLUTCH IL 0706 45 31 5 11 8915 1234 SHIFTER HARNESS TO TILT ON JOYSTICK ROLLER OPTION ru 5 INVIS Md 115816 HO1019 OV MS dL SNVHLL 245 245 E a MS SNVHL QNO H313lHS 1 85 2 ds avo dS dS Md 199 dS YHL 316 495 SHIFTER HARNESS HD34 24 31PT 16 915 YAO H31JIHS XHS NVHL H31JIHS 5 105 SNVHL 105 E HMd XHS NVHL 191 VV 105 105
146. GINE CONTROL MODULE FUEL FILTER PRIMARY a TURBOCHARGER THERMOSTAT ALTERNATOR STARTER MY5530 G10 55A G12 55A 7 7 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 7 4 2 Before considering thermostat replacement check the coolant level fan belt tension and instrument cluster temperature indicator Thermostat Replacement f the engine seems to take a long time to warm up the thermostat may be stuck in the open position and requires replacement f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position If the engine has overheated performance may suffer indicating other damage including a leak ing cylinder head gasket cracked cylinder head or block and or other internal engine damage 7 8 a Thermostat 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
147. ISSVHO YO 1748950 DAD MM ms oD lt Ry ti ABCDEF OPT 9313 5 A1SVW 8 odi ECU 22 GND 050 TRANS TMP SW NS TRANS SOLYY BRNIBLK CAN SHIELD WATT TO START LT TRANS 801 TRANS SOL ONIDL VR TRANS SOLY4 TRANS SOL 5 TRANS GND SIS SVIS EM AT lt 00 E LI ag 8 12 TURNS PER FOOT TWIST lacu al dg 4 VISE ANIS 1 lt a H NIS M OPTIONS HARNESS HD34 24 19SE CHASSIS HARNESS 147 SHIFTER HARNESS
148. JG Service Manual Models G10 55A G12 55A 3126019 Revised January 5 2011 MG 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 amp 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 amp 9 17 May 1 2008 G Revised Danger Warning amp Caution text and pages 1 4 2 10 3 14 3 15 3 16 3 17 amp 3 19 January 5 2011 H Revised page numbers and pages 2 3 thru 2 10 2 13 thru 2 19 3 4 thru 3 29 4 6 thru 4 10 5 4 5 5 5 9 thru 5 11 6 3 6 6 7 6 thru 7 9 7 11 thru 7 15 8 3 thru 8 12 8 14 thru 8 25 9 5 thru 9 12 9 15 thru 9 21 9 23 9 25 thru 9 28 9 31 9 32 9 34 thru 9 36 amp 9 42 thru 9 54 3126019 G10 55A G12 55A EFFECTIVITY PAGE G10 55A G12 55A 3126019 SECTION CONTENTS Section Subject Page Section 1 Safety c 1 1 1 1 1 2 1 2 Disclalmoet iz EP 1 2 1 3 Operation amp Safety 1 2 1 4 Not Operate oad Mr e Rex UE maw 1 2 1 5 Safety Information rore 1 2 1 6 Safety Instructi
149. LIARY HYDRAULIC Sl CONNECTIONS TS ay TILT CYLINDER QUICK SWITCH HOSE CARRIER ASSEMBLY INSIDE BOOM EXTEND RETRACT CHAINS 5 CYLINDER UNDERSIDE OF BOOM 27 s lt HOSE PIVOT PIN gt gt AN SHEAVE G10 55A G12 55A 3 3 CY AS 3 2 BOOM SYSTEM FOUR SECTION 3 2 1 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 Boom System Operation 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 The boom sections are connected by extend and retract chains These chains are routed around sheaves on the second and third boom sections As the second section is forced out hydraulically the third and fourth boom sections are pulled out by the extend chains As hydraulic pressure is applied to the retract port on the extend retract cylinder the second boom section is pulled back into the first boom section and the retract chain pulls the third and fourth boom sections back into the second boom section This mechanical linkage formed by the chains and supporting hardware extends and retracts the third and fourth boom sections a
150. Level 599 640 14 Red Engine External Auxiliary Commanded Dual Output Shutdown Protection Input Special Instructions 649 1378 31 Maint Engine Oil Change Change Lubricating Oil and Filter Condition Interval Exists 687 103 18 Amber Turbocharger 1 Turbocharger 1 Speed Low Data Valid but Speed Below Normal Operational Range Moderately Severe Level 689 190 2 Amber Engine Speed Primary Engine Speed Sensor Error Data Erratic Intermittent or Incorrect 691 1172 3 Amber Turbocharger 1 Turbocharger 1 Compressor Inlet Temperature Compressor Inlet Sensor Circuit Voltage Above Normal or Temperature Shorted to High Source 692 1172 4 Amber Turbocharger 1 Turbocharger 1 Compressor Inlet Temperature Compressor Inlet Sensor Circuit Voltage Below Normal or Temperature Shorted to Low Source 697 1136 3 Amber Sensor Circuit ECM Internal Temperature Sensor Circuit Voltage Voltage Above Normal or Shorted to High Source 9 50 G10 55A G12 55A Electrical System Fault SPN FMI Lamp EE Codes Codes Codes Color SPN Description Cummins Description 698 1136 4 Amber Sensor Circuit ECM Internal Temperature Sensor Circuit Voltage Voltage Below Normal or Shorted to Low Source 719 22 3 Amber Crankcase Pressure AEB15 60 Page 152 of 157 Extended Crankcase Blow by Pressure Circuit Voltage Above Normal or Shorted to High Sourc
151. MY4150 Note Tag each wear pad spacer shim and hardware from each location Note the location of any grease fitting if equipped on each wear pad 1 Remove the top rear wear pads spacers shims and hardware 1 from the rear of the third boom section Remove the left or right side rear wear pad spacer shims and hardware 2 from the rear of the third boom section Verify all disconnected hoses tubes and fittings are capped and or plugged N ail Pull each boom section slightly forward to relieve the tension on the retract chain 3 MY3590 Remove the snap rings and pin connecting the rear retract chain 3 from the chain clevis at the rear of the boom Allow chain to hang out over the rear of the boom G10 55A G12 55A C E 6 Place 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 s 5 4 4 4 II ai pee I MY3450 7 With the third and fourth boom section still connected to a suitable lifting device remove all wear pads spacers shims and hardware
152. S dW31 H31V3H 44 58836 8892558 5 S 111 XAY IY Ps 68822288 3305248 9 H aaoo 81589 2222827 E See ee Sz arua insu 6 meos B 66 VEOGTIOH IH H3IV3H TWO m A i ma ur 5 858 8 5 20 3 B BS 56 e n 58 E GND e O BA B DRRR 2332 RE E _ 2588 RA A WE a ot a Zr HH MJ NI 3 s a 4 X H Mor EN Weslssytii 3 NE Et HSVd 14918 QU n S CAE TU SRSROLUG Se m EF MM oms NT GAH G10 55A G12 55A 9 14 Electrical System 9 5 6 Chassis Schematic John Deere
153. SE HOLDER ATO I 1 BATT GROUND 1 1 ALTERNATOR ENGINE HARNESS MY5040 IPRC har Ae ie ee ere ete eae ea G10 55A G12 55A 9 23 Electrical System 9 6 3 Start amp Charge Circuit John Deere amp Perkins 9 24 BAT POS POS NEGATIVE CABLE 3 0 AWG BLACK I NEGATIVE CABLE A POWER DIST TO FIREWALL POSTIVE CABLE 3 0 AWG RED 6 GRAY 5 VEC TOBATIERY A STARTER A RELAY 25 2 B gt 2 IGNITION 7 ST RLY PWR gt gt lt gt STRTSOL z gt 55 gt 5 2 STRLY s gt E gt 21 2 F 5 Eb qs B TRAN BRK 3 0 AWG RED 12 VDC gt jn lt 7 gt BATTERY lt 5 AWG BLACK d 9 POSITIVE CABLE Z A lt gt S
154. TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P N Loctite P N ND Industries P N 0100011 Vibra TITE 121 Medium Strength Blue i 0100019 Vibra TITE 140 High Strength Red 0100071 Vibra TITE 131 Medium High Strength Red MY4650J G10 55A G12 55A 2 3 General Information and Specifications 2 2 1 SAE Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Torque Torque Loctite 242 or 271 Dry or Loctite 263 OR SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Vibra TITE 111 or 140 K 18 Torque Loctite 262 OR Vibra TITE 131 K 0 15 s Tensile Bolt Dia Clamp Load m sn 4 40 00064 0 1120 00066 TT 6 32 0 1380 0 0099 40 0 1380 00105 8 32 0 1640 0 01400 ____ 36 0 01474 5 10 7 1 4 5 16 3 8 7 16 80 HO 80 20 0500 0 1599 1440 120 165 15 90 120 18 0 5625 0 2030 18250 170 20 15 210 130 175 18 0 6250 0 2560 23000 20 325 570 10 16 0 500 0
155. USIBLE LINK Ks mH 1525446 16 x gt ALTEXG ALT EXC ALT EXC RED 18AWG e 2 T mw 5 gt m9 SIGNALS 48 Le gt 2 n2 4 gt 12 gt gt maNBRK pwr STRLY j a gt TRAN Kli BATT GROUND i T 1 gt ju gt 15 gt Km L 2 2 NE gt lap RL196 82 IS ST RLY ORG 16AWG lt 12512 ENG WARN LT 18AWG Tait Hesel gt 5 5 4 STRLY PWR RED 1oawa 1196 50 zzi ogee gt gt z gt 815585 s gt m SOL ORG t0Awd 19557 1 p JH gt w gt t a 1 gt gt Y Y gt gt BLACK 1 GRAY 2 gt gt Ek 1 HGFEDCBA HGFEDCBA gt gt STRT 1 1 VVVVVVYV gt 29 gt PWR RED 2 0AWG 1 lt 25 1 t 1 PWR STUD i m 7 8 SOLSTUD Elo i POSITIVE CABLE GND STUD on m Rie i z POWER UNIT mE 1 9 1 up mu 4 1 5 5 1 Khe 5 Khs H Khs e i Khz Mes aa Es es uem mE Sa B Ka 1 i 1 i 1 1 1 1 KIs 1 1 1 1 Kle 1 z 1 c
156. Ule amp 5 59710 eu he ES 2 lt 9 9 zi z 705 id s 2 a EN 5 TAMIAS 25 a E 71815 225 a 8 44 MS 5 aj 5 2 TAT IN El ow NHOH NYOH 98 E NYOH 880 HIS BT gl 8 gos HIS gt 8 B lt gt 2 gt T Md NYOH 2 gt T 3OVS gl THM 5 ITINVIS OL ONS 5 0109 0807 gt 2 ITNEVM ONS Tavis TVIS 2 IW DOW 3 A 745 cL 5 5 3 XO V5 8i DUO 5 174015 ONS Md 5 HOV 3979 7 ITO g THO YO 8L YT HSVG T mova Maa gt 154 84 AT INS 2 E 9 NOVASW Evo 5 E 554 EAST 259 zz 594 mo A s z 55 Elise 78 10160 G10 55A G12 55A 9 11 Electrical System 9 5 3 Cab Schematic Cummins U SA 105 DADA E5 E1 E5 E2 TURNER LHS SNVHI TRANSMISSION SHIFTER TURNER 1234858739103 STANDARD JOYSTICK yyy TRANSMISSION LEGEND E3
157. V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden Phone 46 0 850 659 500 Fax 46 0 850 659 534
158. VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV Et 123456 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 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 r VV V V V VVVVVVVVVVVYVVN 1 I 1 1 1 1 H 1 HORN g em 26 SP PWR ic KEVAGN i SHIFTER HARNESS 1 1 Xx j cute EDDY 1 1 1 sO 1 o 1 3 DASH PANEL HARNESS 1 POSITIVE CABLE TO STARTER ALTERNATOR n 12 VDC BATTERY qe Mp emen Hoe 1 1 PWR RED 2AWG i 30A 2 1 FUSE HOLDER ATO 1 1 PWR A RED 2AWG 5 197 2 1 N 1 ECU BAT 022 RED 12AWG 8 1 ECU 022 i2AWG N 5 5 LITTLEFUSE 2 PWR A RED 2AWG gt 1 1 RLT98 1 455 EGU BAT 022 RED 12AWG A ECU BAT 022 RED 12AWG i 2 86 LY _ FC205 lt i 5 3 1 _ Ecu BATI022 RED 18AWG GRID HEATER RELAY i DIAGNOSTIC d 1 STRT PWR lt RED 20 PWR STUD lt 4 lt 1 i lt gt 1 85 Ag 86 ENGINE STARTER RL196 30 1 30 ST RLY PWR RED 10AWG ALTPWR SAWG 1 BATT POSITIVE 87 STARTER RELAY 12V 75 AMP SIGNALS FU
159. X 9 9 OO LO a ay MY4170 17 17 5 Install the four cab to frame mount bolts washers and nuts 17 Torque to 280 305 lb ft 379 414 Nm 6 Install the two cab side mount bolts washers and nuts 16 Torque to 680 720 Ib ft 922 976 Nm 7 Install the engine air filter and hydraulic oil reservoir breather to their brackets at the top of the cab 8 Install the throttle cable to the throttle pedal assembly Refer to Section 4 3 3 Throttle Pedal 9 Pull all the hydraulic hoses and electrical wires through the cab 10 Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations 11 Reconnect the previously labeled electrical connections to their appropriate locations 12 For machines equipped with the heater option reconnect the heater hoses to the cab heater Refer to Section 4 3 7 Heater Air Conditioning System if equipped 13 Install the fuel tank to the cab Refer to Section 7 6 2 Fuel Tank 4 10 14 Fill the cooling system completely with coolant allowing time for the coolant to fill the engine block The cooling system capacity is listed in Section 2 4 Fluid and Lubricant Capacities 15 Properly connect the battery 16 Start the engine and check the operation of all controls Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required Note When the engine is initially started run it b
160. a 7 10 7 7 Engine Exhaust 4 7 12 7 8 Air Gleaner Assembly vex pe ok meetin sews 7 13 7 9 Engine 7 14 7 10 Troubleshooting waded ovp Lp Dre Rer ER MD ES 7 17 Section 8 Hydraulic System xvi pusupa ws sa suda aw i eon iD ca C e 8 1 8 1 Hydraulic Component Terminology 8 2 8 2 Safety InformatioRi cisci ire Reit a RARO 8 3 8 3 Hydraulic Pressure 0 5 5 8 3 8 4 Hydraulic Circuits 22s 8 4 8 5 Hydraulic Reservoir conve Qa prex bu eere hex iE RS 8 13 8 6 Implement Pump Pie ie 8 14 8 7 Gontrol sii ad Veal he og pale t gen die Se Pee aged and oe 8 15 8 8 Hydraulic Cylinders 8 21 Section 9 Electrical System Sees Queen OOS SS 9 1 9 1 Electrical Component 9 3 9 2 Specifications ed eels 9 6 9 3 Safety Information 4 9 6 9 4 Fuses and Relays Bea hig eet epp ba edens 9 6 9 5 Electrical System Schematics
161. able lifting device slowly pull the hose carrier loose from the bottom bracket 5 located approximately halfway in the fourth boom section G10 55A G12 55A C X 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 14 Continue withdrawing the hose carrier fastening the two hydraulic carriers together 15 With the two hose assemblies tied together remove the hose carrier and set on the ground or proper supports 3 8 2 Assembling the Hose Carrier Assembly The following procedure is described with the assumption that all components have been removed and assembly proceeding from the beginning MY2730 1 Place both sections on a suitable stand or support 2 Install the wear pad to the bottom of the upper hydraulic carrier 3 Install the bulkhead fittings to the each hydraulic carrier 4 Install the tube assemblies to the bulkhead fittings on each hydraulic carrier 5 Install the cushion clamps to the tube assemblies and secure to each hydraulic carrier 6 Install the hose carrier to each hydraulic carrier and install each tilt hose and auxiliary hose to the proper fitting or tube connection 7 Tie wrap the hydraulic ho
162. acement tank Dispose of the old tank according to local regulations concerning hazardous materials disposal c Cleaning and Drying If contaminated fuel or foreign material is in the tank the tank can usually be cleaned Note lf a leak is suspected in the fuel tank contact JLG Service Department To clean the fuel tank 1 Have a dry chemical Class B fire extinguisher near the work area 2 Remove the fuel or oil tank drain plug and safely drain any fuel into a suitable container Dispose of fuel properly 3 Clean the fuel tank with a high pressure washer or flush the tank with hot water for five minutes and drain the water Dispose of contaminated water properly 4 Add diesel fuel emulsifying agent to the tank Refer to the manufacturer s instructions for the correct emulsifying agent to water mixture ratio Refill the tank with water and agitate the mixture for 10 minutes Drain the tank completely Dispose of contaminated water properly 5 Refill the fuel tank with water until it overflows Completely flush the tank with water Empty the fuel tank and allow it to dry completely d Assembly 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 regulations e Inspection Note If a leak is suspected in the fuel tank contact a JLG Service Department 1 Inspect the fuel tank tho
163. adiator coolant level and add coolant if required Replace the radiator cap 23 Check for leaks from the engine main hydraulic pump and lines transmission hydraulic reservoir and fuel tank Check the levels of all fluids and lubricants Fill as required Note During the full throttle check NOT operate any hydraulic function NOT steer or apply any pressure to the steering wheel Keep the transmission in N NEUTRAL 24 Obtain and connect an appropriate engine analyzer or tachometer Check the engine rpm at full throttle 25 Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times Check the hydraulic oil level 26 Check for proper operation of all components 27 Turn the engine OFF 28 Install the oil pan cover underneath the engine compartment 29 Close and secure the engine cover 30 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 16 G10 55A G12 55A 7 10 TROUBLESHOOTING Trouble Possible Causes see key below Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfiring Excessive Fuel Consumption Black Exhaust Blue White Exhaust Low Oil Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops 1 2 3 4 5 6
164. affect engine efficiency and performance Note Due to the precise tolerances of diesel injection systems keep the fuel clean and free of dirt and water Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles Use ASTM 2 diesel fuel with a minimum Cetane rating of 40 2 diesel fuel gives the best economy and performance under most operating conditions Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking Inform the owner operator of the machine to use 2 diesel fuel unless ambient temperatures are below 32 F 09 When temperatures are below 32 F 0 C a blend of 1 diesel and 2 diesel fuels known as winterized 2 diesel may be used Note 1 diesel fuel may be used however fuel economy will be reduced Use a low sulfur content fuel with a cloud point the temperature at which wax crystals form in diesel fuel at least 10 below the lowest expected fuel temperature The viscosity of the fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication 7 6 2 Fuel Tank 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 G10 55A G12 55A Engine a F
165. ain 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 Verify pressure is correct Shut engine OFF Slowly remove the gauge line and tee fitting from the compensation cylinder 1 amp 2 Reinstall each hose and torque as required Install any previously removed attachment G10 55A G12 55A Hydraulic System a Pressure Specifications Before S N 0160037877 Hydraulic Circuit Test Port Function Used to Adjustment Pressure Range Test Location 3600 3650 psi Main P1 A Bottom Tilt Down 1 248 252 Bar 500 550 psi Pilot JS1 B No Function 2 34 38 Bar 750 775 psi Standby P1 A No Function 3 52 53 Bar Service Brake BV1 C Bottom Steering 4 1000 1100 psi Supply Any Mode 69 76 Bar Bottom Steering 2400 2500 psi sreenng chee Any Mode 3 165 172 Bar 3500 3525 psi Lift LS2 E Bottom Lift Down 6 241 243 Bar Bottom Boom 3050 3075 psi Retract f 210 212 Bar HYDRAULIC MANIFOLD Es Cz 15 15 D G10 55A Before S N 0160031864 G12 55A Before S N
166. amage etc If the inner surface of the cylinder barrel does not display a smooth finish or is scored or damaged in any way replace the barrel Cylinder Inspection 2 Remove light scratches on the piston head gland rod or inner surface of the cylinder barrel with a 400 600 grit emery cloth Use the emery cloth in a rotary motion to polish out and blend the scratch es into the surrounding surface 3 Check the piston rod assembly for run out If the rod is bent it must be replaced c General Cylinder Assembly Instructions 1 Use the proper tools for specific installation tasks Clean tools are required for installation 2 Install new seals back up rings and o rings on the piston and new seals back up rings o rings and bearing on the head gland Note The extend retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head 3 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod to prevent any damage to the rod Note Protect the finish on the cylinder rod at all times Damage to the surface of the rod can cause seal failure 4 Lubricate and slide the head gland over the cylinder rod Install the piston head on to the end of the cylinder rod Loctite and install the set screw in the piston head Refer to Section 8 8 5 Cylinder Torque Specifications for torque specifications for the piston head and the
167. anism 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 Axle Removal Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on electrical components If using a steam cleaner seal all openings before steam cleaning Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 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 NEUTRAL position engage the 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 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 Remove the fender assembly MY4180 6 If the axle will be disassembled after removal place a suitable receptacle under the axle 1 and wheel hubs drain plugs 2 Remove the drain plugs and allow the axle oil to drain into the receptacle Transfer the used axle oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility 7
168. at low idle for about one minute Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil 7 Inspect for leaks and check level of hydraulic fluid in reservoir Add hydraulic fluid if needed Shut the engine OFF 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 9 Close and secure the engine cover 10 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A 8 8 3 Cylinder Pressure Checking Attach a 5000 psi 345 bar gauge to the test port on the P1 port on the hydraulic manifold to check the system pressure For more information refer to Section 8 4 1 Hydraulic Pressures Note hydraulic cylinder pressure is greater than the main control valve pressure increase the main control valve pressure by adjusting the main relief Generally one half turn clockwise will be adequate to check an individual circuit Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn Re check the main relief setting and adjust if necessary Steering Cylinders The steer cylinder is attached to each axle center housing The steer cylinder assembly can be found in Section 5 3 Axle Assemblies The steer cylinder is covered in the appropriate manufacturer s axle literature 8 23 n Hydraulic System 8 8 5 a
