JLG G12-55A Service Manual

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Page 1

An Oshkosh Corporation Company

Service Manual

Models G10-55A G12-55A

S/N 0160045636 & After including

0160045082, 0160045094, 0160045209, 0160045295,

0160045296, 0160045449

31200795

Revised

October 13, 2014

Page 2

Page 3

EFFECTIVITY PAGE

December 10, 2012 - A - Original Issue Of Manual

January 31, 2014 - B - Revise pages ii, 1-4, 2-14, 3-20, 3-30, 3-31, 4-6, 6-2, 6-4, 6-7, 6-8, 7-2, 7-4, 7-6, 7-7, 7-13, 8-3, 8-8, 8-9, 8-21, 8-22, 9-12, 9-17.

October 13, 2014 - C - Revise pages 1-4, 2-2 thru 2-12, 2-16, 3-20, 3-25, 7-2, 8-4, 8-7, Add 431 Fault Code 9-26.

31200795 G10-55A, G12-55A

Page 4

READ THIS FIRST

OY2700

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387 A

REAR VIEW OF CAB

Modifications

Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations. Any modification must be approved by JLG.

Machine Configuration

Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.

• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra Low Sulfur (ULS) from this point forward.

•If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Low Sulfur (LS) from this point forward.

G10-55A, G12-55A4 31200795

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SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.5 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.6 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.7 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.6 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.7 Hose Carrier Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.9 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.10 Boom Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.11 Boom Chain Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.13 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

G10-55A, G12-55A

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Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Specifications And Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.5 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Section 6

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Transmission Cooler Thermal By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.6 Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Section 7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.6 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.7 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

G10-55A, G12-55A

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Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.7 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9.8 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9.9 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9.10 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9.11 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21

9.12 SAE Diagnostic Trouble and Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

G10-55A, G12-55A

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Section Subject Page

G10-55A, G12-55A

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Section 1

Safety Practices

Contents

PARAGR APH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

G10-55A, G12-55A

1-1

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Safety Practices

1.1 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 methods 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

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

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.

WARNING

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 & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Safety Manual is supplied with each machine and must be kept in manual holder located in cab. In event that Operation & Safety Manual is missing, consult local distributor before proceeding.

1-2

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor or moderate injury.

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Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider BEFORE performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions BEFORE proceeding.

1.6.1 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.

1.6.3 General Hazards

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.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor 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) at a 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.

G10-55A, G12-55A

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Safety Practices

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

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.

Refer to the engine manufacturers manual for specific details concerning the fuel system.

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.

COOLANT SYSTEM CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the coolant system cap while the cooling system is hot. Wear safety glasses. Turn the coolant system cap to the first stop and allow pressure 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.

Properly disconnect battery(s) prior to servicing the fuel or hydraulic systems.

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 safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

1-4

G10-55A, G12-55A

Page 13

Section 2

General Information and Specifications

Contents

PARAGR APH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.3 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.4 Electrical System Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5.1 Fluids (if Equipped for ULS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5.2 Fluids (if Equipped for LS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.5.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.6 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.6.3 1000, 1500, 2000 & 5000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.7 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

G10-55A, G12-55A

2-1

Page 14

General Information and Specifications

MY1000

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located on the left front frame rail behind the left front tire.

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.

2.2 THREAD LOCKING COMPOUND

242

243

271

262

ND Industries Description

Vibra-TITETM121

Vibra-TITETM122

Vibra-TITETM140

Vibra-TITETM131

Medium Strength (Blue)

Medium - High Strength (Red)

High Strength (Red)

JLG P/N

0100011

1001095650

0100019

0100071

Loctite

Loct ite® 243TM can be substituted in place of Loctite® 242TM. Vibra-

TITE

122 can be substituted in place of Vibra-TITETM 121.

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

Page 15

General Information and Specifications

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

T o r q u e

Size TPI Bolt Dia

In Sq In LB I N - L B [N.m] IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT - L B [N.m] FT-LB [N.m] F T -L B [N.m] F T -L B [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

Tensile

Stress Area

Clamp

Load

T o r q u e

(Dry)

T o r q u e

Lubricated

(Loctite® 242

or Vibra-TITE

111 or 140)

or 271TM

T o r q u e

(Loctite® 262

Vibra-TITE

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

G10-55A, G12-55A

2-3

Page 16

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Vibra-TITE

T o r q u e

or 271TM or

1 1 1 o r 1 4 0 )

K=0.18

Size TPI Bolt Dia

In Sq In LB I N - LB [N.m] I N- L B [N.m] I N- L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 43 5

10 24 0.1900 0.01750 1580 60 7

32 0.1900 0.02000 1800 68 8

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB F T-LB [N.m] FT-LB [N.m] F T-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

Tensile Stress

Area

Clamp Load

Torque

(Dry or Loctite® 263)

K=0.20

(Loctite® 242

Torque (Loctite® 262 Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

2-4

G10-55A, G12-55A

Page 17

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Vibra-TITE

T o r q u e

or 271TM or

111 or 140)

K=0.16

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604 380 7 0.8

48 0.1120 0.00661 420 8 0.9

6 32 0.1380 0.00909 580 14 1.5

40 0.1380 0.01015 610 14 1.6

8 32 0.1640 0.01400 900 25 2.8

36 0.1640 0.01474 940 26 2.9

10 24 0.1900 0.01750 1120 36 4.1

32 0.1900 0.02000 1285 42 4.7

1/4 20 0.2500 0.0318 2020 86 9.7 80 9

28 0.2500 0.0364 2320 99 11.1 95 11

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20

24 0.3125 0.0580 3700 15 20 15 21 15 20

3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34

24 0.3750 0.0878 5600 30 40 28 38 25 34

7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48

20 0.4375 0.1187 7550 45 60 44 60 40 54

1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75

20 0.5000 0.1599 10700 75 100 71 97 65 88

9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109

18 0.5625 0.2030 12950 105 145 97 132 90 122

5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156

18 0.6250 0.2560 16300 145 195 136 185 125 170

3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272

16 0.7500 0.3730 23800 255 345 238 324 225 306

7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435

14 0.8750 0.5090 32400 400 545 378 514 355 483

1 8 1.0000 0.6060 38600 545 740 515 700 480 653

12 1.0000 0.6630 42200 600 815 563 765 530 721

1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809

12 1.1250 0.8560 47500 755 1025 713 969 670 911

1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142

12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265

1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496

12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707

1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992

12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237

Tensile Stress

Area

Clamp Load

Torque

(Dry)

K=0.17

(Loctite® 242

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

G10-55A, G12-55A

2-5

Page 18

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Vibra-TITE

T o r q u e

or 271TM or

111 or 140)

K=0.16

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 37 4

10 24 0.1900 0.01750 1580 51 6

32 0.1900 0.02000 1800 58 7

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

Torque

( D r y o r L o c t i t e ® 2 6 3 )

K=0.17

(Loctite® 242

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

2-6

G10-55A, G12-55A

Page 19

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SOCKET HEAD CAP SCREWS

T o r q u e

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

See Note 4

Torque

(Dry) K=0.17

(Loctite® 242

Vibra-TITE

Precoat® 85 K=0.16

or 271TM or

111 or 140) or

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

G10-55A, G12-55A

2-7

Page 20

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS

T o r q u e

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

See Note 4

Torque

(Dry) K=0.17

(Loctite® 242

Vibra-TITE

Precoat® 85 K=0.16

or 271TM or

111 or 140) or

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

2-8

G10-55A, G12-55A

Page 21

General Information and Specifications

2.3.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

T o r q u e

271

131)

271

Size Pitch

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3

4 0.7 8.78 3.82 3.1 2.3 2.8 3.4

5 0.8 14.20 6.18 6.2 4.6 5.6 6.8

6 1 20.10 8.74 11 7.9 9.4 12

7 1 28.90 12.6 18 13 16 19

8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55

12 1.75 84.30 36.7 88 66 79 97

14 2 115 50.0 140 105 126 154

16 2 157 68.3 219 164 197 241

18 2.5 192 83.5 301 226 271 331

20 2.5 245 106.5 426 320 383 469

22 2.5 303 132.0 581 436 523 639

24 3 353 153.5 737 553 663 811

27 3 459 199.5 1080 810 970 1130

30 3.5 561 244.0 1460 1100 1320 1530

33 3.5 694 302.0 1990 1490 1790 2090

36 4 817 355.5 2560 1920 2300 2690

42 4.5 1120 487.0 4090 3070 3680 4290

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

)

Torque (Lub)

(Loctite® 262

Vibra-TITE

T o r q u e

(Loctite® 242

or Vibra-TITETM

111 or 141)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

G10-55A, G12-55A

2-9

Page 22

General Information and Specifications

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS,

CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

T o r q u e

Size Pitch

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22

4 0.7 8.78 5.47

5 0.8 14.20 8.85

6 1 20.10 12.5

7 1 28.90 18.0 25 23 19

8 1.25 36.60 22.8 37 33 27

10 1.5 58.00 36.1 70 65 55

12 1.75 84.30 52.5 125 115 95

14 2 115 71.6 200 180 150

16 2 157 97.8 315 280 235

18 2.5 192 119.5 430 385 325

20 2.5 245 152.5 610 550 460

22 2.5 303 189.0 830 750 625

24 3 353 222.0 1065 960 800

27 3 459 286.0 1545 1390 1160

30 3.5 561 349.5 2095 1885 1575

33 3.5 694 432.5 2855 2570 2140

36 4 817 509.0 3665 3300 2750

42 4.5 1120 698.0 5865 5275 4395

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

K=0.20

)

(Lub or Loctite®

242

Vibra-TITE

or 271TM or

K=0.18

111 or 140)

T o r q u e

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

2-10

G10-55A, G12-55A

Page 23

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Size Pitch

30.55.03

3.5 0.6 6.78

40.78.78

5 0.8 14.20

6 1 20.10

7 1 28.90

8 1.25 36.60

10 1.5 58.00

12 1.75 84.30

14 2 115

16 2 157

18 2.5 192

20 2.5 245

22 2.5 303

24 3 353

27 3 459

30 3.5 561

33 3.5 694

36 4 817

42 4.5 1120

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

2.19 1.1 1.1 1.0

2.95 1.8 1.7 1.5

3.82 2.6 2.4 2.3

6.18 5.3 4.9 4.6

8.74 9 8.4 7.9

12.6 15 14 13

15.9 22 20 19

25.2 43 40 38

36.7 75 70 66

50.0 119 110 105

68.3 186 175 165

83.5 256 240 225

106.5 362 340 320

132.0 494 465 435

153.5 627 590 555

199.5 916 860 810

244.0 1245 1170 1100

302.0 1694 1595 1495

355.5 2176 2050 1920

487.0 3477 3275 3070

(Dry or Loctite® 263

General Information and Specifications

Torque

K=0.17

)

T o r q u e

(Lub or Loctite®

242

Vibra-TITE

or 271

K=0.16

111 or 140)

T o r q u e (Loctite® 262 Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

G10-55A, G12-55A

2-11

Page 24

General Information and Specifications

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,

CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*

T o r q u e

Size Pitch

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22

4 0.7 8.78 5.47

5 0.8 14.20 8.85

6 1 20.10 12.5 13 12 11

7 1 28.90 18.0 21 20 19

8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 55

12 1.75 84.30 52.5 105 100 95

14 2 115 71.6 170 160 150

16 2 157 97.8 265 250 235

18 2.5 192 119.5 365 345 325

20 2.5 245 152.5 520 490 460

22 2.5 303 189.0 705 665 625

24 3 353 222.0 905 850 800

27 3 459 286.0 1315 1235 1160

30 3.5 561 349.5 1780 1680 1575

33 3.5 694 432.5 2425 2285 2140

36 4 817 509.0 3115 2930 2750

42 4.5 1120 698.0 4985 4690 4395

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load See

Note 4

Torque

(Dry or Loctite® 263

K=0.17

)

(Lub or Loctite®

242

Vibra-TITE

or 271TM or

K=0.18

111 or 140)

T o r q u e

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

2-12

G10-55A, G12-55A

Page 25

General Information and Specifications

2.3.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

Size ORFS JIC Flats Method

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

74 lb-ft

(100 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

85 lb-ft

(115 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

1.5 to 1.75

1 to 1.5

1.5 to 1.75

1.0 to 1.5

0.75 to 1.0

Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).

