JLG G10-55A & G12-55A Telehandlers Service Manual (ANSI) - 3126019

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This service manual PDF download for the G10-55A & G12-55A JLG Telescopic Handlers has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Telehandler G10-55A
JLG Telehandler G12-55A


TABLE OF CONTENTS :

    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
        1.6 Safety Instructions
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torque Charts
        2.3 Specifications
        2.4 Fluid and Lubricant Capacities
        2.5 Service and Maintenance Schedules
        2.6 Lubrication Schedules
        
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System - Four Section
        3.3 Boom Assembly Maintenance
        3.4 Complete Boom Removal/ Installation
        3.5 Boom Section Removal/ Installation
        3.6 Extend/Retract Chain Removal/Installation
        3.7 Boom Section Separation Adjustment
        3.8 Hose Carrier Assembly Removal/Installation
        3.9 Quick Switch Assembly
        3.10 Boom Head - Mounted Winch
        3.11 Boom Wear Pads
        3.12 Boom Extend and Retract Chains
        3.13 Forks
        3.14 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
        4.3 Cab Components
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
        5.4 Drive Shafts
        5.5 Wheels and Tires
        5.6 Brakes
        5.7 Towing a Disabled machine
            
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Serial Number
        6.3 Transmission Specifications And Maintenance Information
        6.4 Transmission Replacement
        6.5 Torque Convertor Diaphragm
        6.6 Troubleshooting
        
    Section 7 Engine
        7.1 Introduction - John Deere
        7.2 Introduction - Perkins
        7.3 Introduction - Cummins
        7.4 Engine Cooling System
        7.5 Engine Electrical System
        7.6 Fuel System
        7.7 Engine Exhaust System
        7.8 Air Cleaner Assembly
        7.9 Engine Replacement
        7.10 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
        8.4 Hydraulic Circuits
        8.5 Hydraulic Reservoir
        8.6 Implement Pump
        8.7 Control Valves
        8.8 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Safety Information
        9.4 Fuses and Relays
        9.5 Electrical System Schematics
        9.6 Circuit Breakdowns
        9.7 Engine Start Circuit
        9.8 Window Wiper/Washer Windshield Wiper Motor
        9.9 Cab Heater and Fan
        9.10 Solenoids, Sensors and Senders
        9.11 Display Monitor and Gauges
        9.12 Dash Switches
        9.13 Troubleshooting - John Deere
        9.14 Engine Indicator Lamps - Perkins
        9.15 SAE Diagnostic Trouble Codes and Fault Codes - Cummins


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3126019
Total Pages : 200


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3126019_H_JLG_G10-55A G12-55A_Service
    Effectivity
    Table of Contents
    
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
            1.5.1 Safety Alert System and Signal Words
        1.6 Safety Instructions
            1.6.1 Personal Hazards
            1.6.2 Equipment Hazards
            1.6.3 General Hazards
            1.6.4 Operational Hazards
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torque Charts
            2.2.1 SAE Fastener Torque Chart
            2.2.2 Metric Fastener Torque Chart
            2.2.3 Hydraulic Hose Torque Chart
        2.3 Specifications
            2.3.1 Travel Speeds
            2.3.2 Hydraulic Cylinder Performance
            2.3.3 Electrical System
            2.3.4 Engine Performance Specifications - John Deere
            2.3.5 Engine Performance Specifications - Perkins
            2.3.6 Engine Performance Specifications - Cummins
            2.3.7 Tires
        2.4 Fluid and Lubricant Capacities
        2.5 Service and Maintenance Schedules
            2.5.1 10, 1st 50 & 50 Hour
            2.5.2 1st 250, 250 & 500 Hour
            2.5.3 1000 & 1500 Hour
        2.6 Lubrication Schedules
        