169. before inspection 5 Inspect the solenoid cartridges for proper operation Check by shifting the spool to ensure that it is functioning properly Check that the spring is intact Inspect the cartridge interior for contamination 6 Inspect internal passageways of the steer select manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold 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 7 Install the solenoid valves and cartridges in the steer select housing 8 Attach the steer select valve to the manifold using four new oiled o rings and the four socket head capscrews Steer Select Valve and Manifold Installation 1 Install the steer select valve to the mounting plate under the left front side of the frame using the two bolts 2 Connect all the hydraulic hoses fittings solenoid wire terminal leads etc to the steer select valve 3 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all hose clamp
170. behind dash panel OPTIONAL HEATER AC CONTROLS MY5540 IGNITION SWITCH ALTERNATOR POWER DISTRIBUTION UNIT OIL PRESSURE in engine compartment SWITCH COOLANT TEMPERATURE SENDER OIL PRESSURE SENDER FUEL SHUT OFF k STARTER RELAY MY1030 ENGINE CONTROL MODULE ECM J MY1281 G10 55A G12 55A 9 3 Electrical System 9 1 2 General Overview Perkins 3 IN 1 GAUGE DASH SWITCHES IGNITION SWITCH COOLANT TEMPERATURE SENDER ALTERNATOR 9 4 Below Alternator ENGINE CONTROL MODULE ECM MY1850 OPTIONAL HEATER AC CONTROLS POWER DISTRIBUTION UNIT in engine compartment OIL PRESSURE SWITCH OIL PRESSURE id SENDER 2 e 10320 G10 55A G12 55A Electrical System 9 1 3 General Overview Cummins DASH SWITCHES 3 IN 1 GAUGE OPTIONAL POWER DISTRIBUTION UNIT behind dash panel nul OPTIONAL HEATER AC CONTROLS MY4350 IGNITION SWITCH POWER DISTRIBUTION UNIT FUSE HOLDER in engine compartment COOLANT TEMPERATURE SENDER IT MY4550
171. by spinning them with compressed air this can damage mating surfaces due to lack of lubrication After drying lightly coat components with oil or a rust preventive chemical to help protect them from corrosion If storing components for a prolonged period wrap them in wax paper PERIODIC OPERATION REQUIREMENT Every two weeks drive the machine far enough to cause the drive train components to make several complete revolutions This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity SUBMERSION If the machine has been exposed to water deep enough to cover the hubs disassemble the wheel ends and inspect for water damage and contamination If the carrier housing was submerged in water especially if the water level was above the vent tube breather drain the axle and inspect internal parts for water damage and contamination Before assembling and refilling the unit with the specified lubricant s clean examine and replace damaged parts as necessary Note Use a suitable puller for bearing removal Clean inspect and lubricate all bearings just prior to reassembly If replacement of a damaged bearing cup or cone is necessary replace the cup and cone as a set 5 3 Axles Drive Shafts Wheels and Tires hs 5 3 5 The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mech
172. c Fluid 75W 80 Axles Differential Housing Capacity Front 15 8 quarts 15 liters Rear 16 9 quarts 16 liters Wheel End Capacity 2 quarts 1 9 liters Type of Fluid 0 to 104 F 20 to 40 C Mobilfluid 4249 Tractor Hydraulic Fluid 40 to 0 F 40 to 20 C Mobilfluid LT Hydraulic Fluid 75W 80 Air Conditioning System if equipped System Capacity 2 5 Ib 1134 g Type of Fluid Refrigerant R 134a Tetrafluorethane 2 16 G10 55A G12 55A General Information and Specifications amp 2 5 SERVICE AND MAINTENANCE SCHEDULES 2 5 1 10 1st 50 amp 50 Hour Er EVERY 10 Check Fuel Air Filter Check Engine Check Hydraulic Check Tire Level Restriction Oil Level Oil Level Condition amp Indicator Pressure Check Check Hydraulic Return Check Auto Sway Transmission Filter Indicator Before Function Before Oil Level S N 0160039451 S N 0160038592 Check Wheel Lug Nut Torque Drain Fuel Check Engine Check Check Washer Lubrication Water Coolant Level Battery Fluid Level Schedule Separator if equipped MY4740 G10 55A G12 55A 2 17 General Information and Specifications 2 5 2 1st 250 250 amp 500 Hour Change Change Wheel Change Change Axle Oil End Oil Transmission Transfer Case Oil amp Filter Oil Change Engine Oil Check Axle Check Wheel Air Filter Ch
173. ce valve with a new part 4 Extend the rod 3 as required to allow access to the base of the cylinder 8 21 Hydraulic System n 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 Keep the rod centered within the barrel to help prevent binding 7 Carefully pull the rod assembly 3 along with the head gland 4 out of the cylinder barrel 8 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod to prevent any damage to the rod 9 Remove the set screw from the piston head 5 10 If equipped remove the piston head 5 mounting nut 6 Note may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed Some cylinder parts are sealed with a special organic sealant and locking compound Before attempting to disassemble these parts remove any accessible seals from the area of the bonded parts Wipe off any hydraulic oil then heat the part s un
174. cient lubrication cylinder pivot pin noise and or wear 2 Worn bushing s 1 Lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed 2 Replace bushing s and lubricate at regular intervals 3 30 G10 55A G12 55A C x Problem Cause Remedy 5 Drooping chain or jerky 1 Chain s tension not properly 1 Adjust chain s boom extend or retract adjusted functions 2 Chain s stretched or binding 2 Replace chains as needed Refer to Section 3 7 Boom Section Separation Adjustment 3 Wearpads loose contaminated 3 Replace wear pad Refer to excessively worn or damaged Section 3 11 Boom Wear Pads 4 Contaminated corroded or 4 Remove contamination and or rusted wear pad sliding corrosion from wear pad sliding surfaces surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s 5 Extend Retracthydraulicsystem 5 Refer to Section 8 4 Hydraulic not operating properly Circuits 6 Damaged boom section 6 Replace the damaged boom section Refer to Section 3 3 Boom Assembly Maintenance 6 Boom will not raise or lower 1 Broken hydraulic hosesortubes 1 Locate break replace hose s and or connection leaks or tube s tighten connections 2 Lift lower hydraulic system not 2 Refer to Section 8 4 Hydraulic operating properly
175. ct the battery Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 8 6 IMPLEMENT PUMP For internal service instructions contact your local distributor 8 6 1 a 1 Implement Pump Replacement Pump Removal 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool 4 Properly disconnect the battery Drain the hydraulic reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining Thoroughly clean the pump and surrounding area including all hoses and fittings before proceeding Note Cap all hoses as you remove them to prevent unnecessary fluid spillage 7 Label disconnect and cap the hydraulic hoses attached to the pump Remove the four bolts and lockwashers 2 securing the pump to the transmission top bolts shown only Remove the o ring located between the transmission and the pump Wipe up any hydraulic oil spillage G10 55A G12 55A Hydraulic System n Note DO NOT disassemble the operating pump The pump is pre set from the manufacturer Any adjustments
176. ctor to the wiring harness connector 2 Properly connect the battery 3 Check for proper oil level 4 Start the engine and observe the operator s display for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine low oil obstructed or faulty oil pump defective instrument display 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 8 Fuel Level Sender a Fuel Level Indicator Testing The fuel level sender wiring harness leads can be accessed from the top of the fuel tank 1 Loosen and remove he four screws securing the fuel sender cover 6 2 Disconnect the fuel level sender wiring harness leads 7 from the fuel sender 8 With the help of an assistant touch both harness leads together 3 From the operator s cab have the assistant turn the ignition key switch to the RUN position DO NOT start the engine Observe the fuel level indicator needle on the operator s instrument cluster The reading must be at the FULL mark 4 Turn the ignition key switch to the OFF position The fuel level indicator needle should return to the EMPTY position 9 35 Electrical System b Fuel Level Circuit Tests If the fuel level sender 8 is suspected of giving a false reading perform the following checks 1 9 10 9 If the fuel lev
177. cuit Voltage Below Normal or Shorted to Low Source 488 105 16 Amber Intake Manifold Intake Manifold 1 Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 489 191 18 Amber Transmission Output Transmission Output Shaft Speed Data Valid Shaft Speed but Below Normal Operational Range Moderately Severe Level 497 1377 2 Amber Switch Circuit AEB15 60 Page 151 of 157 Multiple Unit Synchronization Switch Circuit Data Erratic Intermittent or Incorrect 523 611 2 Amber System Diagnostic OEM Intermediate PTO Speed switch code 1 Validation Data Erratic Intermittent or Incorrect 527 702 3 Amber Circuit Voltage Auxiliary Input Output 2 Circuit Voltage Above Normal or Shorted to High Source 528 93 2 Amber Switch Data Auxiliary Alternate Torque Validation Switch Data Erratic Intermittent or Incorrect 529 703 3 Amber Circuit Voltage Auxiliary Input Output 3 Circuit Voltage Above Normal or Shorted to High Source 546 94 3 Amber Fuel Delivery Fuel Delivery Pressure Sensor Circuit Voltage Pressure Above Normal or Shorted to High Source 547 94 4 Amber Fuel Delivery Fuel Delivery Pressure Sensor Circuit Voltage Pressure Below Normal or Shorted to Low Source 551 558 4 Amber Accelerator Pedal Accelerator Pedal or Lever Idle Validation Low Idle Switch Circuit Voltage Below Normal or Shorted to Low Source 553 157 16 Amber Injector Metering Injector Metering Rail 1 Pressure High Data
178. d fittings before proceeding 8 Drain the hydraulic fluid reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 9 Place a suitable container to catch hydraulic fluid drainage beneath the frame Note Slowly remove the hydraulic hoses attached to the main control valve to relieve any possible trapped pressure in the hydraulic line 10 Label disconnect and cap all the hydraulic hoses tubes and wires at the main control valve 11 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 8 15 Hydraulic System 10730 12 Remove the four bolts washers and nuts 1 securing the main control valve to the frame b Main Control Valve Disassembly MY1200 1 To disassemble the individual sections of the main control valve remove the nuts from one end of the tie rods 2 Pull the tie rods out through the sections 2 Disassemble each section assembly as required Some sections include a pre adjusted relief valve that regulates pressure in a specific circuit Note DO NOT adjust any of the relief valve assemblies Tampering with a relief valve will irrevocably alter pressure in the affected circuit requiring recalibration or a new relief valve Disassemble each Valve Section 1 Carefully separate the load sense outlet section from the liftlower section 2 Remove the o rings from between the two sections 8 16 3 Carefully
179. d route the serpentine belt onto the alternator and engine pulleys Release and check the tensioner pulley to verify that it is pivoting freely in order to provide the proper tension on the belt Check for proper belt alignment Refer to the appropriate Operation amp Safety Manual Connect the previously labeled wire leads to the alternator 5 Properly connect the battery 6 Close and secure the engine cover 7 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 27 Electrical System 9 8 WINDOW WIPER WASHER WINDSHIELD WIPER MOTOR 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 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 MY0440 5 Remove the screws that secure the main dash panel Pull out the dash panel to gain access to the wiper motor 3 6 Disconnect the cab harness connectors from the wi
180. drive shaft assembly MUST be replaced Do Not re torque 5 4 2 Refer to Section 2 4 Fluid and Lubricant Capacities for information regarding the lubrication of the grease fittings on the drive shafts Drive Shaft Maintenance 5 4 3 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 Drive Shaft Removal 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 5 Block the wheels 6 The drive shaft assembly is a balanced assembly Mark the yoke and axle transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration G10 55A G12 55A To Transmission To Axle MT0350 7 Remove the four bolts 1 and two straps 2 securing the bearing cross to the transmission output shaft flange Discard bolts 8 Remove the four bolts 3 and two straps 4 securing the bearing crosses to the axle Discard bolts 9 Remove the front drive shaft assembly 10 Repeat the above procedure on the rear drive shaft 5 4 4 1 Disassemble and c
181. e 242 or 271 OR Vibra TITE 111 or 140 Torque Loctite 262 OR Vibra TITE 131 Tensile Stress Area 0 5 0 6 0 7 5 03 6 78 8 78 0 8 14 20 1 20 10 12 5 2890 180 125 228 __ 1 15 580 361 12 175 8430 525 3 4 6 2 817 5090 5 209 4 1120 698 0 NOTES 1 THESE TORQUE VALUES DO APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED MY4710J wo 14 16 18 25 192 119 5 325 20 22 353 2200 90 as 70 27 30 1780 1680 1575 3 2425 2285 2140 4 5 U 4985 G10 55A G12 55A General Information and Specifications 2 2 3 Hydraulic Hose Torque Chart O Ring Face Seal amp JIC Torque Chart Size ORFS JIC Flats Method amp SET dire tee 8 P NS a NS 1 510 1 75 10 he Nm 1 510 1 75 2 ionis 40 7 OE 24 5 an i 0 75 to 1 0 32 N A 0 75 to 1 0 Note By definition the
182. e 729 22 4 Amber Crankcase Pressure Extended Crankcase Blow by Pressure Circuit Voltage Below Normal or Shorted to Low Source 731 723 7 Amber Engine Speed Engine Speed Position 2 mechanical Sensor 2 misalignment between camshaft and crankshaft sensors Mechanical System Not Responding Properly or Out of Adjustment 757 2802 31 Amber Electronic Control Electronic Control Module data lost Condition Module Exists 778 723 2 Amber Engine Speed Engine Speed Sensor Camshaft Error Data Sensor 2 Erratic Intermittent or Incorrect 779 703 11 Amber Auxiliary Equipment Warning Auxiliary Equipment Sensor Input 3 Sensor Input OEM Switch Root Cause Not Known 951 166 2 None Oylinder Power Cylinder Power Imbalance Between Cylinders Data Erratic Intermittent or Incorrect 1117 627 2 None Power Supply Power Lost With Ignition On Data Erratic Intermittent or Incorrect 1139 651 7 Amber Injector Cylinder Injector Cylinder 1 Mechanical System Not 01 Responding Properly or Out of Adjustment 1141 652 7 Injector Cylinder Injector Cylinder 2 Mechanical System Not 02 Responding Properly or Out of Adjustment 1142 653 7 Amber Injector Cylinder Injector Cylinder 3 Mechanical System Not 03 Responding Properly or Out of Adjustment 1143 654 7 Amber Injector Cylinder Injector Cylinder 4 Mechanical System Not 04 Responding Properly or Out of Adjustment 1144 655 7 Amber Injector Cylinder Injector Cylinder 5 Mechanical System
183. e previous capscrew 4 and locknut 5 Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin 2 Align the tilt cylinder pin and screw in the locking bolt 1 Torque as required 55A G12 55A 3 9 3 Quick Switch Removal S N 0160037689 amp After 3 9 4 1 SAS MY5090 Remove the lock bolt 8 holding the tilt cylinder rod end pin 9 to the quick switch assembly 10 Remove the Tilt Cylinder pin Support the quick switch assembly 10 Remove the capscrew 11 and locknut 12 securing the head pin 13 to the boom head 14 Inspect the 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 the pin must be replaced Quick Switch Installation Assemble the quick switch assembly 10 to the boom head 14 Line up the quick switch between the mounts on the boom head The quick switch should be centered in the boom head Coat the quick switch head pin 13 with an anti seize compound Insert the quick switch head pin through the quick switch and boom head Secure with the previous capscrew 11 and locknut 12 Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin 9 Align the tilt cylinder pin and screw in the locking bolt 8 Torque as required 3 23 3 10 BOOM HEAD MOUNTED WINCH 3 10 1 Boom Head Mounted Winch Re
184. e chain 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 tie wrap 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 Remove the chain from the clevis and drop it free from the boom 6 Holding the rope at the front carefully pull the chain out through the back of the boom until it s free 7 Untie the rope and leave it in place for reinstallation of the chain G10 55A G12 55A 3 6 2 Inspect and lubricate chains thoroughly before installation Articulate the chains to make sure all working surfaces are thoroughly lubricated Retract Chain Installation Note If the inner retract chain was removed it must be installed first 1 Fasten a rope to the end of the 3 4 in chain in order to pull it back into the boom 2 Attach the chain to the chain clevis at the rear of the boom 3 Carefully pull the chain into the boom until it can be fastened to the chain clevis 4 Remove the rope 5 Fasten the chain into the clevis by installing the pin and retaining ring 6 Torque the jam nuts to 100 Ib ft 135 Nm To install
185. e engine cover Allow the system fluids to cool 4 Properly disconnect the battery 5 Label disconnect and cap or plug hydraulic hoses in relation to the cylinder 6 Attach a suitable sling to an appropriate lifting device and to the cylinder Make sure the device used can actually support the cylinder 7 Remove the lock bolt and or any retaining clips securing the cylinder pins Remove the cylinder pins 8 Remove the cylinder 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools G10 55A G12 55A a General Cylinder Disassembly 1 Clean the cylinder with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder 2 Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holding equipment if possible WARNING Significant pressure may be trapped inside the cylinder Exercise caution when removing a counterbalance valve or a pilot operated check valve from a cylinder Note Avoid using excessive force when clamping the cylinder in a vise Apply only enough force to hold the cylinder securely Excessive force can damage the cylinder tube 35 MY4300 3 If applicable remove the counterbalance valve 1 from the side of the cylinder barrel 2 Note DO NOT tamper with or attempt to adjust the counterbalance valve cartridge If adjustment or replacement is necessary replace the counterbalan
186. e engine cover Allow the system fluids to cool 4 Properly disconnect the battery JOHN DEERE PERKINS BEFORE S N 0160037186 12 MY1840 PERKINS S N 0160037186 THRU 0160039451 EXCLUDUING 0160039394 amp 0160039397 CUMMINS S N 0160039451 amp AFTER INCLUDING 0160039394 amp 0160039397 MY5060 5 Remove the screws 11 securing the dash panel e Label and disconnect the wires from the gauge remove the gauge bracket 7 Pull the gauge 12 out from the dash 9 37 Electrical System b Disassembly DO NOT disassemble the gauge The gauge is not serviceable Replace the gauge if found to be defective c Gauge Installation and Testing 1 Install the gauge 12 in the dash Install the gauge bracket 2 Connect the previously labeled wires to the gauge 3 Install the dash panel with the previously used hardware 11 4 Properly connect the battery 5 Turn the ignition to the ON position to check the gauge values 6 Close and secure the engine cover 7 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 12 DASH SWITCHES 9 12 1 Note For information on the front windshield wiper rear window wiper and washer systems refer to Section 9 8 Window Wiper Washer Windshield Wiper Motor