2. Mark a dot on one of swivel nut flats and another dot in line on hex of adapter it’s connecting to.

3. Use double wrench method while tightening to avoid hose twist.

4. After connection has been properly tightened, mark a straight line across connecting parts, not covering the dots indicating that the connection has been properly tightened.

32 N/A

Note: By definition the “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.

2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).

3. Use the double wrench method while tightening to avoid hose twist.

4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks.

5. After connection has been properly tightened, mark a straight line across connecting parts indicating that connection has been properly tightened.

270 lb-ft

(366 Nm)

0.75 to 1.0

G10-55A, G12-55A

2-13

Page 26

General Information and Specifications

2.4 SPECIFICATIONS

2.4.1 Travel Speeds

FUNCTION G10-55A and G12-55A

First Gear 3.4 mph (5,47 km/h)

Second Gear 6.2 mph (9,97 km/h)

Third Gear 14.0 mph (22,5km/h)

Fourth Gear 20.0 mph (32,1 km/h)

2.4.2 Hydraulic Cylinder Performance

Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature.

FUNCTION APPROXIMATE TIMES

(seconds)

Boom Extend (Boom Level) 16.3–18.0

Boom Retract (Boom Level) 12.2–14.5

Boom Lift 15.2–16.8

Boom Lower 14.1–15.5

Attachment Tilt Forward 5.8–6.5

Attachment Tilt Rearward 5.0–6.0

Frame Level—Full Right to Left 9.4–10.4

Frame Level—Full Left to Right 10.2–11.3

Outrigger—Down 16.3–18.0

Outrigger—Up 12.2–14.5

2.4.3 Cylinder Drift

CYLINDER

Lift/Lower Cylinder 0.125 in (3.2 mm) per hour

Extend/Retract Cylinder 0.125 in (3.2 mm) per hour

Attachment Tilt Cylinder 0.125 in (3.2 mm) per hour

MAXIMUM ROD TRAVEL

(loaded or unloaded)

2-14

G10-55A, G12-55A

Page 27

General Information and Specifications

2.4.4 Electrical System Engine Performance

Battery

Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free

Quantity 2

Reserve Capacity Minutes @ 25 Amps 180

Cold Cranking Amps @ 0° F (-18° C) 700

Cranking Amps @ 32° F (-18° C) 840

Group/Series Group 31

Alternator 12V, 100 Amps

2.4.5 Engine Specifications

Description G10-55A & G12-55A

Engine Make/Model Cummins QSB 4.5L

Displacement 276 in³ (4,5 liters)

Low Idle 900 rpm

High Idle 2,500 to 2,700 rpm

Horsepower 130 HP (97 kW) @ 2500 rpm

Peak Torque 457 lb-ft (620 Nm) @ 1500 rpm

Fuel Delivery Fuel Injection

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.4.6 Tires

Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).

Note: Pressure for foam filled tires are for initial fill ONLY.

Size Tire Type Minimum Ply/

Star Rating

14.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply Foam - Approx 720 lb (327 kg) 62 psi (4,3 bar)

17.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply Foam - Approx 785 lb (356 kg) 51 psi (3,5 bar)

400/75-28 Duraforce 16 Ply

Foam - Approx 570 lb (259 kg) 73 psi (5,0 bar)

Fill Type Pressure

Pneumatic 65 psi (4,5 bar)

Pneumatic 76 psi (5,2 bar)

G10-55A, G12-55A

2-15

Page 28

General Information and Specifications

2.5 FLUID AND LUBRICANT CAPACITIES

2.5.1 Fluids (if Equipped for ULS)

Ambient Temperature

Compartment or System Type and Classification Viscosities

Min Max Min Max

Engine Crankcase API CJ-4 Multigrade

Transmission and Transfer Case

Axle Differential* and Wheel End

Hydraulic System

Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40

Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40

Boom Chain Lubricant Schaffer 200S Silver Streak

Engine Coolant

Fuel

Blend of #1 diesel and #2 diesel fuels

B5 Biodiesel with Winter Conditioner

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

Mobilfluid 424 10W-30 0 104 -20 40

Exxon Univis HVI -40 0 -40 -20

Ethylene Glycol

and Water

#2 Diesel

B5 Biodiesel

(“winterized” #2)

SAE 15W-40 5 120 -15 49

SAE 0W-40 -40 0 -40 -20

50/50 Mix Standard 60/40 Mix Cold Weather

Ultra Low

Sulfur

(S ≤ 15mg/kg)

Note: Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”

Range

°F °C

Standard

Cold Weather

2-16

G10-55A, G12-55A

Page 29

General Information and Specifications

2.5.2 Fluids (if Equipped for LS)

Ambient Temperature

Compartment or System Type and Classification Viscosities

Min Max Min Max

Engine Crankcase API CI-4 Multigrade

Transmission and Transfer Case

Axle Differential* and Wheel End

Hydraulic System

Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40

Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40

Boom Chain Lubricant Schaffer 200S Silver Streak

Engine Coolant

Fuel

Blend of #1 diesel and #2 diesel fuels

B5 Biodiesel with Winter Conditioner

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

Mobilfluid 424 10W-30 0 104 -20 40

Exxon Univis HVI -40 0 -40 -20

Ethylene Glycol

and Water

#2 Diesel

B5 Biodiesel

(“winterized” #2)

SAE 15W-40 5 120 -15 49

SAE 0W-40 -40 0 -40 -20

50/50 Mix Standard 60/40 Mix Cold Weather

Low Sulfur

(S ≤ 500 mg/kg)

Note: Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”

Range

°F °C

Standard

Cold Weather

G10-55A, G12-55A

2-17

Page 30

General Information and Specifications

2.5.3 Capacities

Engine Crankcase Oil

Capacity with Filter Change 14 quarts (13,3 liters)

Fuel Tank

Capacity 38 gallons (144 liters)

Cooling System

System Capacity 20 quarts (18,9 liters)

Hydraulic System

System Capacity 60.5 gallons (229 liters)

Reservoir Capacity to Middle of Sight Gauge 33 gallons (125 liters)

Auxiliary Hydraulic Circuit Max Flow 10 gpm (37,9 lpm)

Transmission

Capacity with Filter Change 22 quarts (20,8 liters)

Transfer Case

Capacity 1.8 quarts (1,7 liters)

Axles

Differential Housing Capacity

Front 15 quarts (14,2 liters)

Friction Modifier (Front Only) 24 ounce (709,8 milliliter)

Rear 15.5 quarts (14,7 liters)

Wheel End Capacity 2 quarts (1,9 liters)

Air Conditioning System (if equipped)

System Capacity 2.5 lb (1134 grams)

2-18

G10-55A, G12-55A

Page 31

2.6 SERVICE AND MAINTENANCE

MY7410

Check

Transmission

Oil Level

Check Hydraulic

Oil Level

Air Filter

Restriction

Indicator

Check Fuel

Level

Check Engine

Oil Level

EVERY

Check Tire

Condition &

Pressure

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

EVERY

Drain Fuel/

Water

Separator

Check Engine Coolant Level

Check

Battery

Lubrication

Schedule

Check Washer

Fluid Level

(if equipped)

SCHEDULES

2.6.1 10, 1st 50 & 50 Hour

General Information and Specifications

G10-55A, G12-55A

2-19

Page 32

General Information and Specifications

MY7660

250

EVERY

Change Engine

Oil and Filter

Check Axle

Oil Level

Check Wheel

End Oil Levels

Air Filter Vacuator

Valve

Check

Fan Belt

Check Boom

Extend Chains

Check Boom

Wear Pads

Check Transfer Case Oil Level

Check

Rear Axle

Stabilization

Lubrication

Schedule

Change Axle Oil

Change Wheel

End Oil

Change

Transmission

Oil & Filter

Change

Transfer Case

Oil

250

500

EVERY

Change Fuel

Filters

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Engine

Oil and Filter

(Before S/N

0160046716)

(S/N 0160046716 & After)

2.6.2 1st 250, 250 & 500 Hour

Note: Engine oil & filter service interval can be extended. See Engine Manual for details.

2-20

G10-55A, G12-55A

Page 33

2.6.3 1000, 1500, 2000 & 5000 Hour

1500

EVERY

Change

Engine Coolant

Change

Hydraulic

Fluid & Filters

Change

Breather

1000

EVERY

Change

Transmission

Oil & Filter

Change Axle Oil

Change Wheel

End Oil

Change

Transfer Case

Oil

Check Boom

Retract Chains

Lubrication

Schedule

Check

Air Intake

System

2000

EVERY

Change Crankcase

Vent Filter

(if equipped for )ULS

MY6910

5000

EVERY

Engine

Adjustment

General Information and Specifications

G10-55A, G12-55A

2-21

Page 34

General Information and Specifications

OAL0450

EVERY

2.7 LUBRICATION SCHEDULES

a. 50 Hour

2-22

G10-55A, G12-55A

Page 35

b. 250 Hour

OW1211

EVERY

250

General Information and Specifications

G10-55A, G12-55A

2-23

Page 36

General Information and Specifications

OY2080

EVERY

1000

c. 1000 Hour

2-24

G10-55A, G12-55A

Page 37

Section 3

Boom

Contents

PARAGR APH TITLE PAGE

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Complete Boom Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.5.1 Second, Third and Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . 3-6

3.5.2 Third and Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.5.3 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.5.4 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.5.5 Fourth Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.5.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.5.7 Third Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.5.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.5.9 Second Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.5.10 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.5.11 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . 3-15

3.6 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.7 Hose Carrier Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7.2 Assembling Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.7.3 Hose Carrier-Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.7.5 Boom Hose Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.8.1 Hydraulic Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.8.2 Hydraulic Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.8.3 Manual Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.8.4 Manual Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.9 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.9.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.9.2 Wear Pad Installation and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.11 Boom Chain Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.11.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.11.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.11.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.11.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

G10-55A, G12-55A

3-1

Page 38

Boom

3.12 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.13 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.13.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.11.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-2

G10-55A, G12-55A

Page 39

3.1 BOOM SYSTEM COMPONENT

MY7720

EXTEND/RETRACT

CYLINDER

(UNDERSIDE OF BOOM)

AUXILIARY

HYDRAULIC

CONNECTIONS

SECOND BOOM

SECTION

THIRD BOOM

SECTION

FOURTH BOOM

SECTION

RETRACT

CHAINS

EXTEND

CHAINS

QUICK SWITCH

FIRST

BOOM

SECTION

HOSE

SHEAVE

TILT CYLINDER

HOSE CARRIER

ASSEMBLY

(INSIDE BOOM)

PIVOT PIN

TERMINOLOGY

The following illustrations identify the components that are referred to throughout this section.

Boom

G10-55A, G12-55A

3-3

Page 40

Boom

3.2 BOOM SYSTEM - FOUR SECTION

3.2.1 Boom System Operation

The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chain and a single fourth section retract chain.

As the extend/retract cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section.

