JLG G12-55A Service Manual

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

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

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

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

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

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

iii

Section Subject Page

G10-55A, G12-55A

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

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.

G10-55A, G12-55A

Safety Practices

1.6 SAFETY INSTRUCTIONS

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

For all 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

1-3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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