187. e engine cover Allow the system fluids to cool G10 55A G12 55A Properly disconnect the battery MY4250 5 Remove the clamp 11 securing the air intake elbow 12 to the air cleaner assembly 13 Pull the air intake elbow off the air cleaner 6 Remove the capscrews and nuts securing the air cleaner mounting bracket 14 to the air cleaner mounting plate Remove the air cleaner assembly 7 8 2 Air Cleaner Assembly Installation John Deere amp Perkins Note Apply Loctite 242 to the capscrew threads before installation 1 Install the air cleaner assembly 13 to the cab mounting plate with the previously removed hardware 14 2 Place the loosened clamp 11 over the air outlet elbow 12 and install elbow on the air cleaner assembly Adjust and tighten the clamp Properly connect the battery Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 8 3 Air Cleaner Assembly Removal Cummins 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 NEUTRAL position engage the parking brake and shut the engine OFF 7 13 Engine Place Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow th
188. e hose carrier 3 21 11 Uncap and reconnect 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 Verify the auxiliary hoses and or tilt hoses are NOT touching the bottom of the second boom section by viewing the auxiliary hoses and or tilt hoses through the access hole 10 in each side of the second 12 s 876 _ 5 MY2691 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 Tighten the adjusting nut 7 to compress the hose take up compression spring to measure 3 in 76 20 mm 9 Refer to Section 3 8 4 Boom Hose Adjustment if required 14 Torque the jam nut 8 against the adjusting nut 7 15 16 3 8 4 1 to 100 ft lbs 135 5 Nm Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Boom Hose Adjustment Park the machine on a hard level surface level the machine fully extend the boom lower the boom head to the ground place the transmission control lever in N NEUTRAL engage the park
189. e hose carrier at the rear of the boom and at the front of the boom head Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system 8 If equipped label and disconnect any electrical connections at the front and rear of the boom assembly Note Tag or identify each hose to the corresponding fitting it was removed from 3 20 MY2710 9 Loosen and remove both screws and locknuts 2 from the hose carrier bracket at the front of the fourth boom section 10 Loosen and remove the guide bracket 3 from the front of the fourth boom section E 55 29 4 4 il MY2720 11 Loosen and remove the hose carrier bracket 4 at the rear of the third boom section 2700 5 12 Install a sling around the hose carrier the front of the boom With a suit
190. e system fluids to cool gt Properly disconnect the battery MY5070 e Loosen the clamp 15 securing the air intake elbow 16 engine Loosen the capscrews securing the air cleaner mounting bracket 17 to the engine fire wall 7 Remove the air cleaner assembly 17 amp 18 8 Remove the air cleaner mounting bracket 17 from the air cleaner 18 7 8 4 Air Cleaner Assembly Installation Cummins Note Apply Loctite 242 to the capscrew threads before installation 1 Install the air cleaner 18 to the air cleaner mounting bracket 17 2 Install the air cleaner assembly 17 amp 18 to the engine fire wall Tighten the previously loosened capscrews Install the air intake elbow 16 onto the engine Adjust and tighten the clamp 15 Properly connect the battery Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 9 ENGINE REPLACEMENT 7 9 1 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 They will be addressed in the following procedures Engine 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 NEUTRAL po
191. e the main dash panel to gain access to the appropriate hydraulic hoses Refer to Section 9 11 1 Analog Gauges Ta MY0121 5 Label disconnect and cap the four hoses from the side of the steering valve 1 Cap the fittings on the steering valve Label disconnect and plug the load sense hose at the front of the steering valve Cap the fitting on the steering valve 6 Remove the steering wheel 2 disconnect and remove the travel select lever 3 disconnect the instrument panel harness connector 4 7 Remove the steering assembly through the dash panel opening Support the steering valve and remove the four hex head capscrews and four lockwashers Note DO NOT disassemble the orbitrol valve The orbitrol valve is not serviceable and must be replaced in its entirety if defective 4 3 ay 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 89 46 Nm 4 Install new o rings into the steering valve fittings Lubricate the o rings with clean hydraulic oil 5 Uncap and connect the previou
192. eck and Filter Before Oil Level End Oil Levels Vacuator Fan Belt S N 0160039451 Valve Si 3 WA 6 M Check Boom Check Boom Check Transfer Check Lubrication Extend Chains Wear Pads Case Oil Level Rear Axle Schedule Stabilization Change Engine Oil Change Fuel Change Fuel Check Wheel and Filter S N Filter Filter amp Strainer Lug Nut 0160039451 amp After Before S N 0160032082 Torque MY4750 Note Engine oil amp filter service interval can be extended See Engine Manual for details 2 18 G10 55A G12 55A General Information and Specifications 2 5 3 1000 amp 1500 Hour Transmission Oil amp Filter Check Boom Retract Chains Change Engine Coolant G10 55A G12 55A Change Transfer Case Oil Lubrication Schedule Change Hydraulic Fluid amp Filters ae Change Change Wheel Axle Oil End Oil Change Hydraulic Tank Breather Check Air Intake System MY4760 2 19 5 General Information and Specifications 2 6 LUBRICATION SCHEDULES a 50 Hour 0450 2 20 G10 55A G12 55A General Information and Specifications amp b 250 Hour ba
193. ed JI KINO 9 IN 1004334 4 SNUNL ZL ITE su 105 118 ola Jl areata ales 92 28 aS 5 Elo BE Se Slavs 2 BB 252 gg 25 E E ER ES iani ha ha 22 3180 INLISOd 1 SA A v av av av av av PER waive OL 3A1VO3N SA G SATA za SAT AAA YOSNIS NOSN3S aUNSS3id o INVADO anal wand AWALINVIOOD WIVGTO3INVW GN3931NOISSINSNV31 9 19 G10 55A G12 55A E Electrical System Power Unit Schematic Perkins 9 5 11 Nid t9 NMOHS SNOLLOSNNOO 5 AINO EN oa ea zal ta ALON VVVVVVVVVVVVVVVVVVVVV N H RS BS RS Peeves
194. ed to throughout this section TRANSMISSION FILTER BS lt o 52 5 Fw ji z o 5 m o m E RI tc N ci Pella a 2 2s lt 0 22 oc tc o OIL DRAIN PLUG MY0970 OIL FILLER PLUG OIL DRAIN PLUG l o m G10 55A G12 55A 6 2 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 0990 The transmission serial number plate 1 is located on the front of the transmission case behind the oil dipstick Information on the serial number plate is required in correspondence regarding the transmission 6 3 TRANSMISSION SPECIFICATIONS AND MAINTENANCE INFORMATION For transmission oil specifications and maintenance information refer to Section 2 General Information and Specifications Detailed transmission service instructions are provided in the following publications Service Manual P N 31200241 Parts Manual P N 31200257 6 4 TRANSMISSION REPLACEMENT Note Contact the local distributor if internal transmission repair is required during the warranty period Note Cleanliness is of extreme importance Before attempting to remove the transmission thoroughly clea
195. efer to Section 3 7 Boom Section Separation Adjustment Replace chains as needed 2 Chain sheave s not properly 2 Lubricate chain sheave Refer lubricated to Section 2 5 Service and Maintenance Schedules 3 Chain sheave s not rotating 3 Lubricate chain sheave Refer freely to Section 2 5 Service and Maintenance Schedules Repair or replace chain sheave s as needed 4 Improper chain lubrication 4 Lubricate at regular intervals Refer to Section 2 5 Service and Maintenance Schedules Replace chains as needed 3 32 G10 55A G12 55A Section 4 Cab and Covers Contents PARAGRAPH TITLE PAGE 4 1 Operator s Cab and Covers Component Terminology 4 2 4 2 Operators ee eee ha 4 3 4 2 1 Cab Safety se diye pikes baw dang dat gedaan bue x ei dad eeu as 4 3 4 2 2 Serial Number Decal 4 3 4 3 Cab 4 3 4 3 1 Steering Column and Orbitrol 4 3 4 3 2 Service Brake 4 4 4 3 3 Throttle e ee 4 5 4 3 4 Boom Joystick Assembly 4 5 4 3 5 Frame Sway Auxiliary and Outrigger Control Joysticks 4 6 4 3 6 Windshield Wiper
196. el indicator needle does not move check the fuel tank for fuel Check for loose or defective wiring faulty ground connections and corrosion on the fuel tank sender and wiring lead If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN position use a test lamp to determine whether current is flowing from the ignition switch to the fuel level sender If the fuel level indicator does not move and a faulty or defective fuel level sender in the fuel tank has been ruled out and in addition wiring and connectors have been checked and ruled out the fuel level indicator is defective and must be replaced Check that the ignition terminal has current and that the fuse in the fuse panel is not blown Check for broken shorted frayed disconnected or damaged wiring between the fuel level indicator wiring at the cab fuse and relay panel ignition key switch and from the fuel level sender on the fuel tank through the wiring in the cab Check the fuel level sender A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving Refer to Section 9 5 Electrical System Schematics for further information Inclinometer Switch G10 55A Before S N 0160038543 G12 55A Before S N 0160038542 Inclinometer Switch Removal Park the machine on a firm level surface level the machine fully retract the boom raise and support the boom place
197. elivered to the engine A fault code will always accompany a fuel derate If the engine is running at a much lower rate check the fault codes first to see if the engine is experiencing an internal problem 9 13 2 Engine Fault Codes Chart Fault Codes SPN Codes FMI Codes Definition 11 N A N A Analog Throttle A Input High 12 N A N A Analog Throttle B Input High 18 110 3 Engine Coolant Temperature Input Voltage High 19 110 4 Engine Coolant Temperature Input Voltage Low 21 620 3 Sensor Supply Voltage High 1079 3 Sensor Supply Voltage High 22 620 4 Sensor Supply Voltage Low 1079 4 Sensor Supply Voltage Low 23 100 3 Engine Oil Pressure Input Voltage High 24 100 4 Engine Oil Pressure Input Voltage Low 25 105 3 Manifold Air Temperature Input Voltage High 26 105 4 Manifold Air Temperature Input Voltage Low 28 629 13 ECU Error 32 N A N A Signifies Start of Active Fault Codes 33 N A N A Signifies Start of Previously Active Fault Codes 37 174 Fuel Temperature Input Voltage High 38 174 Fuel Temperature Input Voltage Low 39 637 Crank Position Input Noise 9 40 G10 55A G12 55A Electrical System Fault Codes SPN Codes FMI Codes Definition 10 Crank Position Input Pattern Error 42 190 0 Engine Overspeed Extreme 16 Engine Overspeed Moderate 54 158 17 ECU Power Down Error 55 639 1
198. em Fault SPN FMI Lamp mae Codes Codes Codes 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 Engine Control Module Warning internal hardware failure Bad Intelligent Device or Component 349 191 16 Amber Transmission Output Transmission Output Shaft Speed Data Valid Shaft Speed but Above Normal Operational Range Moderately Severe Level 351 627 12 Amber Controller 1 Injector Power Supply Bad Intelligent Device or Component 352 3509 4 Amber 5 Volts DC Supply Sensor Supply Voltage 1 Circuit Voltage Below Normal or Shorted to Low Source 386 3509 3 Amber 5 Volts DC Supply Sensor Supply Voltage 1 Circuit Voltage Above Normal or Shorted to High Source 415 100 1 Red Engine Oil Pressure Oil Pressure Low Data Valid but Below Normal Operational Range Most Severe Level 418 97 15 Maint Water in Fuel Water in Fuel Indicator High Data Valid but Indicator Above Normal Operational Range Least Severe Level 422 111 2 Amber Coolant Level Coolant Level Data Erratic Intermittent or Incorrect 425 175 2 Amber Oil Temperature Engine Oil Temperature Data Erratic Intermittent or Incorrect 428 97 3 Amber Water in Fuel Water in Fuel
199. eplacement life can be predicted The boom chain s normal life expectancy can be expressed as a maximum percent of elongation This is generally 3 As the chain flexes back and forth over the sheave the bearing joints pins and inside link plates gradually incur wear due to articulation 3 12 2 1 Park the machine on a firm level surface raise the boom to a horizontal level position place the transmission control lever in NEUTRAL engage the park brake switch Inspection Guidelines 2 Fully extend the boom until the extend chain is taut Shut the engine off 3 The extend chains will be visible for inspection with the vehicle in this state 4 While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain 5 Inspect the retract chains every 1000 hours of operation 6 Inspect the chains for the following conditions 3 26 Edge Wear ax 21463 Check the chain for wear the link plate edges caused by running back and forth over the sheave The maximum reduction of material should not exceed 5 Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave If the measured plate height 1 is 5 less than the normal plate height 2 discard and replace the chain Elongation It is important to measure the chain in the section
200. er the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key Switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool 4 Properly disconnect the battery 5 Unplug the engine oil pressure sender connector from the wiring harness connector G10 55A G12 55A Electrical System PERKINS JOHN DEERE MY1810 To J 4 SM 5 5 7 7 4640 N 6 Unplug the wiring harness connector from the engine oil pressure sender 4 or switch 5 7 John Deere Perkins The engine oil pressure sender switch is threaded into a fitting on the bracket weldment Remove the sender switch Cummins The engine oil pressure sender is threaded into the engine block directly above the oil filter Remove the sender b Engine Oil Pressure Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part G10 55A G12 55A c Engine Oil Pressure Sender Installation and Testing 1 Thread the engine oil pressure sender into the fitting or engine block snugly then connect the sender conne
201. ering 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 a Removal 1 Open engine cover Allow system fluids to cool 2 Properly disconnect the battery 3 Unplug the axle proximity sensor from the wiring harness 4 Remove the bolts holding the sensor to the steering cylinder barrel b Disassembly 1 Inspect the sensor and the wiring harness connector terminals for continuity Replace a defective or faulty sensor with a new sensor c Installation and Testing 1 Install the bolts holding the sensor to the steering cylinder barrel 2 Connect the axle proximity sensor to the wiring harness 3 Properly connect the battery 4 Close and secure engine cover 5 Start the machine select a steering mode turn the steering wheel until the display unit shows the steering has been locked into the selected mode 9 11 DISPLAY MONITOR AND GAUGES 9 11 1 Analog Gauges a Gauge 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 G10 55A G12 55A 3 Open th
202. ety decals are present and readable on the machine Refer to the Operation amp Safety Manual supplied with machine for information G10 55A G12 55A Section 2 General Information and Specifications Contents PARAGRAPH TITLE PAGE 2 1 Replacement Parts and Warranty Information 2 2 2 2 Torque Chants set ieee asas ae 2 3 2 2 1 SAE Fastener Torque 2 3 2 2 2 Metric Fastener Torque 2 7 2 2 3 Hydraulic Hose Torque Chart 2 10 2 3 Specifications eee ee ee eee nn 2 11 2 3 1 Travel Speeds 2225 iix ae Pees 2 11 2 3 2 Hydraulic Cylinder Performance 2 11 2 3 3 Electrical 2 12 2 3 4 Engine Performance Specifications John Deere 2 12 2 3 5 Engine Performance Specifications 2 12 2 3 6 Engine Performance Specifications Cummins 2 13 2 4 Fluid and Lubricant Capacities 2 15 2 5 Service and Maintenance Schedules 2 17 2 5 1 10 1st 50 amp 50 2 17 2 5 2 1st 250 250 8 500 2 18 2 5 3 1000 amp 1500
203. f lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often Refer to Section 2 5 Service and Maintenance Schedules and Section 2 6 Lubrication Schedules for detailed information Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration Contact the local distributor for guidance G10 55A G12 55A e E d 313 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 Y p 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 Straightness of the upper face of blade 5 and the front face of shank 6 should not exceed 0 5 percent of the length of blade or height of shank 2 Angle 7 between upper face of blade and front face of shank should not exceed 93 degrees 3 Thickness of blade 8 and shank 9 should not be reduced to 90 percent of original thickness Note Contact the local distributor with the fork part number to find the manufactured dimensions of the fork blade 4 Ensure fork leng
204. f the second boom section 3 13 3 5 10 Third amp 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 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 sling or using two slings for better stability around the third boom section and slowly insert the third and fourth boom sections into the second boom section being careful not to damage any surrounding components U L 2 Install adjusting block 17 using existing hardware 18 Torque as required 3 Install chain amp clevis 19 spring 20 spring stop 21 adjusting nut and lock nut 22 24 3 MY3650 4 Allow 0 50 in 1 27 mm A between the end of the clevis 23 and the face of the lock nut 24 Torque lock nut to 100 Ib ft 135 Nm 5 Properly connect the battery 6 Retract the second boom section pulling both retract chains at the same time 25 25 26 B 26
205. fer to driving Section 2 4 Fluid and Lubricant Capacities 2 Drain axle and or wheel end housings and fill to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 3 Correct alignment by adding or removing shims as needed 4 Correct bearing preload by adding or removing shims as needed 5 Replace bearings as needed 6 Replace gears as needed 7 Drain axle and or wheel end housings and fill to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 8 Replace damaged parts 2 Intermittent noise when 1 Universal joint s worn or traveling damaged 2 Differential ring and or pinion gears damaged 1 Repair or replace universal joints as needed 2 Determine cause and repair as needed 3 Vibration or intermittent noise 1 Drive shaft universal joint when traveling assembly ies incorrectly tightened 2 Drive shaft universal joint s worn or damaged 3 Drive shaft s damaged unbalanced 1 Tighten capscrews to correct torque 2 Repair or replace universal joints as needed 3 Replace drive shaft s as needed 5 6 G10 55A G12 55A Axles Drive Shafts Wheels and Tires hs Problem Cause Remedy 4 Oil leaking from axle differential housing and or axle housings 1 Drain and or inspection plugs loose and or o rings damaged or missing Hose fi
206. hafts bene 5 9 5 5 Wheels and Tires ui eld y Eel uy u 5 10 5 6 Brakes d dd dt 5 11 5 7 Towing a Disabled 5 11 Section 6 Transmission u ene ee afe le a e c 6 1 6 1 Transmission Assembly Component Terminology 6 2 6 2 Transmission Serial 6 3 6 3 Transmission Specifications And Maintenance 6 3 6 4 Transmission 2 6 3 6 5 Torque Convertor 6 6 6 6 Troubleshootirig 25 Dedi ubt bere ESL Ea b eR 6 7 Section 7 ENGING 7 1 7 1 Introduction John 7 2 7 2 Introduction 5 7 4 7 3 Introduction Cummins 4 7 6 7 4 Engine Cooling 7 8 7 5 Engine Electrical 7 10 7 6 i wat ne wS REX E
207. hat the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Properly disconnect the battery G10 55A G12 55A Electrical System MY 1030 5 Disconnect the wiring connector at the fuel shut off solenoid 6 lead 6 Remove the fuel shut off solenoid from the fuel b DO NOT disassemble a fuel shut off solenoid Replace a injector pump Fuel Shut off Solenoid Disassembly defective fuel shut off solenoid with a new part Fuel Shut off Solenoid Inspection Replacement Use 12 volt DC source and ground to test the solenoid Energize the solenoid and watch for the plunger to retract If the plunger does not retract replace the fuel shut off solenoid with a new part d 1 2 Fuel Shut off Solenoid Installation Clean the exterior of the fuel injector pump Install the fuel shut off solenoid on the fuel injection pump Do Not Over Tighten Connect the wiring connector at the fuel shut off solenoid lead 4 Properly connect the battery Start the engine If the engine starts the fuel shutoff solenoid is functioning If the engine fails to start the fuel shut off run solenoid may have a poor ground connection Visually check the wiring at the fuel shutoff solenoid leads and or check for continuity with a voltmeter as required Check for fuel and or oil leakage around the solenoid Close and secure the engine cover