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 at the same rate.

The boom section lifts and lowers via action of the lift/ lower cylinder.

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 3.9, “Boom Wear Pads.”)

2. Check hose sheaves and chain rollers.

3. Apply grease at all lubrication points (grease fittings). (Refer to Section 2.7, “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

3-4

WARNING

NEVER weld or drill the boom 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

Page 41

Boom

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.

2. Remove the quick switch assembly. Refer to Section

3.8, “Quick Switch Assembly.”

3. Park the machine on a hard, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

4. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

5. Open engine cover. Allow system fluids to cool.

6. Properly disconnect the batteries.

7. Support the front of the boom by placing a sling behind the boom head.

8. Label, disconnect and cap all hydraulic hoses for the extend/retract and tilt circuits. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

9. Support the lift/lower cylinder on the left side of the machine. Remove the lock bolt and rod end pin. Lower the lift/lower cylinder onto the frame rails. Repeat this step for the right side lift/lower cylinder.

10. Support the compensation cylinder. Remove the lock bolt and rod end pin. Lower the compensation cylinder onto the frame rails.

11. 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.

12. Remove the bolt securing the boom pivot pin. Pull out the boom pivot pin.

13. Lift the complete boom off machine and set on level ground or supports.

3. Install the boom pivot pin.

4. With the sling still in place, install the compensation cylinder, pins and bolts.

5. 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.

6. Uncap and reconnect the previously labeled hydraulic hoses to the extend/retract cylinder.

7. Uncap and connect any remaining hydraulic fittings to their appropriate locations.

8. Recheck the wear pad gaps to ensure they meet the minimum gap requirement. Shim if necessary.

9. Ensure boom chains are properly adjusted. Refer to Section 3.6, “Boom Section Separation Adjustment.”

10. Properly connect the batteries.

11. Start engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid level in reservoir; add fluid if required.

12. Install the quick switch assembly. Refer to Section

3.8.4, “Manual Quick Switch Installation.”

13. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

14. Close and secure the engine cover.

15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

16. Install the previously remove attachment to the quick switch assembly. Refer to the appropriate operation and safety manual.

3.4.2 Complete Boom Installation

1. Park the machine on a hard, level surface, place the transmission control lever in (N) NEUTRAL, engage the park brake, chock the wheels and shut the engine OFF.

2. 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.

G10-55A, G12-55A

3-5

Page 42

Boom

MY3770

MY4130

MY3580

3.5 BOOM SECTION REMOVAL/INSTALLATION

3.5.1 Second, Third and Fourth Boom

Section Removal

1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual.

2. Remove the quick switch assembly. Refer to Section

3.8, “Quick Switch Assembly.”

3. Park the machine on a hard, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

4. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

5. Open engine cover. Allow the system fluids to cool.

9. Remove the tilt cylinder mounting pin (5).

10. Lower tilt cylinder from the boom head.

11. Support the front of the boom by placing a sling behind the boom head.

12. Loosen jam nut and lock nut (6) to release tension from hoses on hose take-up weldment (7).

13. Loosen the hydraulic hoses (8) and electrical cables if equipped on the hose take-up weldment (7). Plug the hose ends and tube ends to prevent dirt and debris from entering the hydraulic system.

6. Label and remove both tilt cylinder hoses (1) 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.

7. Using a suitable lifting device, secure the tilt cylinder barrel with a nylon strap.

8. Remove both retaining clips (4) from each side of the tilt cylinder mounting pin (5).

3-6

14. 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).

15. Loosen and remove the lock nuts (10), adjusting nuts (11), washers (12) and springs (13) from the three extend chain clevises (9).

G10-55A, G12-55A

Page 43

Boom

MY3440

MY4120

MY3540

MY3420

16. Pull the three extend chain clevises (9) off of each chain roller (14) and lay each assembly on the third and fourth boom sections respectively.

Note: It may be necessary to remove the extend chain rollers to help in the removal of the top wear pads.

17. Verify all fittings, tubes and hoses are properly capped and /or plugged.

18. Extend the second boom section to access the retract chain adjusting block.

19. Remove the extend/retract cylinder support (15) from the front of the first boom section.

20. Support the extend/retract cylinder (16) with a suitable sling.

21. Remove the retaining clips (17) from each side of the extend/retract cylinder rod.

22. Remove extend/retract cylinder rod mounting pin (18).

23. 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.

24. Remove the adjusting nut and lock nut (19), retract chain and clevis (20), spring stop (21) and spring (22). Loosen bolts (23) and adjusting block (24).

25. Properly disconnect the batteries.

26. At the rear of the boom, remove both of the hose sheave covers (25).

27. Unbolt the hose carrier bracket (26) from the rear of the second boom section and the hose carrier.

28. Pull hose carrier (27) back to gain access to tilt hose (28) and auxiliary hose (29) connections.

29. 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.

30. 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.

G10-55A, G12-55A

3-7

Page 44

Boom

MY4140

29 28

MY4150

MY3590

31. Remove top rear wear pads, spacers, shims and hardware (30) from rear of second boom section.

32. Remove the left (or right) side rear wear pad, spacer, shims and hardware (31) from the rear of the second boom section.

33. Pull each boom section slightly forward to relieve the tension in retract chain (32).

34. Remove snap rings and pin connecting rear retract chain (32) from chain clevis at rear of boom. Allow chain to hang out over rear of boom.

35. 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.

3.5.2 Third and Fourth Boom Section Removal

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.

2. Remove the left (or right) side rear wear pad, spacer, shims and hardware (2) from the rear of the third boom section.

3. Verify all disconnected hoses, tubes and fittings are capped and/or plugged.

36. 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.

37. Remove both wear pads, spacers, shims, blocks and hardware (29) from front top of first boom section.

38. Remove both wear pads, spacers, shims and hardware (30) from the front bottom of the first boom section.

39. Adjust sling(s) around second boom section to help balance second, third and fourth boom sections.

40. Remove remainder of second, third and fourth boom sections from the first boom section and set on suitable supports.

3-8

4. Pull each boom section slightly forward to relieve the tension on the retract chain (3).

5. Remove snap rings and pin connecting rear retract chain (3) from chain clevis at rear of boom. Allow chain to hang out over rear of boom.

G10-55A, G12-55A

Page 45

Boom

MY3450

MY3510

6. Place a sling around the third boom section. With a suitable lifting device, slowly pull the third and fourth boom sections approximately 25% out of the second boom section.

7. With the third and fourth boom section still connected to a suitable lifting device, remove all wear pads, spacers, shims, and hardware (4) from the front sides of the second boom section.

8. Remove both wear pads, spacers, shims, blocks and hardware (5) from front top of second boom section.

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.

3.5.3 Fourth Boom Section Removal

1. 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.

2. With the fourth boom section still connected to a suitable lifting device, remove all wear pads, spacers, shims, and hardware (8) from the front sides of the third boom section.

3. Remove top and bottom front wear pads, shims and blocks (9) from the third boom section.

4. Loosen and remove the wear pad support plate (10) from the bottom front of the third boom section.

5. 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.

6. Lower fourth boom section onto a suitable support.

G10-55A, G12-55A

3-9

Page 46

Boom

MY3470

MY3610

FRONT OF BOOM

MY3630

MY3490

3.5.4 Hose Carrier Removal

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.

3.5.5 Fourth Boom Section Assembly

1. Place fourth boom section onto suitable supports.

2. 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 lb-ft (135 Nm).

3. Install all wear pads, spacers and shims (3, 4 and 5) at rear of the fourth boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

8. Remove the hose carrier guide bracket from the inside of the fourth boom section (14).

3-10

G10-55A, G12-55A

Page 47

3.5.6 Hose Carrier Installation

MY3480

MY3750

MY3610

FRONT OF BOOM

MY3470

Boom

1. Inspect the hose carrier track (6) for any broken or missing clips. Repair or replace as needed.

2. Remove the caps from the tubes on the hose carrier.

Note: Connect the tilt cylinder hoses and the auxiliary hoses to the hose carrier bulkhead before installing the hose carrier in the fourth boom section.

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).

12. Align hose carrier mounting bracket and install the previously removed hardware to mounting bracket at front of fourth boom section (15). Torque as required.

3. Install tilt cylinder hose (7) to the bottom left fitting on the hose carrier tube (8).

4. Install tilt cylinder hose (9) to the top left fitting on the hose carrier tube (10).

5. Install adaptors (11) to each auxiliary tube at the front right of the hose carrier.

6. Install auxiliary hoses (12) to each adaptor (11) on

7. Orient each auxiliary hose (12) as shown above.

8. Torque each fitting and hose as required.

auxiliary tubes at front right of hose carrier.

13. Install guide bracket (16) P/N using the previously removed hardware (17). Torque as required.

G10-55A, G12-55A

3-11

Page 48

Boom

MY3500

MY3630

MY3510

3.5.7 Third Boom Section Assembly

Note: Inspect and lubricate all extend and retract chains before re-assembly. Refer to Section 3.11.1, “Boom Chain Inspection,” for detailed information.

Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section.

1. Place the third boom section onto suitable supports.

4. 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 lb-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 sling, or two slings for better stability, around fourth boom section and slowly insert fourth boom section into third boom section being careful not to damage any surrounding components.

3. Install the wear pad, support plates and spacers (7)

2. Install the previously removed chain roller (1) at the rear of the third boom section. Insert the mounting pin, retainer plate and hardware. Torque as required.

3. Install all wear pads, spacers and shims (2, 3 and 4) at rear of third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed.Refer to Section 3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

with existing hardware at the inside top front of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

3-12

G10-55A, G12-55A

Page 49

Boom

MY3510

MY4160

3.5.9 Second Boom Section Assembly

1. Place second boom section onto suitable supports.

4. Install the previously removed wear pad support (9) at the front inside of the third boom section. Use the previously removed hardened washers and bolts (10). Torque as required.

5. Install the wear pads, spacers and shims on each side and bottom (8 and 11) at the front of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

Note: Longer bolts (12) may be required to fully engage the threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to page 6, Wear Pad Installation and Lubrication for detailed information.

2. 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.

3. Install the wear pads and spacers (14, 15 and 16) at the rear of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

3.5.10

Third and Fourth Boom Section Installation

Note: Refer to Section 2.3, “Torque Charts,” for standard bolt torque information.

Note: Refer to Section 2.3.3, “Hydraulic Hose Torque Chart,” for standard hose torque information.

Note: Apply Loctite

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.

242 ™to all boom assembly bolts.

G10-55A, G12-55A

3-13

Page 50

Boom

MY3540

MY3650

MY3450

MY3590

2. Install adjusting block (17) using existing hardware (18). Torque as required.

3. Install chain and clevis (19), spring (20), spring stop (21), adjusting nut and lock nut (22).

8. Install the wear pad support plate (27) with existing hardware at inside front of second boom section.

Note: Longer bolts (30) may be required to fully engage threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to Section 3.9.2, “Wear Pad Installation and Lubrication.”

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 lb-ft (135 Nm).

5. Properly connect the batteries.

6. Retract the second boom section pulling both retract chains at the same time.

7. Install the 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. Refer to Section 3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

3-14

9. Install wear pads, spacers and shims on each side and bottom (26, 28 and 29) at front of second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

10. Manually retract the boom sections as required to connect the retract chains.

11. Install bracket and clevis assembly (31) at rear of fourth boom section. Torque mounting bolts.

G10-55A, G12-55A

Page 51

Boom

MY4140

3 2

MY3590

MY3420

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 one or two slings for better stability, around second boom section and slowly insert second, third and fourth boom sections into first boom section being careful not to damage any surrounding components and allowing sufficient room to install wear pads at front of first boom section.