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System - Four Section
            3.2.1 Boom System Operation
        3.3 Boom Assembly Maintenance
        3.4 Complete Boom Removal/ Installation
            3.4.1 Complete Boom Removal
            3.4.2 Complete Boom Installation
        3.5 Boom Section Removal/ Installation
            3.5.1 Second, Third & Fourth Boom Section Removal
            3.5.2 Third & Fourth Boom Section Removal
            3.5.3 Fourth Boom Section Removal
            3.5.4 Hose Carrier Removal
            3.5.5 Fourth Boom Section Assembly
            3.5.6 Hose Carrier Installation
            3.5.7 Third Boom Section Assembly
            3.5.8 Fourth Boom Section Installation
            3.5.9 Second Boom Section Assembly
            3.5.10 Third & Fourth Boom Section Installation
            3.5.11 Second, Third and Fourth Boom Section Installation
        3.6 Extend/Retract Chain Removal/Installation
            3.6.1 Retract Chain Removal
            3.6.2 Retract Chain Installation
            3.6.3 Extend Chain Removal
            3.6.4 Extend Chain Installation
        3.7 Boom Section Separation Adjustment
        3.8 Hose Carrier Assembly Removal/Installation
            3.8.1 Hose Carrier Assembly Removal
            3.8.2 Assembling the Hose Carrier Assembly
            3.8.3 Hose Carrier-Assembly Installation
            3.8.4 Boom Hose Adjustment
        3.9 Quick Switch Assembly
            3.9.1 Quick Switch Removal
            3.9.2 Quick Switch Installation
            3.9.3 Quick Switch Removal
            3.9.4 Quick Switch Installation
        3.10 Boom Head - Mounted Winch
            3.10.1 Boom Head-Mounted Winch Removal
            3.10.2 Boom Head-Mounted Winch Installation
        3.11 Boom Wear Pads
            3.11.1 Wear Pad Inspection
            3.11.2 Wear Pad Installation and Lubrication
        3.12 Boom Extend and Retract Chains
            3.12.1 Boom Chain Inspection
            3.12.2 Inspection Guidelines
            3.12.3 Expose Chains for Inspection
            3.12.4 Chain Lubrication
        3.13 Forks
        3.14 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
            4.2.1 Cab Safety
            4.2.2 Serial Number Decal
        4.3 Cab Components
            4.3.1 Steering Column and Orbitrol Valve
            4.3.2 Service Brake Pedal
            4.3.3 Throttle Pedal
            4.3.4 Boom Joystick Assembly
            4.3.5 Frame Sway, Auxiliary and Outrigger Control Joysticks
            4.3.6 Windshield Wiper Assembly
            4.3.7 Heater/Air Conditioning System (if equipped)
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
            5.3.1 Axle Serial Number Plate
            5.3.2 Axle Specifications
            5.3.3 Axle Internal Service
            5.3.4 Axle Maintenance
            5.3.5 Axle Removal
            5.3.6 Axle Installation
            5.3.7 Axle Assembly and Drive Shaft Troubleshooting
        5.4 Drive Shafts
            5.4.1 Drive Shaft Inspection and Service
            5.4.2 Drive Shaft Maintenance
            5.4.3 Drive Shaft Removal
            5.4.4 Drive Shaft Cleaning and Drying
            5.4.5 Drive Shaft Installation
        5.5 Wheels and Tires
            5.5.1 Removing Wheel and Tire Assembly from Machine
            5.5.2 Installing Wheel and Tire Assembly onto Machine
        5.6 Brakes
        5.7 Towing a Disabled machine
            5.7.1 Manually Releasing the Park Brake
            5.7.2 Manually Resetting the Park Brake
            
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Serial Number
        6.3 Transmission Specifications And Maintenance Information
        6.4 Transmission Replacement
            6.4.1 Transmission Removal
            6.4.2 Transmission Inspection and Internal Repair
            6.4.3 Transmission Installation
            6.4.4 After Transmission Service or Replacement
        6.5 Torque Convertor Diaphragm
            6.5.1 Torque Convertor Diaphragm Removal
            6.5.2 Torque Convertor Diaphragm Installation
        6.6 Troubleshooting
        