208. he 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 Note order to remove the engine drive plates the engine and transmission must be separated 2 Refer to Section 6 4 1 Transmission Removal or Section 7 9 1 Engine Removal 7 MY1120 3 Remove the four bolts holding the diaphragms to the flywheel 4 With the drive plates and torque converter removed loosen and remove the four bolts 7 and eight lock washers holding the two diaphragms 8 to the torque converter 9 5 Replace both diaphragms if damaged 6 5 2 Torque Convertor Diaphragm Installation 1 Install the two new diaphragms on the torque converter and install the four bolts with lock washers 2 Mount the diaphragm converter assembly to the transmission 3 Refer to Section 6 4 3 Transmission Installation or Section 7 9 2 Engine Installation for the remainder of the installation G10 55A G12 55A Transmission 6 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 The transmission should be checked serviced and repaired only by experienced service technicians who are aware of all safety instr
209. heels blocked before performing any service FLUID TEMPERATURE NEVER work on a machine when the engine cooling or hydraulic systems are hot Hot components and fluids can cause severe burns Allow systems to cool before proceeding FLUID PRESSURE Before loosening any hydraulic or diesel fuel component hose or tube turn the engine OFF Wear heavy protective gloves and eye protection NEVER check for leaks using any part of your body use a piece of cardboard or wood instead If injured seek medical attention immediately Diesel fluid leaking under pressure can explode Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin cause infection gangrene and other serious personal injury Relieve all pressure before disconnecting any component part line or hose Slowly loosen parts and allow release of residual pressure before removing any part or component Before starting the engine or applying pressure use components parts hoses and pipes that are in good condition connected properly and are tightened to the proper torque Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations RADIATOR CAP The cooling system is under pressure and escaping coolant can cause severe burns and eye injury To prevent personal injury NEVER remove the radiator cap while the cooling system is hot Wear safety glasses Turn the radiator cap to the first stop and allow pre
210. hten the adjusting nut on the second boom section until the gap D between the washer and boom is 0 375 in 9 52 mm maximum Torque the lock nut to 100 Ib ft 135 Nm G10 55A G12 55A C E 4 After adjusting check to see that 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 _ gt gt MY3790 2 Measure the distance between the second boom section and the third boom section E The dimension should be 0 50 0 75 in 12 7 19 5 mm G10 55A G12 55A Note BOTTOM OF BOOM SHOWN WITH EXTEND RETRACT CYLINDER REMOVED FOR CLARITY Loosen second to third boom section retract chain lock nut and adjusting nut 3 as far as possible Loosen the third to fourth boom section retract chain lock nut and adjusting nut 4 as far as possible Tighten the retract chain adjusting nut 3 until the proper distance E is obtained and proper access hole alignment 2 is obtained Torque the lock nut to 100 lb ft 135 Nm Recheck the extend chain adjustments and readjust if necessary Measure the distance between the third boom section and fourth boom section F The dimension should be G10 55A 17 5 17 75 in 444 5 451
211. iformly to break the bond A temperature of 300 400 F 149 204 C will destroy the bond Avoid overheating or the parts may become distorted or damaged Apply sufficient torque for removal while the parts are still hot The sealant often leaves a white powdery residue on threads and other parts which must be removed by brushing with a soft brass wire brush prior to reassembly 11 Remove the piston head 5 from the rod 3 and carefully slide the head gland 4 off the end of the rod 12 Remove all seals back up rings and o rings from the piston head and all seals back up rings and o rings from the head gland Note The head gland bearing will need to be inspected to determine if replacement is necessary DO NOT attempt to salvage cylinder seals sealing rings or o rings ALWAYS use a new complete seal kit when rebuilding hydraulic components Consult the parts catalog for ordering information 8 22 b Cylinder Cleaning Instructions 1 Discard all seals back up rings and o rings Replace with new items from seal kit to ensure proper cylinder function 2 Clean all metal parts with an approved cleaning Solvent such as trichlorethylene Carefully clean cavities grooves threads etc Note white powdery residue is present on threads or parts it can be removed by using a soft brass wire brush Wipe clean with Loctite Cleaner prior to reassembly 8 8 2 1 Inspect internal surfaces and all parts for wear d
212. ill to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities 4 Refer to Section 9 10 3 Transmission Solenoid Valves 5 Repair or replace parts as needed 6 Replace diaphragm torque convertor Refer to Section 6 4 1 Transmission Removal 7 Tighten capscrews G10 55A G12 55A 6 9 6 Transmission Problem Cause Remedy 7 Oil leaking from transmission 1 Oil leaking from vent high oil level 2 Drain plug loose and or o rings damaged or missing 3 Hose fittings loose 4 Oil leaking at valve bodies possible valve body gaskets damaged or missing and or mounting capscrews not tight 5 Housing capscrews loose 6 Oil leaking at pump possible pump to housing o rings missing or damaged and or pump mounting capscrews not tight 7 Oil leaking at converter bell possible converter leak and or input shaft seal damage 8 Oil leaking at output shaft output shaft seal damaged 9 Oil escaping from breather at shut down 10 Housing damaged 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 Ib ft 130 Nm 2 Replace o rings as needed and tighten plug to 26 Ib ft 35 Nm 3 Tighten fittings 4 Replace gaskets and or tighten capscrews to 7 lb ft 9
213. ing device secure the tilt cylinder INSTALLATION barrel with a nylon strap 9 Remove both retaining clips 4 from each side of 3 5 1 Second Third amp Fourth Boom Section ineEOynder mopn ng pin a Removal 10 Remove the tilt cylinder mounting pin 5 1 Remove any attachment from the quick switch 11 Lower tilt cylinder from the boom head assembly Refer to the appropriate operation and 12 Support the front of the boom by placing a sling safety manual behind the boom head 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 Head Mounted Winch Removal 4 Park the machine on a hard level surface level the machine fully retract boom level the boom H d place the transmission control lever in IN N NEUTRAL engage the park brake and shut the engine OFF 6 5 7 8 5 Place Do Not Operate Tag on both the ignition key 13 Loosen the jam nut and lock nut 6 to release switch and the steering wheel stating that the tension from the hoses on the hose take up machine should not be operated weldment 7 6 Open the engine cover Allow the system fluids to 14 Loosen the hydraulic hoses 8 and electrical cables cool if equipped on the hose take up weldment 7 Plug 31 the hose ends and tube ends to prevent dirt and debris from entering the hydraulic system 13 12 11 10 9 1
214. inor the injury may seem Know the location of a First Aid Kit and know how to use it CLEANLINESS Wear eye protection and clean all components with a high pressure or steam cleaner before attempting service When removing hydraulic components plug hose ends and connections to prevent excess leakage and contamination Place a suitable catch basin beneath the machine to capture fluid run off It is good practice to avoid pressure washing electrical electronic components In the event pressure washing the machine is needed ensure the machine is shut down before pressure washing Should pressure washing be utilized to wash areas containing electrical electronic components JLG recommends a maximum pressure of 750 psi 52 bar ata minimum distance of 12 in 30 5 cm away from these components If electrical electronic components are sprayed spraying must not be direct and for brief time periods to avoid heavy saturation Check and obey all Federal State and or Local regulations regarding waste storage disposal and recycling Safety Practices A 1 6 4 ENGINE Stop the engine before performing any service unless specifically instructed otherwise Operational Hazards 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 w
215. ion wheel onto studs on wheel end of axle 2 Install wheel lug washers 3 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 9 4200 4 Tighten lug nuts an alternating pattern as indicated in figure Torque to 350 400 Ib ft 475 542 Nm 5 Remove machine from supports G10 55A G12 55A 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 For more information on brake disk inspection refer to the Axle Repair Manual P N 31200240 5 7 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 BEFOHE attempting to release the park brake Once the park brake is released the machine s park brake AND service brakes are inoperable 5 7 1 Manually Releasing the Park Brake 5 MZ1020 1 Loosen the nuts of the screws 5 for the manual release of the braking units Draw the nuts back approximately 6 mm 2 Tighten the screws until they are gently seated on the driving plate 3 Carefully tighten each release screw a 1 4 turn ata time in sequence until all have been turned o
216. ircuit Voltage Above Normal or Shorted to High Source 2112 52 4 Amber Coolant Temperature Coolant Temperature 2 Sensor Circuit Voltage Below Normal or Shorted to Low Source 2113 52 16 Amber Coolant Temperature Coolant Temperature 2 Data Valid but Above Normal Operational Range Moderately Severe Level 2114 52 0 Red Coolant Temperature Coolant Temperature 2 Data Valid but Above Normal Operational Range Most Severe Level 2115 2981 3 Amber Coolant Pressure Coolant Pressure 2 Circuit Voltage Above Normal or Shorted to High Source 2116 2981 4 Amber Coolant Pressure AEB15 60 Page 153 of 157 Coolant Pressure 2 Circuit Voltage Below Normal or Shorted to Low Source 2117 2981 18 Amber Coolant Pressure Coolant Pressure 2 Data Valid but Below Normal Operational Range Moderately Severe Level 2182 1072 3 Amber Engine Brake Output Engine Brake Actuator Driver 1 Circuit Voltage 1 Above Normal or Shorted to High Source 2183 1072 4 Amber Engine Brake Output Engine Brake Actuator Driver 1 Circuit Voltage 1 Below Normal or Shorted to Low Source 2185 3512 3 Amber System Diagnostic Sensor Supply Voltage 4 Circuit Voltage code 1 Above Normal or Shorted to High Source 9 52 G10 55A G12 55A Electrical System Fault SPN FMI Lamp E Codes Codes Codes Color SPN Description Cummins Description 2186 3512 4 Amber System
217. l level in the container Have the assistant depress the brake pedal DO NOT open the service brake bleeder without holding the tubing firmly on the bleeder There is pressure at the brakes Carefully open the bleeder with a 12 mm wrench Close the service brake bleeder when air bubbles no longer appear in the oil Release the brake pedal Remove the tubing from the service brake bleeder Repeat Steps 2 and 3 for the remaining service brake bleeders 5 Check hydraulic oil level and add if necessary Conduct a pressure and function check of the service brake Refer to Section 8 4 1 Hydraulic Pressures G10 55A G12 55A Hydraulic System n 8 7 5 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 ata 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 Service Brake Test Conduct the following service brake test on a dry level surface clear of any personnel and or obstacles 1 Place the travel select lever in N NEUTRAL engage the park brake and start the engine 2 Raise the boom to a travel position 3 Depress the service brake disengage the parking brake and place the travel
218. l level in the reservoir Oil level should be to the middle of the sight glass with all cylinders retracted 2 Check hoses tubes fittings and other hydraulic components for leaks bends kinks interference etc 3 Check for air in the hydraulic system Erratic machine performance and or spongy cylinder operation are signs of air in the hydraulic system If air in the hydraulic system is suspected you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid Loose fittings faulty o rings or seals trapped oil leaks system opened for service etc can cause air in the system Determine what is causing air to enter the system and correct it Bleed air from the system 8 4 1 Hydraulic Pressures a Checking Pressure 1 Start the machine and warm the hydraulic system to operating temperature 2 Shut off the machine and install a digital or a 5000 psi 345 bar gauge to the appropriate test port on the hydraulic manifold 3 Start the machine run the engine at high idle and bottom the appropriate hydraulic function Refer to Section 8 4 1 Hydraulic Pressures for the correct pressure rating b Adjusting Hydraulic Pressure 1 Shut the machine off Remove the cap on the relief if necessary 2 Start the machine and loosen the jam nut on the relief Turn the relief clockwise to increase pressure or counter clockwise to decrease pressure Set to the correct pressu
219. le to the battery negative terminal Close and secure the engine cover G10 55A G12 55A 4 3 4 a 1 2 Boom Joystick Assembly Boom Joystick Assembly Removal 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 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Properly disconnect the battery 0950 Lift the joysticks rubber sleeve remove the bolts securing the boom joystick to the cab console 7 Lift the boom joystick from its mounting position Label disconnect and cap the hydraulic hoses attached to the boom joystick Disconnect the electrical harness connector from the joystick Remove the boom joystick assembly Boom Joystick Assembly Installation Uncap and connect the previously labeled hydraulic hoses to their appropriate locations Connect the electrical harness connector to the joystick Install the bolts securing the boom joystick to the cab console Properly connect the battery Test the boom extend retract and boom lift lower joystick function 4 5 Cab and Covers a Move the joystick handle rearward activating the boom lift function The boom should RISE b Move the joystick handle forward
220. lean all parts using an approved cleaning fluid Allow to dry Drive Shaft Cleaning and Drying 2 Remove and burrs or rough spots from all machined surfaces Re clean and dry as required 5 4 5 1 Raise the drive shaft assembly into position The slip yoke end of the drive shaft mounts toward the axle If reinstalling a drive shaft previously removed align the flange yokes according to the alignment marks made during removal Drive Shaft Installation Note The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration 2 Apply Loctite 242 to all mounting bolts 3 Install the two straps 2 and four new bolts 1 securing the bearing crosses to the transmission Torque bolts to 55 60 Ib ft 75 81 Nm 4 Install the two straps 4 and four new bolts 3 securing the bearing crosses to the axle Torque bolts to 55 60 Ib ft 75 81 Nm Repeat the above procedure on the rear drive shaft Properly connect the battery Close and secure the engine cover Unblock the wheels Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 5 9 Axles Drive Shafts Wheels and Tires 5 5 WHEELS AND TIRES A 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 t
221. llation Install the complete air cleaner assembly Refer to Section 7 8 2 Air Cleaner Assembly Installation John Deere amp Perkins or Section 7 8 4 Air Cleaner Assembly Installation Cummins Connect the fuel inlet line to the fuel filter head Connect the fuel return line to the fuel filter head Install the Power Distribution bracket Connect all the previously labeled electrical wire connections on the Power Distribution bracket Connect all the previously labeled electrical wire connections on the engine Install both heater hoses to the engine and tighten clamps if equipped Install the complete radiator assembly Refer to Section 7 4 3 Radiator Oil Cooler and Replacement 7 15 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 limit stop screw until it touches the pedal bracket Note Have an assistant stand by with a Class B fire extinguisher 21 Start the engine and run to normal operating temperature then shut off the engine While the engine is cooling check for leaks 22 Allow the engine to cool Check the r
222. low of fluid no air while engine is cranking 13 Once a constant flow is achieved at the open end of the drain hose disconnect the hose and reinstall the 10 amp fuse to location F3 in the power distribution unit 14 Inspect for leaks and check all fluid levels The hydraulic reservoir oil level must be to the middle of the sight gauge 15 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel c Pump Test Refer to Section 8 3 1 Pressure Checks and Adjustments G10 55A G12 55A 8 7 CONTROL VALVES 8 7 1 The main control valve is mounted at the top of the chassis in front of the mast supports Main Control Valve The main control valve assembly consists of individual working sections with their own valve assemblies each providing a specific hydraulic function a Main Control Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in 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 Properly disconnect the battery Close the engine cover Remove the main valve cover E EE ANE Ps Thoroughly clean the main control valve and surrounding area including all hoses an
223. ly mounted on the machine 1 Park the machine on a firm level surface Allow sufficient overhead and side clearance for cab removal Level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the park brake and shut the engine OFF 2 Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab removal 3 Open the engine cover Allow the system fluids to cool gt Properly disconnect the battery 5 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain petcock and allow the coolant to drain 6 Transfer the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility 7 Tighten the radiator drain petcock 8 Disconnect the cab heater hoses Refer to Section 4 3 7 Heater Air Conditioning System if equipped 4 8 Remove the necessary dash panels to gain access to the electrical wiring connections Label and disconnect the harnesses Push the harness connectors through the opening in the cab Remove the boom joystick from is mounting position Refer to Section 4 3 4 Boom Joystick Assembly Label disconnect and cap all hydraulic hoses attached to the boom joystick Cap fittings and openings to keep dirt and debris from entering the
224. m steering 1 Hose fittings loose 1 Tighten fittings cylinder 2 Steering cylinder o rings and or 2 Replace o rings and seals seals worn or damaged 3 Piston rod seal worn or 3 Replace piston rod seal damaged 4 Cylinder tube damaged 4 Replace cylinder tube G10 55A G12 55A 5 7 hs Axles Drive Shafts Wheels and Tires Problem Cause Remedy 7T Axle overheating 1 Oil level too high 1 Fill oil to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant damaged leaking Capacities 2 Axle and or wheel end housings 2 Drain axle and fill to correct filled with incorrect oil or oil level with hydraulic oil Refer to contaminated or oil level low Section 2 4 Fluid and Lubricant Capacities 3 Dragging park brake 3 Adjust park brake cable as needed 8 High steering effort required 1 Steering hydraulic system not 1 Refer to Section 8 4 Hydraulic operating properly Circuits 2 Excessive joint housing swivel 2 Correct bearing preload by bearing preload adding or removing shims as needed 3 Worn or damaged swivel 3 Replace swivel bearings as bearings needed 9 Slow steering response 1 Steering hydraulic system not 1 Refer to Section 8 4 Hydraulic operating properly Circuits 2 Steering cylinder leaking 2 Repair or replace steering internally cylinder as needed 10 Exces