4. 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.

5. Pull hose carrier from the rear as far as possible to access the hydraulic and if equipped, the electrical connections.

6. If equipped, connect the electrical cable (5) to the fitting on the hose carrier.

7. 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

2. Install all wear pads, spacers and shims (1, 2 and 3) at the front of the first boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.9.2, “Wear Pad Installation and Lubrication,” for detailed information.

3. Re-adjust the sling(s) and push the second, third and fourth boom assembly the remainder of the way

(7) to their proper fitting locations on the hose carrier. Torque as required.

8. Install hose carrier bracket (8) at rear of third boom section and the hose carrier. Torque mounting bolts as required.

9. Install both hose sheave covers (9).Torque mounting bolts as required.

into the first boom section.

G10-55A, G12-55A

3-15

Page 52

Boom

MY3440

MY3800

10. Connect fourth boom section extend chain (10) to clevis at top front of third boom section and adjust to previously measured setting. Do Not tighten lock nut at this time.

11. Connect third boom section extend chains (11) to clevises at top front of second boom section and adjust to previously measured setting. Do Not tighten lock nut at this time.

12. Grease all wear pad at rear of the boom using the grease fittings.

13. Refer to Section 3.7, “Hose Carrier Assembly Removal/Installation,” for proper boom section adjustments.

3.6 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.

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 adjusting nuts on first boom section until gap (D) between flat washers and boom is 0.375 in (9,52 mm) maximum. gap must be equal on both chains. Torque lock nut to 100 lb-ft (135 Nm).

3-16

Note: Verify the exposed threads on both extend chain clevises are kept equal.

3. Tighten 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 lb-ft (135 Nm).

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Boom

MY3820

MY3790

MY3810

Note: BOTTOM OF BOOM SHOWN WITH EXTEND/RETRACT CYLINDER REMOVED FOR CLARITY

4. After adjusting, check to see that the boom sections and access holes (2) are aligned. If they are not, the retract chain will need to be adjusted as well.

Adjust the retract chain as follows:

1. Fully retract the boom.

3. Loosen second to third boom section retract chain lock nut and adjusting nut (3) as far as possible.

4. Loosen the third to fourth boom section retract chain lock nut and adjusting nut (4) as far as possible.

5. Tighten the retract chain adjusting nut (3) until the proper distance (E) is obtained and proper access hole alignment (2) is obtained.

6. Torque the lock nut to 100 lb-ft (135 Nm).

7. Recheck the extend chain adjustments and readjust if necessary.

8. Measure the distance between the third boom section and fourth boom section (F). The dimension should be:

G10-55A - 17.5–17.75 in (444,5–451,3 mm) G12-55A - 18.5–18.75 in (469,9–476,7 mm)

9. Tighten the retract chain adjusting nut (4) until the proper distance (F) is obtained and proper access hole alignment (2) is obtained.

10. Torque the lock nuts to 100 lb-ft (135 Nm).

11. Re-adjust the extend chains as needed.

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

3-17

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Boom

MY2690

MY2710

MY2720

MY2700

FRONT

3.7 HOSE CARRIER ASSEMBLY REMOVAL/INSTALLATION

Hose carrier assembly locates primarily in fourth boom section. It is fastened at bottom front of fourth boom section and at rear of third boom section.

3.7.1 Hose Carrier Assembly Removal

1. Remove any attachment from the quick coupler assembly. Refer to Operation & Safety Manual.

Note: Allow adequate room in front of the machine when removing and installing the hose carrier assembly.

2. 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.

4. Open engine cover. Allow system fluids to cool.

5. Properly disconnect the batteries.

9. Loosen and remove both cap 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.

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 the 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 front and rear of boom assembly.

Note: Tag or identify each hose to the corresponding fitting it was removed from.

3-18

11. Loosen and remove the hose carrier bracket (4) at the rear of the third boom section.

12. Install a sling around hose carrier at front of boom. With a suitable lifting device, slowly pull hose carrier loose from bottom bracket (5) located approximately halfway in the fourth boom section.

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Boom

MY2730

MY2740

MY2700

FRONT

13. When the hose carrier is pulled approximately 25% out of the boom, fasten the two hydraulic carriers together using plastic tie wraps or nylon straps to keep them from separating.

Note: Do Not wrap hose carrier since it will not prevent two hydraulic carriers from moving apart sideways.

14. Continue withdrawing the hose carrier, fastening the two hydraulic carriers together.

15. With two hose assemblies tied together, remove hose carrier and set on ground or proper supports.

3.7.2 Assembling Hose Carrier Assembly

The following procedure is described with the assumption that all components have been removed and assembly proceeding from the beginning.

3.7.3 Hose Carrier-Assembly Installation

1. Clean and lubricate the side surfaces where the hose carrier rides.

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.

6. Install guide bracket (1) on front of hose carrier.

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 bulkhead fittings to 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 hoses 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.

7. Verify that bottom bracket (2) on hose carrier is in place on bottom plate (3) of 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 hose carrier bracket at front of fourth boom section.

10. Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the rear of the hose carrier.

G10-55A, G12-55A

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Boom

MY9310

MY2691

MY4480

MY4470

11. Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the front of the fourth boom section.

12. If equipped, reconnect any electrical connections at the front and rear of the boom assembly.

13. Install the boom 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).

14. Properly connect the battery.

15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. Refer to Section 3.7.4, “Boom Hose Take-up Adjustment,” for detailed adjustment procedure.

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.

5. 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 boom section.

3.7.4 Boom Hose Take-up Adjustment

1. Tighten the adjusting nut (7) to compress the hose take-up compression spring (4) to measure 2.875-

3.187 in (73-81 mm)(9). Refer to Section 3.7.5, “Boom Hose Adjustment,” if required.

2. Torque the jam nut (8) against the adjusting nut (7) to 100 ft-lb (135,5 Nm).

3.7.5 Boom Hose Adjustment

1. 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 brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

6. 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).

7. 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. Refer to Section 3.7.4, “Boom Hose Take-up Adjustment,” for boom hose take-up adjustment.

9. 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.

10. If necessary, loosen the hose clamp (12), pull the auxiliary hoses and/or the tilt hoses, tighten the hose clamp for additional clearance.

11. Replace the auxiliary hoses and/or the tilt hoses if the proper slack, 4 in (101,6 mm)(11) cannot be achieved.

12. Start the machine, raise the boom to level, cycle the extend/retract cylinder, fully extend the boom.

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G10-55A, G12-55A

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Boom

MY7390

MY5090

13. Cycle the auxiliary circuit and/or the tilt circuit, verifying the auxiliary hoses and the tilt hoses are NOT touching the bottom of the second boom section and the proper slack, 4 in (101,6 mm) is maintained.

14. Retract the boom and shut engine OFF.

15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3.8 QUICK SWITCH ASSEMBLY

3.8.1 Hydraulic Quick Switch Removal

7. Remove the head pin (13) and the quick switch assembly (10)

8. Inspect above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired pin must be replaced.

3.8.2 Hydraulic Quick Switch Installation

1. Assemble quick switch assembly (10) to boom head (14). Line up quick switch between mounts on boom head. The quick switch should be centered in the boom head.

2. Coat head pin (13) with an anti-seize compound. Insert head pin through quick switch and boom head. Secure with capscrew (11 ) and locknut (12).

3. Align quick switch with tilt cylinder rod end and insert tilt cylinder rod end pin (9). Align tilt cylinder rod end pin and screw in locking bolt (8). Torque as required.

4. Uncap and install hydraulic hoses (17) to proper fittings on quick switch assembly (10). torque as required.

5. Secure hoses (17) to cylinder cover (15) with clamp hardware (16).

6. Reinstall cylinder cover (15) with the hardware removed earlier.

3.8.3 Manual Quick Switch Removal

1. Remove hardware securing cylinder cover (15) and remove cylinder cover.

2. Remove clamp hardware (16) securing cylinder cover to hydraulic hoses (17).

3. Label and disconnect hydraulic hoses (17) attached to quick switch assembly (10). Drain fluid into suitable container.

4. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

5. Remove lock bolt (8) holding tilt cylinder rod end pin (9) to quick switch assembly (10). Remove tilt cylinder rod end pin.

6. Support quick switch assembly (10). Remove capscrew (11) and locknut (12) securing head pin (13) to boom head (14).

1. Remove lock bolt (8) holding tilt cylinder pin (9) to the quick switch assembly (10). Remove the tilt cylinder pin.

2. Support quick switch assembly (10). Remove capscrew (11) and locknut (12) securing head pin (13) to boom head (14).

G10-55A, G12-55A

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Ma2070

MAM1390

3. Inspect above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired pin must be replaced.

3.8.4 Manual Quick Switch Installation

1. Assemble quick switch assembly (10) to boom head (14). Line up quick switch between mounts on boom head. The quick switch should be centered in the boom head.

2. Coat head pin (13) with an anti-seize compound. Insert head pin through the quick switch assembly and boom head. Secure with capscrew (11) and locknut (12).

3. Align quick switch assembly with tilt cylinder pin and insert tilt cylinder pin (9). Align tilt cylinder pin and screw in locking bolt (8). Torque as required.

3.9 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.

3.9.1 Wear Pad Inspection

Inspect all wear pads for wear. If angle indicators (1) on ends of wear pads are visible, wear pads can be reused. If pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

3.9.2 Wear Pad Installation and Lubrication

Note: Inspect all wear pads. Replace as necessary.

The following wear pad procedure must be followed to insure the proper wear pad installation:

• Wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Loctite

242™ and installing

mounting bolts.

• Apply Loctite

• A spacer (2) with holes must be used before any

242™ to all wear pad mounting bolts.

shim (3) is used.

• A shim (3) must be inserted between 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.

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G10-55A, G12-55A

Page 59

• Maintain a total boom section clearance (5) of

MY5510

MY3620

MX0510

0.070–0.130 in (1,78–3,30 mm) both the horizontal and vertical directions.

Boom

3.10 BOOM EXTEND/RETRACT CHAIN REMOVAL/INSTALLATION

3.10.1 Boom Retract Chain Removal

The following section explains the removal of the retract chains without removing the boom assemblies.

Note: The retract chain on the bottom of the boom must be removed to gain access to the inner retract chain.

To remove retract chain from third to first boom sections:

1. Park the machine on level ground. Place the transmission control lever 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.

3. Properly disconnect the batteries.

4. Attach a suitable sling to the extend/retract cylinder. Remove the extend/retract cylinder support.

5. Remove rod end pin and lower cylinder onto frame rails. Lowering extend/retract cylinder will allow access to chains.

• 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).

• Bolt length should be determined by measuring the distance from face of insert to face of 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 mounting bolts are recessed.

• Wear Pad Bolt Torque: 3/8 - 24 Bolt, 32–37 lb-ft (43–50 Nm) 3/8 - 24 Hollow Bolt, 15–17 lb-ft (20–23 Nm) 1/2 - 20 Bolt, 76–86 lb-ft (103 - 116 Nm) 1/2 - 20 Hollow Bolt, 45–50 lb-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.

• Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.

6. Remove tension from the chain by backing off the jam nut and adjusting nut (1).

7. Remove four bolts (2) from chain adjustment block.

8. Remove chain from clevis (3) at block.

9. Install a nylon tie wrap through holes of 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 front adjustment block, carefully pull chain out through back of boom.