    Section 7 Engine
        7.1 Introduction - John Deere
            7.1.1 Disclaimer and Scope
            7.1.2 Engine Serial Number
            7.1.3 Specifications and Maintenance Information
            7.1.4 Component Terminology
        7.2 Introduction - Perkins
            7.2.1 Disclaimer and Scope
            7.2.2 Engine Serial Number
            7.2.3 Specifications and Maintenance Information
            7.2.4 Component Terminology
        7.3 Introduction - Cummins
            7.3.1 Disclaimer and Scope
            7.3.2 Engine Serial Number
            7.3.3 Specifications and Maintenance Information
            7.3.4 Component Terminology
        7.4 Engine Cooling System
            7.4.1 Radiator Pressure Cap
            7.4.2 Thermostat Replacement
            7.4.3 Radiator/Oil Cooler and Replacement
        7.5 Engine Electrical System
        7.6 Fuel System
            7.6.1 Diesel Fuel
            7.6.2 Fuel Tank
            7.6.3 After Fuel System Service
        7.7 Engine Exhaust System
            7.7.1 Exhaust System Removal
            7.7.2 Exhaust System Installation
        7.8 Air Cleaner Assembly
            7.8.1 Air Cleaner Assembly Removal (John Deere & Perkins)
            7.8.2 Air Cleaner Assembly Installation (John Deere & Perkins)
            7.8.3 Air Cleaner Assembly Removal (Cummins)
            7.8.4 Air Cleaner Assembly Installation (Cummins)
        7.9 Engine Replacement
            7.9.1 Engine Removal
            7.9.2 Engine Installation
        7.10 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
            8.3.1 Pressure Checks and Adjustments
        8.4 Hydraulic Circuits
            8.4.1 Hydraulic Pressures
            8.4.2 Tilt Circuit Port Relief Adjustment
            8.4.3 Hydraulic Schematic
        8.5 Hydraulic Reservoir
            8.5.1 Hydraulic Oil Reservoir Draining
            8.5.2 Hydraulic Oil Reservoir Filling
            8.5.3 Hydraulic Oil Reservoir Removal/ Installation
        8.6 Implement Pump
            8.6.1 Implement Pump Replacement
        8.7 Control Valves
            8.7.1 Main Control Valve
            8.7.2 Main Control Valve Assembly
            8.7.3 Service Brake Valve
            8.7.4 Service Brake Bleeding
            8.7.5 Service Brake Test
            8.7.6 Park Brake Test
            8.7.7 Steering Orbitrol Valve
            8.7.8 Steer Select Valve
        8.8 Hydraulic Cylinders
            8.8.1 General Cylinder Removal Instructions
            8.8.2 Cylinder Inspection
            8.8.3 Cylinder Pressure Checking
            8.8.4 Steering Cylinders
            8.8.5 Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
            9.1.1 General Overview - John Deere
            9.1.2 General Overview - Perkins
            9.1.3 General Overview - Cummins
        9.2 Specifications
        9.3 Safety Information
        9.4 Fuses and Relays
            9.4.1 Engine Compartment
            9.4.2 Cab
            9.4.3 Power Distribution Unit (VEC) - John Deere/Perkins
            9.4.4 Power Distribution Unit (VEC) - Cummins
            9.4.5 Optional Power Distribution Unit (VEC)
        9.5 Electrical System Schematics
            9.5.1 Cab Schematic - John Deere
            9.5.2 Cab Schematic - Perkins
            9.5.3 Cab Schematic - Cummins
            9.5.4 Options Schematic - John Deere/Perkins
            9.5.5 Options - Cummins
            9.5.6 Chassis Schematic - John Deere
            9.5.7 Chassis Schematic - Perkins Before S/N 0160037186
            9.5.8 Chassis Schematic - Perkins S/N 0160037186 Thru 0160039397 Excluding 0160039394 & 0160039397
            9.5.9 Chassis Schematic - Cummins S/N 0160039451 and After Including 0160039394 & 0160039397
            9.5.10 Power Unit Schematic - John Deere
            9.5.11 Power Unit Schematic - Perkins
            9.5.12 Power Unit Schematic - Cummins
        9.6 Circuit Breakdowns
            9.6.1 Constant Power Circuit from Battery - John Deere & Perkins
            9.6.2 Constant Power Circuit from Battery - Cummins
            9.6.3 Start & Charge Circuit - John Deere & Perkins
            9.6.4 Start & Charge Circuit - Cummins
        9.7 Engine Start Circuit
            9.7.1 Starter
            9.7.2 Charging Circuit
            9.7.3 Alternator
        9.8 Window Wiper/Washer Windshield Wiper Motor
            9.8.1 Windshield/Rear Window Washer Reservoir
        9.9 Cab Heater and Fan
            9.9.1 Cab Heater Controls
        9.10 Solenoids, Sensors and Senders
            9.10.1 Fuel Shut-off Solenoid - John Deere
            9.10.2 Park Brake Solenoid Valve
            9.10.3 Transmission Solenoid Valves
            9.10.4 Transmission Temperature Sender
            9.10.5 Engine Coolant Temperature Sender
            9.10.6 Air Manifold Temperature Sensor - John Deere
            9.10.7 Engine Oil Pressure Sender/Switch
            9.10.8 Fuel Level Sender
            9.10.9 Inclinometer Switch
            9.10.10 Front and Rear Axle Proximity Sensors
        9.11 Display Monitor and Gauges
            9.11.1 Analog Gauges
        9.12 Dash Switches
            9.12.1 Ignition Key Switch
            9.12.2 Dash Switches
        9.13 Troubleshooting - John Deere
            9.13.1 Engine Fault Codes Retrieval
            9.13.2 Engine Fault Codes Chart
        9.14 Engine Indicator Lamps - Perkins
        9.15 SAE Diagnostic Trouble Codes and Fault Codes - Cummins
        
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