225. mate Fasteners SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Torque Tensile Torque Torque Loctite 242 or 2717 Loctite amp 262 Bolt Dia Clamp Load OR OR Lubricated Stress Area ey Vibra TITE 111 or 140 Vibra TITE 131 m San tB IB Nm Nm 4 onm wo 8 o9 e T ono o 10 7 98 6 32 01380 00009 580 18 0 01380 610 20 38 sez otea 0090 22 25 3 ss 286 24 0190 0070 120 43 48 32 35 _ _ C 0900 002000 ss s TJ 20 02500 0o18 2020 9 308 9 39 e l 02500 00384 2320 mrs w ws 457 m san tB FB Nm Fe Nm Fre Fr Nm 38 16 746 14 0 4375 0 1063 6800 50 68 35 47 55 75 45 61 20 0435 0187 7550 5 75 4 54 6 82 50 68 12 13 05000 0 1419 900 75 12 5 75 85 16 6 9 20 05000 01599 10700 90 12 65 88 10 16 80 108 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 58 11 34 10 78 9 12 13750 1 3150 73000 1680 2278 1260 1708 1750 2380 1506 2042 NOTES 1 THESE
226. mber Auxiliary Pressure Auxiliary Pressure Sensor Input 2 Circuit Voltage Below Normal or Shorted to Low Source 319 251 2 Maint Real Time Clock Real Time Clock Power Interrupt Data Erratic Power Intermittent or Incorrect 322 651 5 Amber Injector Cylinder 01 Injector Solenoid Cylinder 1 Circuit Current Below Normal or Open Circuit 323 655 5 Amber Injector Cylinder 05 Injector Solenoid Cylinder 5 Circuit Current Below Normal or Open Circuit 324 653 5 Amber Injector Cylinder 03 Injector Solenoid Cylinder 3 Circuit Current Below Normal or Open Circuit 325 656 5 Amber Injector Cylinder 06 Injector Solenoid Cylinder 6 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 334 110 2 Amber Engine Coolant Coolant Temperature Sensor Circuit Data Temperature Erratic Intermittent or Incorrect 338 1267 3 Amber Vehicle Accessories Idle Shutdown Vehicle Accessories Relay Relay Driver Driver Circuit Voltage Above Normal or Shorted to High Source 339 1267 4 Amber Vehicle Accessories Idle Shutdown Vehicle Accessories Relay Relay Driver Driver Circuit Voltage Below Normal or Shorted to Low Source G10 55A G12 55A 9 47 Electrical Syst
227. mical Class B fire extinguisher near the work area Remove the hydraulic oil reservoir drain plug and safely drain any hydraulic oil into a suitable container Dispose of hydraulic oil properly Clean the hydraulic oil reservoir with a high pressure washer or flush the tank with hot water for five minutes and drain the water Dispose of contaminated water properly Inspection Inspect the hydraulic oil reservoir thoroughly for any cracks slices leaks or other damage With the hydraulic oil reservoir 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 Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area Reservoir Installation Place the hydraulic oil reservoir into its original orientation Secure the hydraulic oil reservoir to the frame with the previous mounting hardware Uncap and connect the previously labeled hydraulic hoses to their appropriate locations Install the hydraulic fluid level sight glass using special designed and drilled capscrews and gaskets Install hydraulic filter bracket and hydraulic filter Fill the hydraulic oil reservoir according to specifications Refer to Section 2 4 Fluid and Lubricant Capacities 7 Check the hydraulic oil reservoir for leaks Properly conne
228. moval MY3710 1 Using a suitable lifting device secure the winch assembly 4 with a nylon strap 2 Disconnect the hydraulic hoses 5 3 Loosen and remove the mounting bolts washers and nuts 6 not shown 4 Lower the winch assembly 4 onto a suitable skid or table 3 10 2 Boom Head Mounted Winch Installation 1 Using a suitable lifting device secure the winch assembly 4 with a nylon strap 2 Raise the winch assembly 4 into position behind the boom head 3 Apply Loctite 242 to the previously removed mounting bolts 4 Install the mounting bolts washers and nuts 6 not shown Torque to 200 lb ft 271 Nm 5 Connect the hydraulic hoses 5 3 24 311 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 Wear Pad Inspection 1 1 lt ae Ma2070 Inspect all wear pads for wear If the angle indicators 1 on the ends of the wear pads are visible the wear pads can be reused If the pads show uneven wear front to back they should be replaced Replace pads as a set if worn or damaged 3 11 2 Note Inspect all wear pads Replace as necessary Wear Pad Installation and Lubrication The following wear pad procedure must be followed to insure the proper wear pad installation The wear pad inserts and mo
229. n 2 Pull the pivot pin from the service brake pedal bracket 3 Remove the service brake pedal from the cab Service Brake Pedal Installation Position the service brake pedal in its mounting location within the cab Secure the brake pedal into position with the pivot pin Be sure the brake pedal has the correct range of motion Secure pivot pin with bolt and lockwasher 4 Properly connect the battery 5 Close and secure the engine cover G10 55A G12 55A Cab and Covers a 4 3 3 a 1 Throttle Pedal Throttle Pedal Removal 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 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Properly disconnect the battery 0940 4 Disconnect electrical harness connector 4 Remove the bolts 5 securing the throttle pedal to the throttle pedal bracket 6 Remove the throttle pedal assembly from the cab Throttle Pedal Installation Position the throttle pedal in its mounting location within the cab Secure the throttle pedal into position with the pivot pin Install the throttle pedal ball joint to the throttle pedal Connect the battery negative cab
230. n cracked seized or otherwise improper parts that could affect the safe and proper functioning of the machine axles and drive shafts 5 3 AXLE ASSEMBLIES 5 3 1 The front and rear axle serial number plate is located on a mounting pad on the front side of the center section of each axle Information on the serial number plate is required in correspondence regarding the axle Axle Serial Number Plate Supply information from the axle serial number plate when communicating about an axle assembly or axle components 5 3 2 General axle specifications are found in Section 2 General Information and Specifications Axle Specifications G10 55A G12 55A 5 3 3 Detailed axle service instructions covering the axle differential brakes and wheel end safety repair disassembly reassembly adjustment and troubleshooting information are provided in the Axle Repair Manual P N 31200240 Axle Internal Service 5 3 4 Axle Maintenance CLEANING Clean parts with machined or ground surfaces such as gears bearings and shafts with emulsion cleaners or petroleum based cleaners DO NOT steam clean internal components and the interior of the planetary hub and axle housing Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Remove old gasket material from all surfaces DRYING Use clean lintless towels to dry components after cleaning DO NOT dry bearings
231. n the exterior of the transmission to help prevent dirt from entering during the replacement process Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components G10 55A G12 55A 6 4 1 Transmission Removal A 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 Ib 454 kg 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 steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove engine cover to allow easier access to the transmission 5 Drain the hydraulic oil reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 6 Properly disconnect the battery 7 Thoroughly clean the transmission and surrounding area including all hoses and fittings before proceeding 0980 8 Place a suitable receptacle under the transmission drain plug 2 Remove the transmission drain plug and allow the transmission oil to drain into the receptacle Repeat drain procedure with the drop box 3 6 3 Transmission
232. n Cab Route a sling with a minimum lifting capacity of 1000 Ibs 453 kg under the inner four braces 13 and behind the center cross support above the wind shield or install two lifting eye bolts 14 in the threaded holes on the roof of the cab above the B pillars 15 Enclosed Cab Install two lifting eye bolts 14 in the threaded holes on the roof of the cab above the B pillars 15 Route a sling with a minimum lifting capacity of 1000 16 453 kg through the lifting eye bolts 16 oO OO OO MY4170 17 Remove the two cab side mount bolts in the cab 16 Remove the four cab to frame bolts flat washers and nuts 17 Remove the mirrors and all other cab components as needed if not previously removed 55A G12 55A 4 5 Carefully begin to lift the cab Stop and check that all wiring hydraulic hoses and fasteners are disconnected or removed 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 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 Assure that no personnel enter the cab while it is bei
233. n each end of the valve section Assemble the Main Control Valve 1 Place all three tie rods 2 with the washers and nuts through the end main control valve section 2 Stand the end main control valve section on end 3 Install the proper o rings and load sense shuttle on the inner face of the end main control valve section Align the tilt control valve section over the three tie rods and slide onto the end main control valve section G10 55A G12 55A Hydraulic System Using the proper o rings and load sense shuttle repeat step three for the remaining valve sections and lastly the inlet end valve section Install the three washers and nuts on the tie rods Torque to 30 Ib ft 41 Nm Main Control Valve Installation 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 Prime the main control valve by filling the inlet openings with fresh filtered hydraulic oil from a clean container before attaching the hoses Use new oiled o rings as required Uncap and connect all previously labeled hoses clamps etc to the main control valve Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps Fill the hyd
234. n full turn 360 4 Repeat steps 1 thru 3 for the other side of the differential Note After the machine has been towed to a secure location reactivate the parking brake Carefully follow the procedures from start to finish Contact the local distributor if you are unsure about any part of the procedure or for specific instructions concerning your particular situation ES Axles Drive Shafts Wheels and Tires 5 7 2 Manually Resetting the Park Brake Note Block the wheels of the machine BEFOHE 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 A MZ1020 1 Loosen each release screw 5 only 1 4 turn ata time in sequence until each screw has lost contact with the guide pin 2 Remove the screws along with the nuts and seals Replace the seals lubricate the screws with a silicone based grease and re install the screws along with the nuts 3 Adjust the nut of the screw heads in relation to the arm by 1 18 in 30 mm 4 Repeat steps 1 thru 3 for the other side of the differential 5 After repairs to the machine have been made start the machine and check the park brake and service brakes for proper function Refer to Section 8 7 4 Service Brake Bleeding Section 8 7 5 Service Brake Test and Section 8 7 6 Park Brake Test 5 12 G10 55A G12 55A
235. n the ground cable over the correct starter mounting bolt Secure the starter with the three fasteners Connect the positive battery cable to the upper solenoid stud Install the wires to the upper solenoid stud and secure with lock washer and nut Connect the wire to the solenoid mounting stud Properly connect the battery Close and secure the engine cover G10 55A G12 55A Electrical System 6 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 7 2 Charging Circuit MY0370 Before using a battery charger an attempt can be made to recharge the battery by jump starting the machine Refer to the appropriate Operation amp Safety Manual Allow the engine to run which will enable the alternator 2 to charge the battery If the engine alternator charging warning indicator illuminates perform the following checks 1 Check all battery cable connections at the battery and verify that they are clean and tight 2 Check the external alternator wiring and connections and verify that they are in good condition 3 Check the fan belt condition and tension 4 Run the engine and check the alternator for noise A loose drive pulley loose mounting hardware worn or dirty internal alternator bearings a defective stator or defective diodes can cause noise Replace a worn or defective alternator 9 7 3 Alternator a Alternator Removal 1 Place a Do
236. nd the engine fan 2 f necessary install the engine fan 3 Install the radiator fan shroud 4 Uncap and connect the previously labeled hoses to the radiator oil cooler and or transmission cooler 5 Connect both intercooler hoses 6 Install the coolant recovery tank Uncap and connect the previously removed hose 7 Open the radiator cap and fill the radiator completely with coolant Replace and tighten the radiator cap Refer to Section 2 4 Fluid and Lubricant Capacities for proper capacities 8 Properly connect the battery 9 Run the engine to operating temperature Visually check for leaks with the engine running Check the coolant level in the overflow bottle and fill or drain as necessary 10 Close and secure the engine cover 11 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 10 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 6 FUEL SYSTEM 7 6 1 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 Diesel Fuel Note Use only diesel fuel designed for diesel engines Some heating fuels contain harmful chemicals that can seriously
237. ng bolts are recessed Wear Pad Bolt Torque 3 8 24 Bolt 32 37 Ib ft 43 50 Nm 3 8 24 Hollow Bolt 15 17 Ib ft 20 23 Nm 1 2 20 Bolt 76 86 Ib ft 103 116 Nm 1 2 20 Hollow Bolt 45 50 Ib ft 61 68 Nm Torque wear pad bolts after shimming is completed Lubricate the face and pockets of each wear pad after being installed Boom Section Wear Pad Pathway Lubrication Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease 6 Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease G10 55A G12 55A 3 12 BOOM EXTEND AND RETRACT CHAINS 3 12 1 Boom Chain Inspection A WARNING Worn pins stretched or cracked links or corrosive environments can cause chain failure A chain failure could result in uncontrolled boom movement loss of load or machine instability Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation The retract chains need to be exposed and inspected every 1000 hours of operation Environmental conditions and dynamic impulse shock loads can drastically affect normal operating conditions and require more frequent inspection intervals Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit Some
238. ng devises being used to keep the boom sections from moving 7 Properly connect the battery 8 Adjust the extend chains as needed Refer to Section 3 7 Section Separation Adjustment 3 18 9 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 3 7 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 gt 4 gt MY3800 4 Measure the gap D between the flat washer at the extend chain anchor on the top front of the first boom section and the second boom section If the gap is greater that 0 375 in 9 52 mm the boom chains will need to be adjusted Adjust the extend chain as follows 1 Loosen the lock nut 1 on each of the extend chains 2 Tighten the adjusting nuts on the first boom section until the gap D between the flat washers and boom is 0 375 in 9 52 mm maximum The gap must be equal on both chains Torque the lock nut to 100 Ib ft 135 Nm Note Verify the exposed threads on both extend chain clevises are kept equal 3 Tig
239. ng removed from the machine Inspect the condition of the fittings clamps hydraulic hoses etc Replace parts as indicated by their condition Inspect and replace other machine parts that are exposed with the cab removed Repair or replace as required CAB INSTALLATION 1 Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab installation 14 13 MY0610 Open Cab Route a sling with a minimum lifting capacity of 1000 Ibs 453 kg under the inner four braces 13 and behind the center cross support above the wind shield or install two lifting eye bolts 14 in the threaded holes on the roof of the cab above the B pillars 15 Enclosed Cab Install two lifting eye bolts 14 in the threaded holes on the roof of the cab above the B pillars 15 Route a sling with a minimum lifting capacity of 1000 Ibs 453 kg through the lifting eye bolts 4 9 Cab and Covers 4 Use 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 n d 16 16
240. ngine water temperature sender if connected to the thermostat housing Properly connect the battery 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 This overfilling will compensate for any air trapped in the cooling system Run the engine to operating temperature Visually check for leaks with the engine running Check the coolant level in the overflow bottle and fill or drain as necessary Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 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 4 Ifthe engine runs hot check the temperature of the upper radiator hose If the hose is not hot the thermostat may be stuck in the closed position If the engine has overheated performance may suffer indicating other damage including a leaking cylinder head gasket cracked cylinder head or block and or other internal engine damage Radiator Oil Cooler Removal Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel selec
241. no currently active detected faults warnings diagnostics or events ON OFF Active Diagnostic Should the warning lamp illuminate Engine is running during engine running this normally but has one or indicates that an Active diagnostic more faults with engine Electrical fault is present management system ON FLASH Derate Should the warning lamp illuminate Engine is running but has Invoked by Active and the shutdown lamp flash one or more Active Diagnostic during engine running this diagnostic events that indicates that an Active diagnostic have initiated engine Electrical fault is present The derate diagnostic is sufficiently serious to invoke engine derate FLASH OFF Warning Should the warning lamp flash Engine is running Warning only during engine running this normally but has one or indicates that one or more of the more monitored engine engine protection strategy warning parameters outside of the values have been exceeded but acceptable range notto a level that will invoke Derate or Shutdown FLASH FLASH Derate Should both the Warning Lamp Engine is running but Warning and and Shutdown Lamp flash during one or more of the Derate engine running this indicates that monitored engine one or more of the engine parameters has gone protection strategy values have beyond that of warning been exceeded beyond the level only and has now required to invoke engine derate exceeded those set for engine derate ON ON Engine Shutdo
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243. o be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using an approved replacement tire It is recommended that replacement tires have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability Foam filled tires have a positive effect on the weight stability and handling characteristics of the machine especially under load The use of hydrofill as a tire fill substance is not recommended because of possible environmental impact Large bore valve stems are used to help expedite tire inflation and deflation An inner tube may be used if a tire does not provide an airtight seal Check tire inflation pressures when the tires are cold When mounting a tire on the wheel the tire must be mounted on the wheel respective of the directional tread pattern of the tire this produces a left or right