13. Untie the rope and leave it in place for reinstallation of the chain.

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Boom

To remove the retract chain from the fourth to second boom sections:

1. Remove the jam nut (4) from the chain clevis installed in the chain adjustment block.

2. Back off the adjusting nut fully on the chain clevis. Do not remove the nut from the clevis.

3. Remove the chain from the clevis, install a nylon tiewrap through the holes in the chain, making a loop with the tie-wrap and tie a rope to the loop.

4. Move to the back of the boom and pull the chain to the rear to allow slack for removal.

5. 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.

3.10.2 Boom Retract Chain Installation

Inspect and lubricate chains thoroughly before installation. Articulate the chains to make sure all working surfaces are thoroughly lubricated.

Note: If the inner retract chain was removed, it must be installed first.

1. Fasten a rope to the end of the 3/4 in. chain in order to pull it back into the boom.

2. Attach chain to chain clevis at rear of 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 lb-ft (135 Nm).

To install 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 chain to chain clevis at rear of 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 lb-ft (475-530 Nm).

7. Install extend/retract cylinder and cylinder support.

8. Adjust the retract chains as needed. Refer to Section

3.7, “Hose Carrier Assembly Removal/Installation.”

9. Properly connect the batteries.

10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3.10.3 Boom Extend Chain Removal

The following section explains the removal of the extend chains without removing the boom assemblies.

1. Park the machine on level ground. Place the transmission control lever in (N) 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.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Properly disconnect the batteries.

4. Secure the boom sections together to prevent uncontrolled boom run out when the extend chains are removed.

5. On the chain being removed, loosen and remove the jam nut from the rear chain clevis and back off the adjusting nut on the chain clevis to the end of the threads. Do not completely remove the nut.

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 slack to chain clevis at front of 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.

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Boom

3.10.4 Boom Extend Chain Installation

The following section explains the installation of the retract chains without removing the boom assemblies.

Inspect and lubricate the chains thoroughly before the installation.

1. Fasten the previously used rope to the end of the extend chain.

2. Carefully pull the chain into the boom to the chain clevis anchor.

3. Fasten the chain to clevis with a pin and cotter pin.

4. At the 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 clamping devises being used to keep the boom sections from moving.

7. Properly connect the batteries.

8. Adjust the extend chains as needed. Refer to Section 3.7, “Hose Carrier Assembly Removal/ Installation.”

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3.11 BOOM CHAIN INSPECTION

AND LUBRICATION

3.11.1 Boom Chain Inspection

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 effects can be as follows:

• Moisture—Corrosive rusting reduces chain strength by pitting and cracking.

• Temperature—Low temperature reduces the 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.

G10-55A, G12-55A

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MZ1463

MY1360

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 replacement 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.

3.11.2 Inspection Guidelines

1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

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 retract chains every 1000 hours of operation.

6. Inspect chains for following conditions:

Edge Wear

Check the chain for wear on 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 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 apart, the distance after 12 pins should be 9 in.

3-26

If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain.

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Boom

MZ1466

MZ1465

MZ1467

MZ1468

MZ1469

MZ1470

MZ1471

Distorted or Battered Link Plates

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.

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 the chain’s endurance limit.

• Stress Corrosion Cracking - The

outside link plates are particularly susceptible to stress corrosion cracking (10).

• 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

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 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.

• Ultimate Strength Failure These types of failures are caused by overloads far in excess of the design load. Either fractured plates (11) or enlarged holes (12) can occur. If either of these failures occurs, the chain should be replaced immediately.

•Tight Joints

- All joints in the chain should flex freely. Tight joints (13) 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.

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Boom

3.11.3 Expose Chains for Inspection

d. Extend Chains

1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position.

2. Fully extend the boom until both extend chains are taut. Shut the engine OFF.

The extend chains will be visible for inspection with the machine in this state.

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 retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the chains should be removed and inspected. Refer to Section 3.10, “Boom Extend/Retract Chain Removal/Installation” for detailed information. Replace if necessary.

3.11.4 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated. Refer to Section 2.5, “Fluid and Lubricant Capacities,” for proper lubricant.

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 of 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 2.6, “Service and Maintenance Schedules,” and Section 2.7, “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.

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.

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Boom

MH6460

3.12 FORKS

3.13 EMERGENCY BOOM LOWERING PROCEDURE

Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately.

Daily Inspection

To avoid instability of the machine, the extend/retract cylinder MUST BE fully retracted prior to retracting the lift cylinders. If circumstances prevent retraction of the extend/retract cylinder first, lower the lift cylinders the minimum amount necessary and resume retraction of the extend/retract cylinder as soon as possible in accordance with the machines load chart.

WARNING

Properly support the boom before attempting to proceed with the emergency boom lowering procedure.

WARNING

If possible, safely remove and/or secure the load on the machine before starting the boom lowering

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 local distributor with fork part number to find manufactured dimensions of fork blade.

4. Ensure that the fork length (10) is adequate for intended loads.

5. The Fork markings should be legible, re-stamp markings 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).

procedure. If load cannot be removed, the machine load chart MUST be followed.

3.13.1 Equipment and Supplies Required

Auxiliary Hydraulic Power Supply:

• Portable hydraulic unit or another machine with an auxiliary hydraulic power supply with a capacity to hold up to 22 gal (83 L) of hydraulic oil from the machine during lowering process.

Note: If another machine is being used, the hydraulic reservoir must be drained to accept a minimum of 22 gal (83 L) of hydraulic oil before attempting this procedure.

• Standard Mechanic Tools.

NOTICE

EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply hydraulic oil must be compatible with hydraulic oil shown in Section 2.4, “Fluids and Lubricant Capacities.”

G10-55A, G12-55A

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Boom

MAL2690

G10-55A/G12-55A

Hoses:

• Two Hydraulic Hoses - Approximately 10 ft (3,0 m) each, with a minimum I.D. of

0.375 in (9,5 mm) and a minimum rating of 4000 psi (275,8 bar).

G10-55A or G12-55A - Fittings:

• Two -12 ORFS Caps

• Two -12 ORFS Plugs

Adaptors:

• Two -12 ORFS 90° Adaptors

Note: The adaptor size may vary depending on the hose ends of the auxiliary hydraulic power supply.

3.13.2 Lowering Procedure

a. Retract the boom as follows:

1. If equipped with Personal Work Platform, rescue occupants prior to performing procedure.

2. Properly support the boom before attempting to proceed with the emergency boom lowering procedure.

3. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

4. Properly support the boom as required.

5. Place a suitable receptacle under the main control valve.

6. Remove the plastic cover from the top of the main control valve.

WARNING

Loss of hydraulic oil is limited to the amount trapped within each tube/hose. Slowly loosen each hydraulic tube fitting to release any possible hydraulic oil pressure that may be trapped between the main control valve and the counterbalance valve of the extend/retract cylinder or the lift/lower cylinder.

7. Remove the brackets (5) that is attached to the steel tubes supporting the plastic cover.

8. Loosen and remove any clamps securing the extend/retract cylinder (1 & 2) and lift/lower cylinder tubes (3 & 4) together and to the frame.

9. Disconnect the extend/retract cylinder tubes (1 & 2) from the main control valve. Install plugs in tubes to prevent fluid loss. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

10. Using the hoses and fittings specified, connect the hoses between the auxiliary hydraulic power supply and the tubes removed from the main control valve extend/retract section of the affected machine. Retract tube (1) is the supply and extend tube (2) is the return. Connect the hoses in the proper order to ensure that the cylinder is retracted, not extended.

11. Remove the previously installed the boom support.

12. Use the auxiliary power supply to slowly retract the extend/retract cylinder.

13. Properly support the boom as required.

14. Loosen and remove the jumper hoses, caps, plugs and reconnect the extend/retract cylinder tubes. Torque as required.

b. Lower the boom as follows:

1. Place a suitable receptacle under the main control valve.

2. Disconnect the lift/lower cylinder tubes (3 & 4) from the main control valve. Install plugs in tubes to prevent fluid loss. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

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G10-55A, G12-55A

Page 67

3. Using the hoses and fittings specified, connect the hoses between the auxiliary hydraulic power supply and the tubes removed from the main control valve lift/lower section of the affected machine. Lift tube (3) is the return and lower tube (4) is the supply. Connect the hoses in the proper order to ensure that the boom is lowered, not raised.

4. Remove the previously installed boom support.

5. Use the auxiliary power supply to slowly lower the boom.

6. Loosen and remove the jumper hoses, caps, plugs and reconnect the lift/lower cylinder tubes. Torque as required.

7. Install the previously remove clamps securing the extend/retract and lift/lower cylinder tubes.

8. Install the plastic cover over the top of the main control valve.

9. Transfer any hydraulic oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

10. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

11. Remove the Do Not Operate Tag on both the ignition key switch and steering wheel.

Boom

G10-55A, G12-55A

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Boom

3.14 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during operation of the boom.

Problem Cause Remedy

1. Boom will not extend or retract

2. Boom shifts to right or left when extending.

3. Excessive boom pivot pin noise and/or wear.

4. Excessive Compensation cylinder pivot pin noise and/ or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder, Refer to Section

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bearing(s). 2. Replace bearing(s) and

1. Insufficient lubrication. 1. Lubricate at regular intervals.

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8.4, “Hydraulic Circuits.”

8.8, “Hydraulic Cylinders.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.9, “Boom Wear Pads.”

Refer to Section 2.7, “Lubrication Schedules.” Replace worn pins as needed.

lubricate at regular intervals. Refer to Section 2.7, “Lubrication Schedules.”

Refer to Section 2.7, “Lubrication Schedules.” Replace worn pins as needed.

3-32

2. Worn bushing(s). 2. Replace bushing(s) and lubricate at regular intervals.

G10-55A, G12-55A

Page 69

Problem Cause Remedy

Boom

5. Drooping chain, or jerky boom extend or retract functions.

6. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes

1. Chain(s) tension not properly adjusted.

2. Chain(s) stretched or binding. 2. Replace chains as needed.

3. Wear pads loose, contaminated, excessively worn or damaged.

4. Contaminated, corroded or rusted wear pad sliding surfaces.

5. Extend/Retract hydraulic system not operating properly.

6. Damaged boom section. 6. Replace the damaged boom

and/or connection leaks.

2. Lift/lower hydraulic system not operating properly.

1. Adjust chain(s).

Refer to Section 3.6, “Boom Section Separation Adjustment.”

3. Replace wear pad. Refer to Section 3.9, “Boom Wear Pads.”

4. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

5. Refer to Section 8.4, “Hydraulic Circuits.”

section. Refer to Section 3.3, “Boom Assembly Maintenance.”

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8.4, “Hydraulic Circuits.”

7. Excessive Lift/Lower cylinder pivot pin noise and/or wear.

3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer toSection

8.8, “Hydraulic Cylinders.”

4. Seized boom pivot pin bearing. 4. Replace bearing.

1. Insufficient lubrication. 1. Lubricate at regular intervals. Refer to Section 2.6, “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 2.7, “Lubrication Schedules.”

G10-55A, G12-55A

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Boom

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 3.9, “Boom Wear Pads.”

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

9. Auxiliary hydraulics will not operate.

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer

1. Auxiliary hydraulic system not operating properly.

2. Chain sheave(s) not properly lubricated.

3. Chain sheave(s) not rotating freely.

2. Reduce cycle times.

3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. Refer to Section 8.4, “Hydraulic Circuits.”

to Section 3.6, “Boom Section Separation Adjustment.”Replace chains as needed.

2. Lubricate chain sheave. (Refer to Section 2.6, “Service and Maintenance Schedules.”

3. Lubricate chain sheave. Refer to Section 2.6, “Service and Maintenance Schedules.” Repair or replace chain sheave(s) as needed.