244. ocks from the front and rear of both tires on the other axle Note ALWAYS use new o rings when servicing the machine 16 17 18 19 20 21 22 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil Uncap and connect the steering and brake lines at their axle fittings Check the hydraulic reservoir oil level Start the engine Turn the steering wheel several times lock to lock operate the frame tilt function several times in both directions and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary Install the optional fender assembly Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Note The service brake and parking brake circuits will need to bled after axle installation Refer to Section 8 7 4 Service Brake Bleeding 5 5 ES Axles Drive Shafts Wheels and Tires 5 3 7 Axle Assembly and Drive Shaft Troubleshooting 2 Axle and or wheel end housings filled with incorrect oil or oil level low 3 Incorrect alignment of ring and pinion gears 4 Incorrect pinion input shaft bearing preload 5 Worn or damaged bearings 6 Worn or broken gear teeth 7 Contamination in the axle 8 Axle housing damaged Problem Cause Remedy 1 Excessive axle noise while 1 Oil level too low 1 Fill oil to correct level Re
245. olant to drain 7 Transfer the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility 8 Tighten the radiator drain petcock 9 Remove the bolts that secure the seat to the cab Remove the seat G10 55A G12 55A Cab and Covers ay 0190 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 12 Loosen the hose and disconnect the heater air duct hoses 12 G10 55A G12 55A HEATER WITH AIR CONDITIONING SHOWN 16 16 14 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 Remove the bolts 16 securing the heater assembly to the cab Remove the heater assembly b Heater Assembly Installation Note If machine is equipped with air conditioning the air conditioning system must be charged by the local JLG dealer or certified air conditioning service center 1 Position the heater assembly to its original orientation in the cab Secure with the previous hardware 2 Connect the previously labeled electrical connections 3 Connect
246. ons x pue pb Dex kde gane De dubi qas s ue 1 3 1 7 Safety tua hae oe aetna ee ee bb d vt d Mero 1 4 Section 2 General Information and Specifications 2 1 2 1 Replacement Parts and Warranty 2 2 2 2 a pee dads Ad De ged edge oer 2 3 2 3 SPCCHICATIONS 22 Bia ce enn eerie teas 2 11 2 4 Fluid and Lubricant 2 15 2 5 Service and Maintenance 2 17 2 6 Lubrication Schedules 2 20 Section 3 BOOM 2042 22 OD c ea C D a us 3 1 3 1 Boom System Component 3 3 3 2 Boom System Four 3 4 3 3 Boom Assembly 3 4 3 4 Complete Boom Removal Installation 3 5 3 5 Boom Section 1 3 6 3 6 Extend Retract Chain 3 16 3 7 Boom Section Separation
247. ont of the fourth boom section 15 Torque as required MY3480 13 Install guide bracket 16 P N using the previously removed hardware 17 Torque as required 3 5 7 Note Inspect and lubricate all extend and retract chains before re assembly Refer to Section 3 12 1 Boom Chain Inspection for detailed information Third Boom Section Assembly 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 e4 2 2 E ee 1 M 2 Install the previously removed chain roller 1 at rear of the third boom section Insert the mounting pin retainer plate and hardware Torque as required 3 Install the previously removed wear pads and spacers 2 at each side 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 3 12 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
248. ontrollably depress the throttle pedal Note Do Not hold the accelerator pedal in the fully depressed position for more than ten seconds Damage to the power train could occur 6 Smoothly and controllably fully release the throttle pedal 7 The machine should remain stationary during the test 8 If the machine does not remain stationary during this test contact the local distributor for proper service 9 Engage the park brake place the travel select lever in N NEUTRAL lower the boom and shut engine OFF 8 7 7 Steering Orbitrol Valve 4280 The steering orbitrol valve 7 is located the base of the steering wheel shaft concealed by the lower dash cover The valve is not serviceable and must be replaced in its entirety if defective For detailed information refer to Section 4 3 1 Steering Column and Orbitrol Valve 8 19 Hydraulic System 8 7 8 Steer Select Valve MY4290 The machine can be used in the front wheel four wheel or crab steering mode The steer select valve 8 controls the direction of hydraulic fluid flow to the steering cylinder mounted on each axle The steer select valve is attached to a mounting plate under the frame near the left front corner of the cab Verify the correct operation of the steer select valve solenoids before considering replacement of the valve Refer
249. oom unless approved in writing by the manufacturer The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling G10 55A G12 55A N VU VU 3 4 COMPLETE BOOM REMOVAL INSTALLATION 3 4 1 Complete Boom Removal 1 Remove any attachment from the quick switch assembly Refer to the appropriate operation and safety manual Remove the quick switch assembly Refer to Section 3 9 1 Quick Switch Removal If equipped remove the Boom Head Mounted Winch Refer to Section 3 10 1 Boom Head Mounted Winch Removal 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool 7 Properly disconnect the battery 8 Support the front of the boom by placing a sling 10 11 12 13 14 3 4 2 1 behind the boom head Label disconnect and cap all hydraulic hoses for the extend retract and tilt circuits Cap fittings and openings to keep dirt amp debris from entering the hydraulic system Support the lift lower cylinder on the left side of the machine Remove the lock bolt and rod
250. oper fluid level 4 Start the engine allow it to reach operating temperature and observe the operator s display cluster for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire damaged transmission improper or low fluid etc 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 5 Engine Coolant Temperature Sender a Engine Coolant Temperature Sender 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 G10 55A G12 55A Electrical System Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Properly disconnect the battery CUMMINS ENGINE SHOWN Unplug the engine coolant temperature sender connector 1 from the wiring harness connector The engine coolant temperature sender 2 is located near the upper radiator hose thermostat housing and threaded into the engine block Remove the sender Engine Coolant Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or
251. ough the cylinder and cylinder anchor Secure the cylinder mount pin with one capscrew and a new locknut Apply multi purpose grease through the self tapping lube fitting to lubricate the self align bearing and the cylinder mount pin Install the drive shaft assemblies Refer to Section 5 4 5 Drive Shaft Installation If reinstalling an axle previously removed from the machine position the driveshaft yoke on the axle according to the alignment marks made earlier If installing a new axle note the position of the driveshaft yoke at the transmission Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission MY4180 10 Tighten the axle oil drain plug loosen and remove the axle oil fill plug 1 Refer to Section 2 4 Fluid and Lubricant Capacities for proper oil and capacities LEVEL MY0220 G10 55A G12 55A 11 12 13 14 15 Rotate wheel hubs 90 degrees so the drain plug 2 becomes the fill plug 3 Refer to Section 2 4 Fluid and Lubricant Capacities for proper oil and capacities Install the wheel and tire assemblies Refer to Section 5 5 2 Installing Wheel and Tire Assembly onto Machine Carefully remove the jack hoist or overhead crane and sling supporting the axle Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the machine to the ground Remove the bl
252. ow radiator removal or remove the hoses tubes from the engine Inspect the hoses and replace if necessary Loosen and remove the hoses 6 attached to the oil cooler Plug and or cap the hoses to prevent dirt and debris from entering the hydraulic 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 9 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 13 Remove the radiator fan guard 14 Remove the nuts and washers the radiator fan shroud and pull the shroud back over the fan 15 Remove the nuts and washers from the radiator and oil cooler mounts 16 Carefully lift the radiator and oil cooler out of the engine compartment Note If more clearance is needed to remove the radiator the engine fan may be removed for easier access b Radiator Oil Cooler Installation 1 Install the isolator mounts to the bottom of the radiator and oil cooler Place the radiator and oil cooler in the engine compartment at their original orientations Secure with the previously used hardware Note Be sure there is adequate clearance between the radiator a
253. per motor 7 Remove the linkage attached to the wiper motor 8 Loosen and remove the four bolts holding the wiper motor to the mounting bracket Note Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing 9 Remove the motor from the inside of the cab 9 28 b Disassembly DO NOT disassemble the motor The motor is not serviceable Replace motor if found to be defective c Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found d Installation and Testing 1 Install all required hardware to the motor assembly 2 Align motor with the mounting holes and bolt the motor to the mounting bracket 3 Connect the wiper linkage to the wiper motor shaft Note Align the wiper linkage arm with the flat on the motor shaft to ensure wiper stroke covers window area and it does not swipe past the glass area 4 Connect the cab harness connectors to windshield wiper motor connectors 5 Replace the main dash panel to its original orientation Secure with the previously used screws 6 Properly connect the battery 7 Turn ignition key switch to the RUN position and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved 8 If previously removed install hydraulic hoses under the dash Refer to Section 4 3 1 Steering Column and Orbitrol Valve
254. r Installation 91 14 nu ci 5 13 lt FRONT BOOM 1 2 Remove the caps from the tubes on the hose carrier MY3480 Inspect the hose carrier track 6 for any broken or missing clips Repair or replace as needed 5 63 MY3750 Note Connect the tilt cylinder hoses and auxiliary hoses to the hose carrier bulkhead before installing the hose carrier in the fourth boom section 3 Install tilt cylinder hose 7 to the bottom left fitting on the hose carrier tube 8 Install tilt cylinder hose 9 to the top left fitting on the hose carrier tube 10 Install adaptors 11 to each auxiliary tube at the front right of the hose carrier Install auxiliary hoses 12 to each adaptor 11 no the auxiliary tubes at the front right of the hose carrier 7 Orient each auxiliary hose 12 as shown above Torque each fitting and hose as required G10 55A G12 55A 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 Align the hose carrier 14 to the hose carrier guide bracket 13 CS PT n 15 MY3470 12 Align the hose carrier mounting bracket and install the previously removed hardware to mounting bracket at the fr
255. raulic fluid reservoir Refer to Section 8 5 2 Hydraulic Oil Reservoir Filling Properly connect the battery Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 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 hyaraulic fluid to the reservoir as needed 9 10 11 12 f Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools Install the main control valve cover Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Main Control Valve Test Conduct a pressure check of the hydraulic system in its entirety Adjust pressure s as required Refer to Section 8 3 1 Pressure Checks and Adjustments G10 55A G12 55A 8 7 3 Service Brake Valve a Service Brake Valve 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 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
256. rb the machine while removing the axle Balance the axle and prevent it from tipping turning or falling while removing it from beneath the machine Place the axle on a suitable support or holding stand 5 3 6 1 Before proceeding ensure that the machine will remain in place during axle installation Block the front and rear of both tires on the axle that is already installed on the machine Axle Installation 2 If applicable raise the machine using a suitable jack or hoist Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation G10 55A G12 55A Axles Drive Shafts Wheels and Tires hs 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 Position the axle under the frame and align the axle housings with the holes in the frame Install the four axle bolts and nuts Tighten and torque to 530 565 Ib ft 718 766 Nm Move the oylinder into position on the axle cylinder anchor Insert a cylinder mount pin thr
257. re G10 55A G12 55A Hydraulic System n 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 4 f the proper pressure cannot be set use the accompanying hydraulic schematic and or the electrical schematic to help troubleshoot and correct the problem 8 4 2 Tilt Circuit Port Relief Adjustment The following procedure is specific to the tilt circuit only and should be performed and verified if the main and or load sense circuits pressures are in question 1 Remove any attachment from the quick coupler assembly Refer to Section 3 9 Quick Switch Assembly Raise the boom for access to the compensation cylinder MY5520 Slowly loosen and remove the retract 1 hose from the compensation cylinder Install a tee fitting to the retract 1 port of the compensation cylinder Reconnect the previously removed retract 1 hose to the tee fitting Slowly loosen and remove the extend 2 hose from the compensation cylinder Install a tee fitting to the extend 2 port of the compensation cylinder Reconnect the previously removed extend 2 hose to the tee fitting and cap the open port Install a digital or a 5000 psi 345 bar gauge to the retract 1 port tee fitting on the compensation cylinder Start the machine and warm the hydraulic system to operating
258. re Data Valid but Above Normal Operational Range Moderately Severe Level 131 91 3 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor Position Circuit Voltage Above Normal or Shorted to High Source 132 91 4 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor Position Circuit Voltage Below Normal or Shorted to Low Source 133 974 3 Red Remote Accelerator Remote Accelerator Pedal or Lever Position Sensor Circuit Voltage Above Normal or Shorted to High Source 134 974 4 Red Remote Accelerator Remote Accelerator Pedal or Lever Position Sensor Circuit Voltage Below Normal or Shorted to Low Source 135 100 3 Amber Engine Oil Pressure Oil Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 141 100 4 Amber Engine Oil Pressure Oil Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 143 100 18 Amber Engine Oil Pressure Oil Pressure Low Data Valid but Below Normal Operational Range Moderately Severe Level 144 110 3 Amber Engine Coolant Coolant Temperature Sensor Circuit Voltage Temperature Above Normal or Shorted to High Source 145 110 4 Amber Engine Coolant Coolant Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source G10 55A G12 55A 9 43 Electrical System Fault SPN FMI Lamp m Codes Codes Codes Color SPN Description Cummins Description 146
259. re aware of all safety instructions and particular component features Note Contact the JLG Service Department if internal transmission repair is required during the warranty period 9 10 4 Transmission Temperature Sender a Transmission Temperature Sender Removal The transmission temperature sender 10 is located at the bottom left side of the transmission housing 9 32 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 Unplug the transmission temperature sender connector from the wiring harness connector 6 The sender is threaded into the transmission housing Remove the sender b Transmission Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part c Transmission Temperature Sender Installation and Testing 1 Thread the transmission temperature sender into the transmission housing snugly then connect the sender connector to the wiring harness connector 2 Properly connect the battery 3 Check for pr
260. re Level 2363 1073 4 Amber Engine Compression Engine Brake Actuator Circuit 2 Voltage Brake Output 2 Below Normal or Shorted to Low Source 2365 1112 4 Amber Engine Brake Output Engine Brake Actuator Driver Output 3 Circuit 3 Voltage Below Normal or Shorted to Low Source 2367 1073 3 Amber Engine Compression Engine Brake Actuator Circuit 2 Voltage Brake Output 2 Above Normal or Shorted to High Source 2368 1112 3 Amber Engine Brake Output Engine Brake Actuator Driver 3 Circuit Voltage 3 Above Normal or Shorted to High Source 2372 95 16 Amber Engine Fuel Filter Fuel Filter Differential Pressure Data Valid but Differential Pressure Above Normal Operational Range Moderately Severe Level 2373 1209 3 Amber Exhaust Gas Exhaust Gas Pressure Sensor Circuit Voltage Pressure Above Normal or Shorted to High Source 2374 1209 4 Amber Exhaust Gas Exhaust Gas Pressure Sensor Circuit Voltage Pressure Below Normal or Shorted to Low Source 2375 412 3 Amber Exhaust Gas Exhaust Gas Recirculation Temperature Sensor Recirculation Circuit Voltage Above Normal or Shorted to Temperature High Source 2376 412 4 Amber Exhaust Gas Exhaust Gas Recirculation Temperature Sensor Recirculation Circuit Voltage Below Normal or Shorted to Temperature Low Source 2377 647 3 Amber Fan Clutch Output Fan Control Circuit Voltage Above Normal or Device Driver Shorted to High Source 2425 730 4 Intake Air Heater 22 Intake Air Heater 2 Circui
261. repair assembly adjustment and troubleshooting information are provided in the appropriate Perkins engine service manual G10 55A G12 55A 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 CONTROL L1 MODULE FUEL FILTER O C FUEL INJECTOR PUMP JP OIL FILTER 10260 ALTERNATOR TURBOCHARGER 0270 G10 55A G12 55A Engine 7 3 INTRODUCTION CUMMINS 7 3 1 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 Disclaimer and Scope Note These instructions cover only the routine maintenance removal installation and troubleshooting of the engine Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis repair and componen
262. retract chain as the boom is slowly extended If there is ANY question that one or all the retract chains are damaged the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary Note DO NOT attempt to repair a chain Replace a stretched or damaged chain with a new part Always replace both the chain and the clevis It is recommended that when any chain is replaced that all chains and clevis be replaced at the same time 3 28 3 12 4 After inspection and before being returned to service chains must be lubricated with Mystik Tetrimoly Grease Chain Lubrication The lubricant must penetrate the chain joint to prevent wear Applying lubricant to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links To prepare the chain for lubrication the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces All surplus lubricant should be wiped away from the external surfaces DO NOT use a solvent for this wiping operation Regular application o
263. rical System 9 4 3 Power Distribution Unit VEC John Deere Perkins IGN1 CB3 F4 CB2 CB 1 F9 F7 _ IGN3 F10 27011 Fii 2 212 F5 ACCY2 MY1250 Connector Legend No Function Amp Rating CB1 Options Power 3 20 CB2 Options Power 4 20 CB3 Options Power 1 20 CB4 Options Power 2 20 F1 Trans Park Brake Power 15 F2 Alternator Excite 5 F3 Engine ECU Ignition Power 10 F4 Gauge Power 10 F5 Spare Accessory Power 15 F6 Auxiliary Electric Power 10 F7 Horn Power 15 F8 Spare Battery Power 25 F9 Engine ECU Battery Power 25 F10 Steer Sway Power 10 F11 Rear Axle Stabilizer Tilt Power 10 F12 Key Battery Power 15 IGN1 Ignition 1 IGN 2 Ignition 2 ACCY1 Accessory 1 ACCY2 Accessory 2 G10 55A G12 55A 9 7 Electrical System 9 4 4 Power Distribution Unit VEC Cummins IGN1 F15 F4 F16 F14 Fis 9 7 IGN3 F10 Ld En ACCY1 gt F12 5 ACCY2 F6 MY4610 Connector Legend
264. riefly 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 17 Wait for the engine to cool and check the coolant level Add coolant to the overflow bottle as required to bring the coolant to the proper level 18 Install the mirrors and all other cab components as needed if removed 19 Close and secure the engine cover 20 Unblock the wheels 21 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G10 55A G12 55A Section 5 Axles Drive Shafts Wheels and Tires Contents PARAGRAPH TITLE PAGE 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 2 General 5 3 5 3 Axle 5 5 3 5 3 1 Axle Serial Number 5 3 5 3 2 Axle 5 3 5 3 3 Axle Internal 5 3 5 3 4 Axle 5 3 5 3 5 Axle Removal tines cack end pita ve Rape 5 4 5 3 6 Axle Installation 5 4 5 3 7 Axle Assembly and Drive Shaft Troubleshooting
265. roleum 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 fluid has a flash point that ranges from 300 600 F 150 318 C and an auto ignition temperature of 500 750 F 262 402 C Accordingly periodically inspect all hydraulic system components hoses tubes lines fittings etc Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard If in doubt replace the component Operate the hydraulic controls after the engine has stopped to relieve trapped pressure Note Residual pressure may remain in hydraulic cylinders hoses valve bodies components etc If the hyaraulic lines going to or coming from a component are taut slowly and cautiously relieve bleed off pressure Whenever you disconnect a hydraulic line coupler fitting or other component slowly and cautiously loosen the part involved A hissing sound or slow seepage of hydraulic fluid may occur in most cases After the hissing sound has ceased continue removing the part Any escaping oil should be directed into an appropriate container Cap or otherwise block off the part to prevent further fluid seepage Hydraulic system maintenance will at times require that the engine be operated Al
266. roughly 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 Check the reservoir for leaks by applying a soap solution to 7 11 Engine the exterior and look for bubbles to appear 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 Refer to Section 2 4 Fluid and Lubricant Capacities 7 Check fuel tank for leaks 8 Properly connect the battery 9 Close and secure the engine cover 10 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 6 3 1 Drain and flush the fuel tank if it was contaminated After Fuel System Service 2 Vent air from the fuel system in accordance with the instructions found in the appropriate Operation amp Safety Manual 3 Fill the fuel tank with fresh clean diesel fuel as required 7 12 7 7 ENGINE EXHAUST SYSTEM 7
267. s g h 11 u 11 1 i 12 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 510 G10 55A G12 55A MY4160 Install the previously removed chain roller 13 at the rear of the second boom section Insert the mounting pin retainer plate and hardware Torque as required Install the previously removed wear pads and spacers 14 at the top rear of the second 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 Install the previously removed wear pads and spacers 15 at each side rear of the second 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 Install the previously removed wear pads and spacers 16 at the bottom rear of the second 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 Shims may be required to maintain a 0 070 0 130 in 1 78 3 30 mm gap at the top rear o
268. s 4 Properly connect the battery 5 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions G10 55A G12 55A Hydraulic System n 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 8 Close and secure the engine cover 9 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel d Steering Test Refer to Section 8 4 1 Hydraulic Pressures 1 Conduct a pressure check of the steering hydraulic circuit 2 Check each steering mode for proper function 8 8 HYDRAULIC CYLINDERS 8 8 1 General Cylinder Removal Instructions 1 Remove any attachment from the machine Park the machine on a firm level surface and fully retract the boom Allow sufficient work space around the hydraulic cylinder being removed Support the boom if the lift lower cylinder is being removed Place the travel select lever in NEUTRAL engage the park brake shut the engine OFF and chock wheels 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 th
269. s are included with a new transmission G10 55A G12 55A Transmission 6 4 3 Transmission Installation A 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 Install two guide studs near the top of the bell housing holes 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 Align the torque converter align the transmission bolt holes with the two studs in the bell housing Install the eight bolts and washers and torque to 53 Ib ft 72 Nm Remove the two alignment studs and install and torque the last two transmission mounting bolts Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers Apply Loctite 242 to the transmission mount bolts and torque to 125 140 lb ft 169 190 Nm the engine over slowly by hand and align each of the four torque convertor diaphragm bolts through the access plug in the bell housing Install them one at atime DO NOT fully tighten until all of the capscrews and locknuts are in place Torque to 26 39 lb ft 35 59 Nm Replace access plug 7 Remove the hoist or overhead crane and sling 10 11 12 13 14
270. se 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 Disclaimer and Scope Note These instructions cover only the routine maintenance removal installation and troubleshooting of the engine Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis repair and component replacement A gradual running in break in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F 60 C Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds DO NOT apply an overload to the engine 7 4 7 2 2 The Perkins 1104D serial number Is stamped on top of the engine Information contained in the serial number is required in correspondence with the engine manufacturer Engine Serial Number 7 2 3 Specifications and Maintenance Information For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Detailed Perkins engine service instructions covering disassembly inspection internal
271. section REAR STEERING CYLINDER TRANSMISSION DROP BOX REAR AXLE ASSEMBLY REAR DRIVE SHAFT REAR AXLE FRONT STEERING WHEEL HUBS 2 CYLINDER FRONT DRIVE SHAFT FRONT AXLE WHEEL HUBS ASSEMBLY 2 MY0570 5 2 G10 55A G12 55A Axles Drive Shafts Wheels and Tires 5 2 GENERAL INFORMATION A 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 Before performing any inspection maintenance or service operation thoroughly clean the unit The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts Carefully inspect the integrity of all moving parts bearings yokes tubes gears shafts etc and fasteners nuts bolts washers etc as they are subject to major stress and wear Always replace elastic locknuts and any damaged wor
272. securing the joystick to the cab 3 Install the dash panel to its original position with the previously used hardware 4 Properly connect the battery 5 Test the complete range of the joystick functions 6 Close and secure the engine cover 4 3 6 Windshield Wiper Assembly Refer to Section 9 8 Window Wiper Washer Windshield Wiper Motor for removal and installation information 4 3 7 Heater Air Conditioning System if equipped Note If machine is equipped with air conditioning DO NOT loosen or disconnect any air conditioning hoses until the air conditioning system has been properly drained by the local distributor or certified air conditioning service center a Heater 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 NEUTRAL position 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 Place a suitable container beneath the radiator Slowly turn the radiator cap to the first stop allow any pressure to escape Remove the radiator cap 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain petcock and allow the co
273. 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 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 c Main Control Valve Parts Cleaning Clean all components with a suitable cleaner such as triclorethylene before continuing Blow dry d Main Conirol Valve Parts Inspection Inspect all parts and internal passageways for wear damage etc If inner surfaces of any component DO NOT display an ultra smooth polished finish or are damaged in any way replace the damaged part Often dirty hydraulic fluid causes failure of internal seals damage to the polished surfaces within the component and wear of and or harm to other parts 8 7 2 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 Main Control Valve Assembly Assemble each Valve Section 1 Reassemble any check valves compensator valves anti cavitation valves or shock valves from each individual valve sections if equipped 2 Install the control spool being careful not to nick or scratch the valve section bore or the control spool 3 Install the end caps o
274. ses together where they extend from each end of the hose carrier 8 Fasten the two hydraulic carriers together using plastic tie wraps or nylon straps for stability G10 55A G12 55A 3 8 3 1 Clean and lubricate the side surfaces where the hose carrier rides Hose Carrier Assembly Installation 2 Fully collapse the hose carriers and secure together using plastic tie wraps or nylon straps to keep them from separating 3 Install a sling around the balance point of the hose carrier With a suitable lifting device slowly insert the hose carrier into the front of the fourth boom section 4 Remove the first plastic tie wrap or nylon strap as the hose carrier is being inserted into the front of the fourth boom section 5 Continue inserting the hose carrier and removing the plastic tie wraps or nylon straps until the hose carrier is fully inserted into the boom MY2740 6 Install the guide bracket 1 on the front of the hose carrier 2700 2 3 7 Verify that the bottom bracket 2 on the hose carrier is in place on the bottom plate 3 of the fourth boom section 8 Install the cap screws washers and nuts to the hose carrier bracket at the rear of the third boom section 9 Install both cap screws and locknuts to the hose carrier bracket at the front of the fourth boom section 10 Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the rear of th
275. sition engage the parking brake and shut the engine OFF 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 and remove the battery Properly disconnect and remove the second battery if equipped 5 Remove the engine cover Mark the position of the cover to help with cover adjustment when being reinstalled 6 Remove the oil pan cover underneath the engine compartment 7 Drain and remove the radiator assembly Refer to Section 7 4 3 Radiator Oil Cooler and Replacement 8 Remove the heater hoses attached to the engine if equipped Note The engine harness is routed and attached to the engine using hold down clamps and plastic wire ties at various places on the engine Before removing engine ensure that the harness has been completely separated disconnected from the engine Move the harness clear of the engine and with the help of an observer ensure that the engine clears the harness during removal 9 Label and disconnect all electrical wire connections on the engine 10 Label and disconnect all electrical wire connections on the Power Distribution bracket 11 Remove the Power Distribution bracket 12 Disconnect and cap the fuel inlet line at the fuel filter head 13 Disconnect and cap the fuel return line from the fuel filter head G10
276. sive noise when brakes 1 Brake discs worn 1 Check brake discs for wear are engaged Refer to Section 5 6 Brakes 2 Brake discs damaged 2 Replace brake discs 11 Brakes will not engage 1 Brake hydraulic system not 1 Refer to Section 8 4 Hydraulic operating properly Circuits 2 Brake piston o rings and seals 2 Replace o rings and seals damaged leaking 12 Brakes will not hold the 1 Brake discs worn 1 Check brake discs for wear machine or braking power Refer to Section 2 4 Fluid and reduced Lubricant Capacities 2 Brake hydraulic system not 2 Refer to Section 8 4 Hydraulic operating properly Circuits 3 Brake piston o rings and seals 3 Replace o rings and seals 5 8 G10 55A G12 55A Axles Drive Shafts Wheels and Tires 54 DRIVE SHAFTS 5 4 1 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 Drive Shaft Inspection and Service 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 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 Note Any bolt removed from the
277. sly labeled load sense hose to the steering valve 6 Uncap and connect the remaining previously labeled four hoses to the steering valve Note If necessary install the main dash panel Refer to Section 9 11 1 Analog Gauges 7 Properly connect the battery 8 Startthe engine and check the operation of steering system Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required 9 Close and secure the engine cover C Steering Test Conduct a pressure check of the steering hydraulic circuits at the main control valve Refer to Section 8 3 1 Pressure Checks and Adjustments 4 3 2 Service Brake Pedal a Brake Valve Removal Refer to Section 8 7 3 Service Brake Valve for removal information b Brake Valve Installation Refer to Section 8 7 3 Service Brake Valve for installation information 4 4 Service Brake Pedal Removal 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 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Properly disconnect the battery MY0140 Remove the bolt and lockwasher 1 securing the service brake pedal pivot pi
278. ssure to escape before removing the cap completely Failure to follow the safety practices could result in death or serious injury FLUID FLAMABILTITY DO NOT service the fuel or hydraulic systems near an open flame sparks or smoking materials NEVER drain or store fluids in an open container Engine fuel and hydraulic fluid are flammable and can cause a fire and or explosion DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause an explosion PRESSURE TESTING When conducting any test only use test equipment that is correctly calibrated and in good condition Use the correct equipment in the proper manner and make changes or repairs as indicated by the test procedure to achieve the desired result LEAVING MACHINE Lower the forks or attachment to the ground before leaving the machine TIRES Always keep tires inflated to the proper pressure to help prevent tipover DO NOT over inflate tires NEVER use mismatched tire types sizes or ply ratings Always use matched sets according to machine specifications MAJOR COMPONENTS Never alter remove or substitute any items such as counterweights tires batteries or other items that may reduce or affect the overall weight or stability of the machine BATTERY DO NOT charge a frozen battery Charging a frozen battery may cause it to explode Allow the battery to thaw before jump starting or connecting a battery charger 1 7 SAFETY DECALS Check that all saf
279. t Voltage Below Normal or Shorted to Low Source 2426 730 3 Intake Air Heater 2 Intake Air Heater 2 Circuit Voltage Above Normal or Shorted to High Source 9 54 G10 55A G12 55A Electrical System Fault SPN FMI Lamp ES A E Codes Codes Codes Color SPN Description Cummins Description 2555 729 3 Amber Inlet Air Heater Intake Air Heater 1 Circuit Voltage Above Driver 1 Normal or Shorted to High Source 2556 729 4 Amber Inlet Air Heater Intake Air Heater 1 Circuit Voltage Below Driver 1 Normal or Shorted to Low Source 2557 697 3 Amber Auxiliary PWM Auxiliary PWM Driver 1 Voltage Above Driver 1 Normal or Shorted to High Source 2558 697 4 Amber Auxiliary PWM Auxiliary PWM Driver 1 Voltage Below Driver 1 Normal or Shorted to Low Source 2963 110 15 None Engine Coolant Engine Coolant Temperature High Data Valid Temperature but Above Normal Operational Range Least Severe Level 2973 102 2 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit Data Erratic Intermittent or Incorrect G10 55A G12 55A 9 55 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
280. t lever in the N NEUTRAL position engage the parking brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Properly disconnect the battery G10 55A G12 55A 11 Slowly turn the radiator to the first stop and allow any pressure to escape Remove the radiator cap Place a suitable container beneath the radiator drain Place a funnel at the base of the radiator to channel the drained coolant into a container Loosen the drain cock and slowly remove to allow the coolant to drain Transfer the coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Tighten the radiator drain cock Label disconnect and cap the hoses attached to the coolant recovery tank Remove the coolant recovery tank CUMMINS RADIATOR ASSSEMBLY MY4530 Loosen the clamps on the hoses tubes 4 attached to the intercooler Work the hoses off the intercooler 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 Loosen the clamps on the hoses 5 attached to the radiator Work the hoses off the radiator Position the hoses out of the way to all
281. t replacement A gradual running in break in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F 60 C Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds DO NOT apply an overload to the engine 7 6 7 3 2 The Cummins serial number Is stamped on top of the engine Information contained in the serial number is required in correspondence with the engine manufacturer Engine Serial Number 7 3 3 Specifications and Maintenance Information For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Detailed Cummins engine service instructions covering disassembly inspection internal repair assembly adjustment and troubleshooting information are provided in the appropriate Cummins engine service manual G10 55A G12 55A 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 FUEL FILTER SECONDARY FUEL INJECTOR ac _ PUMP OIL FILTER EN
282. t temperature sender switch connector from the wiring harness connector Unplug the air manifold temperature sensor connector from the wiring harness connector 3 1 1 MY1270 The air manifold temperature sensor 3 is threaded into the engine block Remove the sender Air Manifold Temperature Sensor Inspection and Replacement Inspect the sensor and the wiring harness connector terminals for continuity Replace a defective or faulty sensor with a new part Air Manifold Temperature Sensor Installation and Testing Thread the air manifold temperature sensor into the air manifold snugly then connect the sensor connector to the wiring harness connector Properly connect the battery Check for proper coolant level 9 34 9 10 7 Start the engine allow it to reach operating temperature and observe the operator s instrument cluster for warning indication If the sensor is not defective the problem could be elsewhere possibly in a shorted wire improper running engine improper or low coolant obstructed or faulty radiator coolant pump loose fan belt defective instrument display etc Close and secure the engine cover 6 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Engine Oil Pressure Sender Switch Engine Oil Pressure Sender Switch Removal Park the machine on a firm level surface level the machine fully retract the boom low
283. t the same rate The boom section lifts and lowers via action of the lift lower cylinder 3 4 3 3 BOOM ASSEMBLY MAINTENANCE These instructions provide the complete boom assembly removal and installation or the second third and fourth boom sections removal and installation Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions The boom assembly consists of the first second and third section booms and supporting hardware Note Before removing the boom or boom section the carriage or any other attachment must be removed from the quick switch Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions During service of the boom perform the following 1 Check wear pads Refer to Section 3 11 Boom Wear Pads 2 Check hose sheaves and chain rollers 3 Apply grease at all lubrication points grease fittings Refer to Section 2 6 Lubrication Schedules 4 Check for proper operation by operating all boom functions through their full ranges of motion several times Depending on your particular circumstance the following procedures explain the removal installation of individual boom sections or removal installation of the complete boom A WARNING NEVER weld or drill the b