3-34

4. Improper chain lubrication. 4. Lubricate at regular intervals. Refer to Section 2.6, “Service and Maintenance Schedules.” Replace chains as needed.

G10-55A, G12-55A

Page 71

Section 4

Cab and Covers

Contents

PARAGR APH TITLE PAGE

4.1 Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.3 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

6. Close and secure the engine cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.5 Frame Level, Auxiliary and Outrigger Control Joysticks . . . . . . . . . . . . . . 4-6

4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.7 Heater/Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . 4-6

4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

G10-55A, G12-55A

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Page 72

Cab and Covers

MY6920

TRANSMISSION

CONTROL LEVER

INSTRUMENT

PANEL

STEERING WHEEL

FRAME LEVEL

INDICATOR

BOOM CONTROL

JOYSTICK

ACCESSORY CONTROL

LEVER (if equipped)

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

IGNITION

SWITCH

FRAME LEVEL

CONTROL JOYSTICK

AUXILIARY CONTROL

JOYSTICK

FUEL TANK

RIGHT HAND PANEL

DECOMPRESSION

VALV E

OUTRIGGER CONTROL

JOYSTICKS

4.1 OPERATORS CAB AND COVERS COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.

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G10-55A, G12-55A

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4.2 OPERATOR CAB

MAL1430

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

4.2.1 Cab Safety

WARNING

The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value.

DO NOT weld, grind, drill, repair or modify the cab in any way. Any modification or damage to cab structural components requires cab replacement.

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 Serial Number Decal

Cab serial number decal is located on left side of cab, behind seat. Information specified on serial number plate includes cab model number, cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

4.3 CAB COMPONENTS

Cab and Covers

5. Label, disconnect and cap four hoses from side of steering valve (1). Cap fittings on steering valve. Label, disconnect and plug load sense hose at front of steering valve. Cap fitting on steering valve.

6. Remove the steering wheel (2).

7. Disconnect and remove the transmission control lever (3).

8. Remove the steering assembly through dash panel opening.

9. Support the steering valve, and remove the four hex-head capscrews and four lockwashers (4).

4.3.1 Steering Column and Orbitrol Valve

a. Orbitrol Valve Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

Note: It may be necessary to remove the main dash panel to gain access to the appropriate hydraulic hoses. Refer to Section 9.12.1, “Gauges.”

G10-55A, G12-55A

Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective.

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Cab and Covers

MY0140

b. Orbitrol Valve Installation

1. Secure steering valve to steering column with four hex-flange capscrews and four lockwashers.

2. Install steering column through dash panel opening. Position steering valve to its original orientation in the cab.

3. Install the transmission control lever and connect the lever

4. Install steering wheel assembly. Torque steering wheel nut to 29–34 lb-ft (39–46 Nm).

5. Install new o-rings into the steering valve fittings. Lubricate the o-rings with clean hydraulic oil.

6. Uncap and connect the previously labeled load sense hose to the steering valve.

7. Uncap and connect the remaining previously labeled four hoses to the steering valve.

Note: If necessary, install the main dash panel. Refer to Section 9.12.1, “Gauges.”

8. Properly connect the batteries.

9. Start engine and check operation of steering system. Check for hydraulic fluid leaks. Check hydraulic fluid level in tank and add fluid as required.

10. Close and secure the engine cover.

11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

c. Service Brake Pedal Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

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

5. Remove the bolt and lockwasher (1) securing the service brake pedal pivot pin (2).

6. Pull pivot pin from service brake pedal bracket (3).

7. Remove the service brake pedal from the cab.

d. Service Brake Pedal Installation

1. Position the service brake pedal in its mounting location within the cab.

2. Secure the brake pedal into position with the pivot pin.

3. Be sure the brake pedal has the correct range of motion. Secure pivot pin with bolt and lockwasher.

4. Properly connect the batteries.

5. Close and secure the engine cover.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

G10-55A, G12-55A

Page 75

Cab and Covers

MY0940

MY0950

4.3.3 Throttle Pedal

a. Throttle Pedal Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Properly disconnect the batteries.

4.3.4 Boom and Tilt Joystick Assembly

a. Joystick Assembly Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries

4. Disconnect the electrical harness connector (4).

5. Remove the bolts (5) securing the throttle pedal to the throttle pedal bracket (6).

6. Remove the throttle pedal assembly from the cab.

b. Throttle Pedal Installation

1. Position the throttle pedal in its mounting location within the cab.

2. Secure throttle pedal into position with pivot pin.

3. Install throttle pedal ball joint to throttle pedal.

4. Properly connect the batteries.

5. Verify proper throttle pedal operation.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

5. Lift the joystick’s rubber sleeve, remove the bolts securing the boom joystick to the cab (7).

6. Lift the joystick from its mounting position.

7. Label, disconnect and cap the hydraulic hoses attached to boom joystick.

8. Disconnect the tilt function electronic connector.

9. Remove the joystick assembly.

G10-55A, G12-55A

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Cab and Covers

MY0960

b. Joystick Assembly Installation

1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations.

2. Connect the tilt function electronic connector.

3. Install the bolts securing the joystick to the cab.

4. Properly connect the batteries.

5. Test the complete range of the joystick functions per control decal in cab or Operation & Safety manual.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.5 Frame Level, Auxiliary and Outrigger Control Joysticks

a. Joystick Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. Remove the screws (8) securing the dash panel (9) to the cab. Remove the dash panel.

6. Remove any hardware securing joystick to cab.

7. Label, disconnect and cap the hydraulic hoses attached to the joystick.

8. Remove the joystick from the cab.

b. Joystick Installation

3. Install the dash panel to its original position with the previously used hardware.

4. Properly connect the batteries.

5. Test the complete range of the joystick functions per control decal in cab or Operation & Safety manual.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.6 Windshield Wiper Assembly

Refer to Section 9.9, “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 transmission control lever in the (N) 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.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. Place a suitable container beneath radiator. Slowly turn surge allowing any pressure to escape. Remove surge tank 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 coolant 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.

1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations.

2. Install the bolts securing the joystick to the cab.

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Page 77

10. Remove the bolts securing the front plate (10) to the

MY0190

MAL0420

MY4390

HEATER WITH AIR

CONDITIONING SHOWN

seat riser weldment (11).

11. Remove the bolts securing the seat riser weldment to the cab. Remove the riser weldment.

Cab and Covers

13. Loose hose clamps securing 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.

12. Loosen the hose and disconnect the heater air duct hoses (12).

b. Heater Assembly Installation

Note: If machine is equipped with air conditioning, air conditioning system must be charged by local distributor 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 previously labeled electrical connections.

3. Connect previously labeled heater hoses to their appropriate locations.

4. Connect the previously labeled air conditioning hoses to their appropriate locations.

5. Install the seat riser weldment.

6. Install the front plate to the seat riser weldment.

7. Install the cab seat.

8. 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 2.5, “Fluids and Lubricant Capacities.”

9. Properly connect the batteries.

G10-55A, G12-55A

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Cab and Covers

Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

10. Wait for the engine to cool and check the coolant level. Add coolant as required to bring the coolant to the proper level.

11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.4 CAB REMOVAL

WARNING

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 cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace cab. Contact local distributor with any questions about 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 securely mounted on the machine.

1. Park machine on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage park brake and shut 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 engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. If equipped with cab heater:

• Place a funnel at base of radiator to channel drained coolant into container. Loosen drain petcock and allow coolant to drain.

• Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.

• Tighten the radiator drain petcock.

• Disconnect cab heater hoses. Refer to Section

4.3.7, “Heater/Air Conditioning System (if equipped).”

6. Remove necessary dash panels to gain access to electrical wiring connections. Label and disconnect harnesses. Push harness connectors through opening in the cab.

7. Remove boom joystick from is mounting position. Refer to Section 4.3.4, “Boom and Tilt Joystick Assembly.” Label, disconnect and cap all hydraulic hoses attached to the boom joystick. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

8. Remove frame level and attachment tilt and auxiliary control joystick. Refer to Section 4.3.5, “Frame Level, Auxiliary and Outrigger Control Joysticks.” Label, disconnect and cap all hydraulic hoses attached to joystick. Cap all fittings and openings to keep dirt and debris from entering hydraulic system.

9. 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.

10. 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.

11. 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.

12. Push all hydraulic hoses through opening in cab.

13. Disconnect the throttle cable from the throttle assembly. Refer to Section 4.3.3, “Throttle Pedal.”

14. Disconnect engine air filter and hydraulic oil reservoir breather from their brackets at top of cab. Move air filter and breather clear from cab so they do not become damaged during cab removal.

15. Remove the fuel tank from the cab. Refer to Section

7.6.2, “Fuel Tank.”

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16. Open Cab: Route a sling with a minimum lifting

MY0610

MY4170

MY0610

capacity of 1000 lb (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).

17. Enclosed Cab: Install two lifting eye bolts (14) in the threaded holes on roof of cab above B pillars (15).

Cab and Covers

21. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

22. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift cab and remove it from frame. Readjust position of sling as needed to help balance cab during removal.

23. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is being removed from the machine.

24. Inspect condition of fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

25. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

4.5 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.

18. Remove two cab side-mount bolts in cab (16).

19. Remove the four cab-to-frame bolts, flat washers and nuts (17).

20. Remove the mirrors and all other cab components as needed, if not previously removed.

G10-55A, G12-55A

2. Open Cab: Route a sling with a minimum lifting capacity of 1000 lb (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).

3. Enclosed Cab: Install two lifting eye bolts (14) in threaded holes on roof of cab above B pillars (15).

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Cab and Covers

MY4170

4. Use a hoist or overhead crane and sling attached to the cab. Carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation.

14. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.5, “Fluids and Lubricant Capacities.”

15. Properly connect the batteries.

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.

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.

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 lb-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 heater option, reconnect the heater hoses to the cab heater. Refer to Section 4.3.7, “Heater/Air Conditioning System (if equipped).”

13. Install fuel tank to the cab. Refer to Section 7.6.2, “Fuel Tank.”

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Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGR APH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2 Axle Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.1 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.3 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-5

5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6.1 Wheel and Tire Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6.2 Wheel and Tire Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

G10-55A, G12-55A

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Axles, Drive Shafts, Wheels and Tires

MY6930

FRONT AXLE

ASSEMBLY

FRONT STEERING

CYLINDER

FRONT DRIVE SHAFT

REAR DRIVE SHAFT

REAR STEERING

CYLINDER

REAR AXLE

ASSEMBLY

TRANSMISSION

DROP BOX

FRONT AXLE

WHEEL HUBS

(2)

REAR AXLE

WHEEL HUBS (2)

5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.

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WARNING

MY4180

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

5.2 AXLE SERIAL NUMBER

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.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

Axles, Drive Shafts, Wheels and Tires

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in the (N) NEUTRAL position, engage parking brake, straighten all wheels and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. Remove the optional fender assembly.

5.3 AXLE SPECIFICATIONS AND MAINTENANCE INFORMATION

For axle, oil specifications and maintenance information, refer to Section 2, “General Information and Specifications.”

Detailed axle service instructions are provided in the following publications:

• Service Manual (P/N 31200240)

• Parts Manual (P/N 31200728)

5.4 AXLE REPLACEMENT

5.4.1 Axle Removal

Front and rear axle assemblies differ in that front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; rear axle has neither. Following steps outline a typical axle removal procedure, suitable for either front or rear axle assembly.

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.

6. If axle will be disassembled after removal, place a suitable receptacle under axle (1) and wheel hubs drain plugs (2). Remove drain plugs and allow axle oil to drain into receptacle. Transfer used axle oil into a suitable covered container, and label container as “Used Oil.” Dispose of used oil at an approved recycling facility.

7. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.

8. Block front and rear of both tires on axle that is not being removed. Ensure that machine will remain in place during axle removal before proceeding.

9. Raise machine using a suitable jack or hoist. Place suitable supports under both sides of frame and lower machine onto supports. Ensure that 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 axle being removed. (Refer to Section 5.6.1, “Wheel and Tire Assembly Removal.”)

Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern “arrows” facing in the direction of forward travel.

12. Remove the drive shaft assembly. Refer to Section

5.5.3, “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 bolts and locknuts securing axle to frame.

G10-55A, G12-55A

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Axles, Drive Shafts, Wheels and Tires

MY4180

MY6940

LEVEL

15. Remove axles from machine using jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb machine while removing axle. Balance axle and prevent it from tipping, turning or falling while removing it from beneath machine. Place axle on a suitable support or holding stand.

5.4.2 Axle Installation

1. Before proceeding, ensure that machine will remain in place during axle installation. Block front and rear of both tires on the axle that is already installed on the machine.

2. If applicable, raise machine using a suitable jack or hoist. Place suitable supports beneath frame and lower machine onto supports, allowing enough room for axle installation. Ensure that machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove axle from its support or holding stand. Balance axle and prevent it from tipping, turning or falling while positioning it beneath machine. DO NOT raise or otherwise disturb machine while installing axle. Keep axle supported and balanced on jack, hoist or overhead crane and sling throughout the installation procedure.

4. Position axle under frame, and align axle housings with holes in frame.

5. Install four axle bolts and nuts. Tighten and torque to 530-565 lb-ft (718-766 Nm).

6. Move cylinder into position on axle cylinder anchor. Insert a cylinder-mount pin through cylinder and cylinder anchor. Secure the cylinder-mount pin with one capscrew and a new locknut.

7. Apply multi-purpose grease through the self-tapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin.

8. Install the drive shaft assemblies. (Refer to Section

5.5.5, “Drive Shaft Installation.”)

9. If reinstalling an axle previously removed from the machine, position driveshaft yoke on axle according to alignment marks made earlier. If installing a new axle, note position of driveshaft yoke at transmission. Align driveshaft yoke on axle in same plane as yoke on transmission.

10. Tighten axle oil drain plug, loosen and remove axle oil fill plug (1). (Refer to Section 2.5, “Fluids and Lubricant Capacities,” for proper oil and capacities.

11. Rotate wheel hubs 90 degrees so drain plug (2) becomes fill plug (3). Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”,” for proper oil and capacities.

12. Install the wheel and tire assemblies. Refer to Section 5.6.2, “Wheel and Tire Assembly Installation.”

13. Carefully remove jack, hoist or overhead crane and sling supporting the axle.

14. Carefully raise machine using a suitable jack or hoist. Remove supports from beneath frame and lower the machine to ground.

15. Remove blocks from front and rear of both tires on other axle.

Note: ALWAYS use new o-rings when servicing the machine.

16. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.

17. Uncap and connect the steering and brake lines at their axle fittings.

18. Check the hydraulic reservoir oil level.

19. Start engine. Turn 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.

20. Install the optional fender assembly.

21. Close and secure the engine cover.

22. 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.”

5-4

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Axles, Drive Shafts, Wheels and Tires

5.4.3 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.”

2. Axle and/or wheel end housings

filled with incorrect oil or oil level low.

3. Incorrect alignment of ring and

pinion gears.

4. Incorrect pinion (input) shaft

bearing preload.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end housings

2. Drain axle and/or wheel end housings and fill to correct level with hydraulic oil. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.”

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by adding or removing shims as needed.

and fill to correct level with hydraulic oil. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.”

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

8. Axle housing damaged. 8. Replace damaged parts.

1. Universal joint(s) worn or damaged. 1. Repair or replace universal joints as needed.

2. Differential ring and/or pinion

gears damaged.

1. Drive shaft universal joint

assembly(ies) incorrectly tightened.

2. Drive shaft universal joint(s) worn

or damaged.

3. Drive shaft(s) damaged/unbalanced. 3. Replace drive shaft(s) as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

2. Repair or replace universal joints as needed.

G10-55A, G12-55A

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Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

5. Oil leaking from wheel end housing (planet carrier).

1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Engine Repair Manual.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm).

7. Replace housing(s) as needed.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

2. Replace o-ring.

6. Oil leaking from steering cylinder.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

1. Hose fittings loose. 1. Tighten fittings.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged. 3. Replace piston rod seal.

4. Cylinder tube damaged. 4. Replace cylinder tube.

3. Replace seal and/or fork joint shaft.

41 lb-ft (55 Nm).

2. Replace o-rings and seals.

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Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with hydraulic oil.

Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.”

8. High steering effort required.

9. Slow steering response.

10. Excessive noise when brakes are engaged.

11. Brakes will not engage.

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

3. Dragging park brake. 3. Adjust park brake cable as needed.

1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

3. Worn or damaged swivel bearings. 3. Replace swivel bearings as needed.

1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally. 2. Repair or replace steering cylinder

1. Brake discs worn. 1. Check brake discs for wear. Refer to

2. Brake discs damaged. 2. Replace brake discs.

1. Brake (hydraulic) system not operating properly.

2. Drain axle and fill to correct level with hydraulic oil. Refer to Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.”

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Correct bearing preload by adding or removing shims as needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

as needed.

Section 5.7, “Brakes.”

1. Refer to Section 8.4, “Hydraulic Circuits.”

12. Brakes will not hold the machine or braking power reduced.

G10-55A, G12-55A

2. Brake piston o-rings and seals damaged (leaking).

1. Brake discs worn. 1. Check brake discs for wear. Refer to

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

2. Replace o-rings and seals.

Section Note:, “Friction Modifier required for axle differentials, see Section 2.5.3, “Capacities.”.”

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Replace o-rings and seals.

5-7

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Axles, Drive Shafts, Wheels and Tires

MAL2220

5.5 DRIVE SHAFTS

5.5.1 Drive Shaft Inspection and Service

Inspect areas where drive shaft flange yokes and slip yokes mount to drive shafts. Attempt to turn each drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise.

Note: To help ensure optimum performance, drive shaft assemblies are specially balanced as a unit at 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.

Note: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.

5.5.2 Drive Shaft Maintenance

Refer to Section 2.5, “Fluids and Lubricant Capacities,” for information regarding lubrication of drive shafts.

5.5.3 Drive Shaft Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. Block the wheels.

6. The drive shaft assembly is a balanced assembly. Mark yoke and axle, transmission and shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of drive shaft must be in same plane to help prevent excessive vibration.

7. Remove four bolts and two straps (1) securing bearing cross to the transmission output shaft flange. Discard bolts.

8. Remove four bolts and two straps (2) securing bearing crosses to the axle. Discard bolts.

9. Remove front drive shaft assembly (3).

10. Remove four bolts and two straps (4) securing bearing cross to transmission output shaft flange. Discard bolts.

11. Remove four bolts and two straps (5) securing bearing crosses to rear axle (6) at carrier bearing. Discard bolts.

12. Remove rear drive shaft assembly (6).

13. Remove four bolts and two straps (7) securing bearing cross to rear axle. Discard bolts.

14. Remove two bolts, nuts and washers (8) securing carrier bearing to frame.

15. Remove rear drive shaft assembly (9).

5.5.4 Drive Shaft Cleaning and Drying

1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.

2. Remove and burrs or rough spots from all machined surfaces. Re-clean and dry as required.

5.5.5 Drive Shaft Installation

1. Raise drive shaft assembly into position. Slip-yoke end of drive shaft mounts toward axle. If reinstalling a drive shaft previously removed, align flange yokes according to alignment marks made during removal.

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Axles, Drive Shafts, Wheels and Tires

Note: The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

2. Apply Loctite

3. Install two straps and four new bolts (1) securing front axle (3) bearing crosses to transmission. Torque bolts to 55-60 lb-ft (75-81 Nm).

4. Install two straps and four new bolts (2) securing front axle (3) bearing crosses to axle. Torque bolts to 55-60 lb-ft (75-81 Nm).

5. Install two straps and four new bolts (7) securing rear axle (9) bearing crosses to axle. Torque bolts to 55-60 lb-ft (75-81 Nm).

6. Install previously removed bolts, nuts and washers (8) and secure the carrier bearing to frame. Torque to 55 lb-ft (75 Nm).

7. Install two straps and four new bolts (4) securing the rear axle (6) bearing crosses to the transmission. Torque bolts to 55-60 lb-ft (75-81 Nm).

8. Install two straps and four new bolts (4) securing the rear axle (6) bearing crosses to the rear axle (9) at the carrier bearing. Torque bolts to 55-60 lb-ft (75-81 Nm).

9. Properly connect the batteries.

10. Close and secure the engine cover.

11. Unblock the wheels.

12. Remove Do Not Operate Tags from both ignition key switch and steering wheel.

243TM to all mounting bolts.

5.6 WHEELS AND TIRES

WARNING

Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over.

It is recommended that a replacement tire to be same size, ply and brand as originally installed. Refer to 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 tire and wheel assembly.

G10-55A, G12-55A

5.6.1 Wheel and Tire Assembly Removal

1. Park the machine on a firm, level surface, 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 an Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

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Axles, Drive Shafts, Wheels and Tires

MY4190

MY4200

4. Place a suitable jack under axle pad closest to wheel being removed. Raise machine and position a suitable support beneath axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly.

5. Lower the machine onto the support.

6. Remove lug nuts and lug washers in an alternating pattern.

7. Remove wheel and tire assembly from machine.

5.6.2 Wheel and Tire Assembly Installation

4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 350-400 lb-ft (475-542 Nm).

5. Remove machine from supports.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

Note: If the machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel (5).

Note: Verify valve stems face outward on all wheel and tire assemblies.

1. Position 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.

5.7 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).

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MZ1020

5.8 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power, before using the emergency towing procedures outlined below.

Note: Block the wheels of the machine BEFORE attempting to release the park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable.

5.8.1 Manually Releasing the Park Brake

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 at a time in sequence until all have been turned on full turn 360°.

4. Repeat steps 1 thru 3 for other side of differential.

Note: After machine has been towed to a secure location, reactivate parking brake. Carefully follow procedures from start to finish. Contact local JLG dealer if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation.

5.8.2 Manually Resetting the Park Brake

Note: Block the wheels of the machine BEFORE attempting to reset the machine’s park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable.

1. Loosen each release screw (5), only 1/4 turn at a time, in sequence, until each screw has lost contact with the guide pin.

2. Remove screws along with nuts and seals. Replace seals, lubricate screws with a silicone-based grease and re-install screws along with 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 other side of differential.

5. After repairs to machine have been made, start machine and check 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, “Steering Orbitrol Valve.”

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Axles, Drive Shafts, Wheels and Tires

This Page Intentionally Left Blank

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Page 93

Section 6

Transmission

Contents

PARAGR APH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . 6-3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5

6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.4.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.6 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.6.1 Torque Convertor Diaphragm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.6.2 Torque Convertor Diaphragm Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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Transmission

M 6951Y

OIL DRAIN PLUG

OIL FILLER PLUG

TRANSFER CASE

BREATHER

OIL FILL TUBE AND

DIPSTICK

TRANSMISSION

FILTER

OIL DRAIN TUBE

SHIFT SOLENOIDS

TORQUE CONVERTER

6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.

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MY6960

6.4 TRANSMISSION REPLACEMENT

WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of transmission. Refer to local distributor and applicable Transmission Service Manual for assistance with comprehensive transmission diagnosis, repair and component replacement.