284. temperature Tilt the forks down to allow the tilt cylinder to fully retract G10 55A G12 55A 10 11 12 13 14 15 Monitor the gauge and slowly raise the boom The gauge should read 4100 psi 282 bar If pressure is correct proceed to step 14 MY4490 FRONT OF MACHINE If the pressure requires adjustment and if the machine is equipped with a Rexroth main control valve adjust the relief on the A port and repeat steps 9 and 10 If the machine is equipped with a Husco main control valve the relief on the A port is non adjustable and must be replaced Replace and repeat steps 9 and 10 Verify pressure is correct Shut engine OFF Remove the digital or the 5000 psi 845 bar gauge from the retract 1 port tee fitting on the compensation cylinder and cap the open port Remove the cap and install a digital or a 5000 psi 345 bar gauge to the extend 2 port tee fitting on the compensation cylinder Start the machine and if needed warm the hydraulic system to operating temperature Tilt the forks up to allow the tilt cylinder to fully extend Monitor the gauge and slowly lower the boom The gauge should read 4100 psi 282 bar If pressure is correct proceed to step 23 8 5 Hydraulic System 21 22 23 24 25 8 6 4490 FRONT OF MACHINE If the pressure requires adjustment and if the machine is equipped with a Rexroth m
285. th 10 is adequate for intended loads 5 Fork markings should be legible re stamp if required 6 Compare fork tips 11 when mounted on a carriage Maximum difference in height of fork tips is 3 percent of the length of the blade 10 G10 55A G12 55A 3 29 CY 3 14 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom Problem Cause Remedy 1 Boom will not extend or 1 Broken hydraulic hose s or 1 Locate break replace hose s retract tube s and or connections or tube s tighten connections leaking 2 Extend retract hydraulic system 2 Refer to Section 8 4 Hydraulic not operating properly Circuits 3 Faulty extend retract cylinder 3 Repair cylinder Refer to Section 8 8 Hydraulic Cylinders 2 Boom shifts to right or left 1 Boom side wear pads 1 Shim wear pads to correct gap when extending improperly shimmed or worn Replace wear pads as needed Refer to Section 3 11 Boom Wear Pads 3 Excessive boom pivot pin 1 Insufficient lubrication 1 Lubricate at regular intervals noise and or wear 2 Worn bearing s Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed 2 Replace bearing s and lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules 4 Excessive Compensation 1 Insuffi
286. the outer retract chain 1 Fasten a rope to the end of the chain in order to pull it back into the boom 2 Attach the chain to the chain clevis at the rear of the boom 3 Carefully pull the chain into the boom until it can be fastened to the chain clevis 4 Remove the rope 5 Fastened the chain into the clevis by installing the pin and cotter pin 6 Install the chain adjustment block and mounting bolts Torque the chain adjustment block mounting bolts to 360 390 Ib ft 475 530 Nm 7 Install the extend retract cylinder and cylinder support 8 Adjust the retract chains as needed Refer to Section 3 7 Boom Section Separation Adjustment 9 Properly connect the battery 10 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 3 6 3 The following section explains the removal of the extend chains without removing the boom assemblies Extend Chain Removal 1 Park the machine on level ground Place the transmission control lever in NEUTRAL engage the parking brake switch level the boom extend the boom far enough to access the chain anchor and the clevis through the top rear access hole shut the engine OFF 3 17 b Boom Place Do Not Operate Tag 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
287. thods and proper repair procedures are essential for the safety of the individual doing the work for the safety of the operator and for the safe reliable operation of the machine All references to the right side left side front and rear are given from the operator s seat looking in a forward direction Supplementary information is available from JLG in the form of Service Bulletins Service Campaigns Service Training Schools the JLG website other literature and through updates to the manual itself 1 2 DISCLAIMER All information in this manual is based on the latest product information available at the time of publication JLG reserves the right to make changes and improvements to its products and to discontinue the manufacture of any product at its discretion at any time without public notice or obligation 1 3 OPERATION 4 SAFETY MANUAL The mechanic must not operate the machine until the Operation amp Safety Manual has been read amp understood training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator An Operation amp Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab In the event that the Operation amp Safety Manual is missing consult the local distributor before proceeding 14 DO NOT OPERATE TAGS Place Do Not Operate Tags on the ignition key switch and the steering
288. time replacement is necessary ROPS FOPS must be properly installed using fasteners of correct size and grade and torqued to their specified value WARNING DO NOT weld grind drill repair modify the cab any way Any modification or damage to cab structural components requires cab replacement Refer to page 2 9 in the Operators amp Safety Manual To help ensure optimum safety protection and performance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information 4 2 2 The cab serial number decal is located on the left side of the cab behind the seat Information specified on the serial number plate includes the cab model number the cab serial number and other data Write this information down in a convenient location to use in cab correspondence Serial Number Decal 4 3 CAB COMPONENTS 4 3 1 Steering Column and Orbitrol Valve a Orbitrol Valve 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 G10 55A G12 55A 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 Note may be necessary to remov
289. ts are removed Place blocks under the transmission to help support it during removal Remove both rear transmission mount bolts and lockwashers securing the transmission mount to the frame Remove the bolts and washers holding the transmission to the engine Remove the capscrews and lockwashers securing each rear transmission mount to the transmission Carefully remove the transmission from the machine Avoid causing damage to the transmission or surrounding parts Lift the transmission clear of the machine and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service Secure the transmission so that it will not move or fall 26 27 28 29 6 4 2 Remove any external transmission components as required including the transmission temperature switch and inlet and outlet cooler hose fittings Cover all transmission openings 0990 Remove the transmission oil filter 4 and dispose of properly Clean the filter mounting surface Cover or cap the oil filter mount If transmission oil is suspect to contamination or torque converter is damaged remove the converter and flex plate from the transmission Remove the bolt and washers holding the converter to the flex plate Transmission Inspection and Internal Repair If replacing the entire transmission transfer the transmission temperature switch to the replacement transmission The gear shift solenoid
290. ttings loose Axle shaft seal damaged or missing and or worn or damaged shaft sealing surfaces Input shaft multi seal ring damaged or missing and or worn or damaged pinion input shaft sealing surfaces Axle casing to brake housing and or brake housing to differential assembly o rings and or seals worn or damaged Axle housing mounting nuts and capscrews loose Differential and or axle housing s damaged 1 Replace o rings as needed and tighten plugs to 96 Ib ft 130 Nm Tighten fittings Replace seal and or joint coupling fork shaft axle shaft Replace multi seal ring and or input shaft Adjust ring and pinion alignment and bearing preload as described in the Engine Repair Manual Replace o rings and seals Tighten housing nuts and capscrews to 288 Ib ft 390 Replace housing s as needed 5 Oil leaking from wheel end housing planet carrier Oil level plugs loose and or o rings damaged or missing O ring between hub and housing planet carrier damaged or missing Replace o rings as needed and tighten plugs to 96 Ib ft 130 Nm Replace o ring 3 Shaft seal damaged or missing 3 Replace seal and or fork joint and or worn or damaged shaft shaft sealing surfaces 4 Housing capscrews loose 4 Tighten housing capscrews to 41 Ib ft 55 Nm 5 Housing planet carrier damaged 5 Replace housing planet carrier 6 Oil leaking fro
291. ty messages carefully read understand and follow the instructions before proceeding 1 6 1 Personal Hazards PERSONAL SAFETY GEAR Wear all the protective clothing and personal safety gear necessary to perform the job safely This might include heavy gloves safety glasses or goggles filter mask or respirator safety shoes or a hard hat LIFTING NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards LIFTING OF EQUIPMENT Before using any lifting equipment chains slings brackets hooks etc verify that it is of the proper capacity in good working order and is properly attached NEVER stand or otherwise become positioned under a suspended load or under raised equipment The load or equipment could fall or tip DO NOT use a hoist jack or jack stands only to support equipment Always support equipment with the proper capacity blocks or stands properly rated for the load HAND TOOLS Always use the proper tool for the job keep tools clean and in good working order and use special service tools only as recommended G10 55A G12 55A 1 6 3 SOLVENTS Only use approved solvents that are known to be safe for use HOUSEKEEPING Keep the work area and operator s cab clean and remove all hazards debris oil tools etc General Hazards FIRST AID Immediately clean dress and report all injuries cuts abrasions burns etc no matter how m
292. uctions and particular component features transmission repair is required during the warranty period Problem Cause Remedy or will not shift properly 1 Transmission will not engage 1 Oil level too high or low Transmission control lever not functioning properly and or a fault in the wiring harness Transmission control lever not functioning properly and or a fault in the wiring harness Transmission valve body solenoids not functioning properly Pilot operated shift valves not operating properly Pump output pressure low Clutch piston o rings damaged Clutch discs worn or damaged Coupling shafts or gear teeth damaged 1 Fill transmission to correct level with hydraulic oil Refer to Section 2 4 Fluid and Lubricant Capacities Refer to Section 9 5 Electrical System Schematics Refer to Section 9 5 Electrical System Schematics Clean the valve spool and housing Replace return spring as needed Refer to Section Note Contact the local distributor if internal transmission repair is required during the warranty period Problem 2 Low or no pump flow or pressure Replace o rings Replace clutch discs Replace couplings G10 55A G12 55A 6 7 Transmission Problem Cause Remedy 2 Low or no pump flow or 1 Low oil level 1 Fill transmission to correct level pressure with
293. uel Tank 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 NEUTRAL position engage the parking brake and shut the engine OFF 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 Note If replacing the tank remove all internal and external components from the old tank and retain for use on the replacement tank Note Have a dry chemical Class B fire extinguisher near the work area a Xl MY4230 5 Remove fuel tank drain plug 1 and drain fuel into an approved and suitable container Dispose of fuel properly 6 Label disconnect and cap the supply fuel line 2 from the bottom of the fuel tank 7 Label disconnect and cap the return fuel line 3 from the bottom of the fuel tank 8 Disconnect the fuel gauge harness 4 9 Remove screws securing fuel sender 5 to the tank Remove fuel sender from tank 10 Remove the bolts on the fuel tank hold down bar 13 11 Lift the empty fuel tank from the rear of the cab G10 55A G12 55A b Disassembly The fuel tank is a one piece unit and cannot be disassembled The fuel level indicator can be removed and reused on the new repl
294. uired 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 11 Manually retract the boom sections as required to connect the retract chains 31 EET s MY3590 12 Install the bracket and clevis assembly 31 at the rear of the fourth boom section Torque mounting bolts 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 Place the sling or using two slings for better stability around the second boom section and slowly insert the second third and fourth boom sections into the first boom section being careful not to damage any surrounding components and allowing sufficient room to install the wear pads at the front of the first boom section G10 55A G12 55A MY4140 2 Install the previously removed wear pads spacers and shims at the bottom front of the first boom section 1 Snug mounting bolts Shim as needed AFTER boom section is installed to maintain a 0 070 0 130 in 1
295. ummins 9 23 9 6 3 Start amp Charge Circuit John Deere amp 9 24 9 6 4 Start amp Charge Circuit 9 25 9 7 Engine Start Circuit ere e ead e ER IE es 9 26 9 7 1 Gack eR 9 26 9 7 2 Charging Circuit 9 27 9 7 3 Alternator uu sassa I XR ed q 9 27 G10 55A G12 55A 9 1 Electrical System 9 2 9 8 9 9 9 10 9 11 9 12 9 13 9 14 9 15 Window Wiper Washer Windshield Wiper Motor 9 28 9 8 1 Windshield Rear Window Washer Reservoir 9 29 Cab Heater and Fan oscuro Xe bx mE x 9 30 9 9 1 Cab Heater 1 5 9 30 Solenoids Sensors and Senders 9 30 9 10 1 Fuel Shut off Solenoid John 9 30 9 10 2 Park Brake Solenoid Valve 9 31 9 10 3 Transmission Solenoid Valves 9 32 9 10 4 Transmission Temperature 9 32 9 10 5 Engine Coolant Temperature 9 32 9 10 6 Manifold Temperature Sensor John Deere 9 34 9 10 7 Engine Oil Pressure Sender Switch
296. unting bolts MUST be clean from any grease oil or other contaminates before applying Loctite 242 and installing mounting bolts Apply Loctite 242 to all wear pad mounting bolts 4 1390 spacer 2 with holes must be used before shim 3 is used A shim 3 must be inserted between the spacer 2 and wear pad support plate block or boom section 4 The number of shims can vary at each shim point The bottom wear pads must be shimmed equally on each side G10 55A G12 55A C E 5510 Maintain a total boom section clearance 5 of 0 070 0 130 in 1 78 3 30 mm both the horizontal and vertical directions i E lt m 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 The bolt length should be determined by measuring the distance from the face of the insert to the face of the boom B including any spacer shim s and washer s Bolt thread engagement in the wear pad insert should be 0 275 0 040 in 6 98 1 0 mm One or two hardened washers are to be used on each wear pad bolt except where noted otherwise DO NOT use more than two hardened washers Use only one hardened washer if mounti
297. w Normal or Shorted to Low Source 285 639 9 Amber SAE J1939 Datalink SAE J1939 Multiplexing PGN Timeout Error Abnormal Update Rate 286 639 13 Amber SAE J1939 Datalink SAE J1939 Multiplexing Configuration Error Out of Calibration 287 91 19 Red Accelerator Pedal SAE J1939 Multiplexing Accelerator Pedal or Position Lever Sensor System Error Received Network Data In Error 288 974 19 Red Remote Accelerator SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error Received Network Data In Error 9 46 G10 55A G12 55A Electrical System Fault SPN FMI Lamp E A Codes Codes Codes Color SPN Description Cummins Description 292 441 14 Red Auxiliary Auxiliary Temperature Sensor Input 1 Special Temperature 1 Instructions 293 441 3 Amber OEM Temperature Auxiliary Temperature Sensor Input 1 Circuit Voltage Above Normal or Shorted to High Source 294 441 4 Amber OEM Temperature Auxiliary Temperature Sensor Input 1 Circuit Voltage Below Normal or Shorted to Low Source 295 108 2 Amber Barometric Pressure Barometric Pressure Sensor Circuit Data Erratic Intermittent or Incorrect 296 1388 14 Red Auxiliary Pressure Auxiliary Pressure Sensor Input 1 Special Instructions 297 1388 3 Amber Auxiliary Pressure Auxiliary Pressure Sensor Input 2 Circuit Voltage Above Normal or Shorted to High Source 298 1388 4 A
298. ways follow safety precautions A major cause of hydraulic component failure is contamination Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs Sand grit and other contaminants can damage the finely machined surfaces within hydraulic components If operating in an exceptionally dirty environment change filters and inspect the fluid more often When servicing the system cap or plug hydraulic fittings hoses and tube assemblies Plug all cylinder ports valves and the hydraulic reservoir and pump openings until installation occurs Protect threads from contamination and damage G10 55A G12 55A Some hydraulic functions are actuated by interfacing with electrical system components switches solenoids and sensors When the hydraulic system is not functioning properly check the electrical aspect of the malfunctioning circuit also Refer to Section 9 5 Electrical System Schematics in this manual 8 3 HYDRAULIC PRESSURE DIAGNOSIS JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting the JLG Pressure Test Kit The kit is contained in a durable polyethylene carrying case for demanding field service conditions Hydraulic Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system The kit includes Gauges for testing high and low pressure circuits Fittings couplers
299. wn Should both the Warning Lamp Engine is either shutdown and Shutdown Lamp illuminate during engine running this indicates that either 1 One or more of the engine protection strategy shutdown values has been exceeded 2 serious Active diagnostic has been detected Shortly after time duration to be agreed engine will shutdown or shutdown is imminent one of more monitored engine parameters have gone beyond that of warning or derate and have now exceeded those set for engine shutdown or a serious Active diagnostic has been detected 9 42 G10 55A G12 55A Electrical System 9 15 SAE DIAGNOSTIC TROUBLE CODES AND FAULT CODES CUMMINS Temperature Fault SPN FMI Lamp ee EET Codes Codes Codes Color SPN Description Cummins Description 111 629 12 Red Controller 1 Engine Control Module Critical internal failure Bad intelligent Device or Component 115 612 2 Red System Diagnostic Engine Speed Position Sensor Circuit lost both Code 2 of two signals from the magnetic pickup sensor Data Erratic Intermittent or incorrect 122 102 3 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 123 102 4 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 124 102 16 Amber Boost Pressure Intake Manifold 1 Pressu
300. y hardware securing the heater control from the dash panel Remove the control from the panel b Disassembly DO NOT disassemble the cab heater and fan controls The controls are not serviceable Replace controls if found to be defective 9 30 c Installation and Testing 1 Check that the variable speed fan control is in the OFF position 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 5 Install the screws securing the dash panel to the cab 6 Properly connect the battery 7 Turn the ignition key to the ON position and check the fan speeds If further repair is needed refer to Section 9 5 Electrical System Schematics 8 Start the machine and allow engine to warm to operating temperature Check heat control at different levels 9 Close and secure the engine cover 10 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 10 SOLENOIDS SENSORS AND SENDERS 9 10 1 Fuel Shut off Solenoid John Deere a Fuel Shut off Solenoid 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 t

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