6.2 TRANSMISSION SERIAL NUMBER

Transmission serial number plate (1) is located on front of transmission case behind 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 31200728)

Note: Contact local distributor if internal transmission repair is required during the warranty period.

Cleanliness is of extreme importance. Before attempting to remove transmission, thoroughly clean exterior of transmission to help prevent dirt from entering during replacement process. Avoid spraying water or cleaning solution onto or near transmission shift solenoids and other electrical components

6.4.1 Transmission Removal

WARNING

NEVER lift a transmission alone; enlist the help of at

least one assistant or use a suitable hoist or overhead crane and sling with a minimum lifting capacity of 1000 lb (454 kg).

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open the engine cover. Allow the system fluids to cool.

4. Remove engine cover. Mark position of cover to help with cover adjustment when being reinstalled.

5. Drain the hydraulic oil reservoir. Refer to Section

8.5.1, “Hydraulic Oil Reservoir Draining.”

6. Properly disconnect the batteries.

7. Thoroughly clean the transmission and surrounding area, including all the hoses and fittings, before proceeding.

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8. Place a suitable receptacle under transmission drain cock (2). Open transmission drain cock, and allow transmission oil to drain into receptacle. Remove drain plug and repeat drain procedure with the drop box (3).

9. Transfer used transmission oil into a suitable, covered container, and label container as “Used Oil.” Dispose of used oil at an approved recycling facility. Close the transmission drain cock. Clean and reinstall the drop box drain plug.

10. Remove the transmission-to-axle drive shafts. Refer to Section 5.5.3, “Drive Shaft Removal.”

11. Remove exhaust components from turbo to exhaust pipe. Refer to Section 7.5, “Engine Exhaust System.”

12. Remove the implement pump. Refer to Section

8.6.1, “Implement Pump Replacement.”

13. Label and disconnect transmission temperature switch connector and shift solenoid wiring harness connectors.

14. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission.

15. Remove access cover from bottom of engine bell housing. This will allow access to remove four bolts holding the torque convertor diaphragm to the engine flywheel.

16. Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts to be accessed. Remove them one at a time.

17. Wipe up any spilled hydraulic and transmission oil.

18. Connect a lifting strap or chain to lifting eye at top of transmission, and to a suitable hoist or overhead crane. Operate hoist or crane to remove slack from chain, but DO NOT raise transmission at this time.

19. Place blocks under rear of engine for support BEFORE transmission mounts are removed.

20. Place blocks under the transmission to help support it during removal.

21. Remove both rear transmission mount bolts and lockwashers securing transmission mount to frame.

22. Remove the bolts and washers holding the transmission to the engine.

23. Remove the capscrews and lockwashers securing each rear transmission mount to the transmission.

24. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts.

25. 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. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings.

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6.4.3 Transmission Installation

WARNING

NEVER lift a transmission alone; enlist the help of at

least one assistant or use a suitable hoist or overhead crane and sling.

1. Install two guide studs near the top of the bell housing holes.

2. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis.

3. 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 lb-ft (72 Nm). Remove the two alignment studs and install and torque the last two transmission mounting bolts.

4. Install capscrews and lockwashers securing rear transmission mount to transmission. Torque capscrews to 125-140 lb-ft (170-190 Nm).

27. Remove the transmission oil filter (4) and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount.

28. If transmission oil is suspect to contamination or torque converter is damaged, remove the converter and flex plate from the transmission.

29. Remove the bolt and washers holding the converter to the flex plate.

6.4.2 Transmission Inspection and

Internal Repair

If replacing entire transmission, transfer transmission temperature switch to replacement transmission. Gear shift solenoids are included with a new transmission.

5. Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers. Apply Loctite torque to 125-140 lb-ft (169-190 Nm)

6. 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 lb-ft (35-59 Nm). Replace access plug.

7. Remove the hoist or overhead crane and sling.

8. Connect the transmission temperature switch connector and the shift solenoid wiring harness connectors.

9. Secure wiring harness to transmission housing.

10. Connect the transmission oil cooler inlet and outlet hoses at the transmission.

11. Install the hydraulic pump. Refer to Section 8.6.1, “Implement Pump Replacement.”

12. Install the transmission-to-axle drive shafts. Refer to Section 5.5.5, “Drive Shaft Installation.”

13. Install exhaust components from turbo to exhaust pipe. Refer to Section 7.5, “Engine Exhaust System.”

14. Clean the transmission oil filter mounting surface.

15. Apply a thin film of clean hydraulic oil to the new transmission filter gasket. Install the new filter and torque to 20-25 lb-ft (27-34 Nm).

24™ to the transmission mount bolts and

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6.4.4 After Transmission Service or Replacement

In general:

1. Check transmission oil level and add oil as required.

2. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning.

3. Drain and flush entire transmission cooling system.

4. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.

Note: Check transmission oil level with engine at idle and oil at normal operating temperature.

16. Fill the transmission. Refer to Section 2.5, “Fluids and Lubricant Capacities,” for proper capacity.

17. Transmission oil may 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 & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

18. Transmission transfer case fluid may be added through the fill plug (6). Install fill plug and tighten when filled to appropriate level.

19. Properly connect the batteries.

Note: Check transmission oil level with engine at idle and transmission oil cold.

20. Apply park brake, shift transmission control lever to the (N) NEUTRAL position and lower the forks or attachment to the ground.

21. Remove the transmission dipstick (5) and check the oil level. The oil level should be at the MAX line.

22. If oil is low, add oil as required and recheck level.

23. Replace the transmission dipstick. when finished.

24. Install the engine cover.

25. Close and secure engine cover.

26. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.Close and secure the engine cover.

27. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

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 & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

6. Transmission transfer case fluid may be added through the fill plug (6). Install fill plug and tighten.

7. Apply park brake, shift transmission control lever to the (N) NEUTRAL position and lower the forks or attachment to the ground.

8. Remove the transmission dipstick (5) and check the oil level. The oil level should be at the MAX line.

9. If oil is low, add oil as required and recheck level.

10. Replace the transmission dipstick. when finished.

11. Close and secure engine cover.

12. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.

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MAL2180

6.5 TRANSMISSION COOLER THERMAL BY-PASS VALVE

6.5.1 Thermal By-Pass Valve

Cartridge Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake, and shut engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open engine cover. Allow system fluids to cool.

4. Properly disconnect the batteries.

5. Thoroughly clean the transmission and surrounding area, including all the hoses and fittings, before proceeding.

6. Place a suitable receptacle under transmission drain cock (7). Open transmission drain cock, and allow transmission oil to drain into receptacle. Remove drain plug and repeat drain procedure with the drop box (8).

7. Transfer used transmission oil into a suitable, covered container, and label container as “Used Oil.” Dispose of used oil at an approved recycling facility. Close the transmission drain cock. Clean and reinstall the drop box drain plug.

8. Remove transmission oil filter (9) and dispose of properly. Clean filter mounting surface. Cover or cap oil filter mount.

9. Transfer used transmission oil into a suitable, covered container, and label container as “Used Oil.” Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission and drop box drain plugs.

10. Place a suitable container beneath transmission cooler fittings on hydraulic cooler. Transfer any transmission oil into a properly labeled container. Dispose of properly.

11. Label, disconnect and cap the transmission oil cooler hoses (10) at the thermal by-pass valve (11). Cap all fittings and openings to prevent dirt and debris from entering.

12. Loosen and remove the cartridge (12) from side of thermal by-pass valve. Plug opening to prevent dirt and debris from entering system.

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Transmission

6.5.2 Thermal By-Pass Valve Cartridge Installation

1. Remove the plug and install the new cartridge (12) in the thermal by-pass valve (11).

2. Uncap and connect previously labeled transmission oil cooler hoses (10) to thermal by-pass valve.

3. Clean transmission oil filter mounting surface.

4. Apply a thin film of clean hydraulic oil to new transmission filter gasket. Install new filter and torque to 20-25 lb-ft (27-34 Nm).

5. Fill the transmission. Refer to Section 2.5, “Fluids and Lubricant Capacities,” for proper capacity.

6. Properly connect batteries.

Note: Check transmission oil level with engine at idle and transmission oil cold.

7. Apply park brake, shift transmission control lever to (N) NEUTRAL position and lower the forks or attachment to ground.

8. Open engine cover.

9. Remove transmission dipstick (5) and check oil level. Oil level should be at MAX line. Add oil as required.

10. Replace transmission dipstick.

11. Close and secure engine cover.

12. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.

6.6 TORQUE CONVERTOR DIAPHRAGM

6.6.1 Torque Convertor Diaphragm Removal

Note: In order to remove engine drive plates, engine and transmission must be separated.

2. Refer to Section 6.4.1, “Transmission Removal,” or Section 7.7.1, “Engine Removal.”

3. Remove four bolts holding diaphragms to flywheel.

4. With drive plates and torque converter removed, loosen and remove four bolts (7) and eight lock washers holding the two diaphragms (8) to the torque converter (9).

5. Replace both diaphragms if damaged.

6.6.2 Torque Convertor Diaphragm Installation

1. Install two new diaphragms on 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

6-8

Section 7.7.2, “Engine Installation,” for the remainder of the installation.

G10-55A, G12-55A

JLG G12-55A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

EFFECTIVITY PAGE

1.1 INTRODUCTION

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

1.5 SAFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.3 OPERATION & SAFETY MANUAL

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

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

2.2 THREAD LOCKING COMPOUND

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

2.3.2 Metric Fastener Torque Chart

2.3.3 Hydraulic Hose Torque Chart

2.4 SPECIFICATIONS

2.4.1 Travel Speeds

2.4.2 Hydraulic Cylinder Performance

2.4.3 Cylinder Drift

2.4.4 Electrical System Engine Performance

2.4.5 Engine Specifications

2.4.6 Tires

2.5 FLUID AND LUBRICANT CAPACITIES

2.5.1 Fluids (if Equipped for ULS)

2.5.2 Fluids (if Equipped for LS)

2.5.3 Capacities

2.6.1 10, 1st 50 & 50 Hour

2.6.2 1st 250, 250 & 500 Hour

2.6.3 1000, 1500, 2000 & 5000 Hour

2.7 LUBRICATION SCHEDULES

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

3.5.2 Third and 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

Third and Fourth Boom Section Installation

3.5.11 Second, Third and Fourth Boom Section Installation

3.6 BOOM SECTION SEPARATION ADJUSTMENT

3.7 HOSE CARRIER ASSEMBLY REMOVAL/INSTALLATION

3.7.1 Hose Carrier Assembly Removal

3.7.2 Assembling Hose Carrier Assembly

3.7.3 Hose Carrier-Assembly Installation

3.7.4 Boom Hose Take-up Adjustment

3.7.5 Boom Hose Adjustment

3.8 QUICK SWITCH ASSEMBLY

3.8.1 Hydraulic Quick Switch Removal

3.8.2 Hydraulic Quick Switch Installation

3.8.3 Manual Quick Switch Removal

3.8.4 Manual Quick Switch Installation

3.9 BOOM WEAR PADS

3.9.1 Wear Pad Inspection

3.9.2 Wear Pad Installation and Lubrication

3.10 BOOM EXTEND/RETRACT CHAIN REMOVAL/INSTALLATION

3.10.1 Boom Retract Chain Removal

3.10.2 Boom Retract Chain Installation

3.10.3 Boom Extend Chain Removal

3.10.4 Boom Extend Chain Installation

3.11.1 Boom Chain Inspection

3.11.2 Inspection Guidelines

3.11.3 Expose Chains for Inspection

3.11.4 Chain Lubrication

3.12 FORKS