G12-55A
Table of contents
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An Oshkosh Corporation Company
Illustrated Parts Manual
Models
G10-55A
G12-55A
Before S/N 0160045636 excluding
0160045082, 0160045094,
0160045209, 0160045295,
0160045296 & 0160045449
3126020
Revised
September 27, 2013
EFFECTIVITY PAGE
i3126020 G10-55A, G12-55A
December 19, 2003 - A - Original Issue Of Manual
April 16, 2004 - B - Revised Manual
December 30, 2004 - C - Revised Manual
June 3, 2005 - D - Revised Manual
September 30, 2005 - E - Revised Manual
April 24, 2006 - F - Revised Manual
August 25, 2006 - G - Revised Manual
February 23, 2007 - H - Revised Manual
July 6, 2007 - I - Revised Manual
August 8, 2007 - J - Revised Manual Tier III updates
November 14, 2008 - K - Revised Manual
August 10, 2009 - L - Revised Manual
November 6, 2009 - M - Revised Manual
August 13, 2010 - N - Revised Manual
April 13, 2011 - O - Revised Manual
September 20, 2011 - P - Revised Manual
May 2, 2012 - Q - Revised Manual
March 4, 2013 - R - Revised Manual
September 27, 2013 - S - Revised Manual
EFFECTIVITY PAGE
ii G10-55A, G12-55A 3126020
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
3126020 G10-55A, G12-55A iii
SECTION 1 –
FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1 Frame Shrouding & Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Axle & Wheel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-3 Outrigger Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
SECTION 2 –
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Bearings, Pads, Spacers & Shims, (First Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4 Bearings, Pads, Spacers & Shims, (Second Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-5 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-6 Bearings, Pads, Spacers & Shims, (Third Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-7 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-8 Bearings, Pads, Spacers & Shims, (Fourth Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2-9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
SECTION 3 –
ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1 Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-4 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-5 Truss Boom With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-6 100 Degree Swing Carriage With Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-7 Sheet Material Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-8 100 Degree Drywall Swing Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-9 Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-10 Personnel Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3-11 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-13 Fork Mounted Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-14 Grapple Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-15 Fork Pin Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-16 Dual Fork Positioning Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-17 6 Ft Mast With 72 In Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-18 8 Ft Standard Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-19 8 Ft Side Tilt Electric Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3-20 50 in Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
SECTION 4 –
ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1 Engine Assembly - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
3126020 G10-55A, G12-55A iv
4-2 Engine Assembly - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 Engine Assembly - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-4 John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-5 Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-6 Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-7 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-8 Radiator Assembly - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4-9 Radiator Assembly - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-10 Radiator Assembly - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-11 Air Cleaner Installation - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4-12 Air Cleaner Installation - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4-13 Air Cleaner Installation - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4-14 Air Cleaner Installation - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-15 Air Cleaner Installation - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4-16 Exhaust Installation - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-17 Exhaust Installation - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-18 Exhaust Installation - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-19 ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4-20 ZF Transmission - Converter & Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-21 ZF Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4-22 ZF Transmission - Forward Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4-23 ZF Transmission - Reverse Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4-24 ZF Transmission - 1st Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4-25 ZF Transmission - 2nd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-26 ZF Transmission - 3rd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4-27 ZF Transmission - 4th Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-28 ZF Transmission - Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-29 ZF Transmission - Control Unit & Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4-30 ZF Transmission - Gearshift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4-31 ZF Transmission - Oil Pump, Filter & Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4-32 ZF Transmission - Transfer Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
SECTION 5 –
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Front Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 Front Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5 Front Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-7 Rear Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-8 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-9 Rear Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-10 Rear Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-11 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
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FIGURE NO. TITLE PAGE NO.
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5-12 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
SECTION 6 –
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-3 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-4 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-5 Heating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-6 Open Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-7 Air Conditioning - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-8 Air Conditioning - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-9 Air Conditioning - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-10 Air Conditioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
SECTION 7 –
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 Boom Joystick With Adjustable Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 Hydraulic Controller - Sway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-3 Hydraulic Controller - Outrigger & Sway/Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-4 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-5 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-6 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
SECTION 8 –
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 Supply Circuit - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 Supply Circuit - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-3 Supply Circuit - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8-4 Dump Circuit - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8-5 Dump Circuit - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8-6 Dump Circuit - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8-7 Steer Select - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8-8 Steer Select - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
8-9 Service/Park Brake - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8-10 Service/Park Brake - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8-11 Boom Joystick - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8-12 Boom Joystick - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8-13 Sway Controller - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8-14 Sway Controller - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8-15 Sway Controller - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
8-16 Auxiliary Controller - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
8-17 Auxiliary Controller - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
8-18 Outrigger Controller - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
3126020 G10-55A, G12-55A vi
8-19 Outrigger Controller - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
8-20 Lift Cylinder - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
8-21 Lift Cylinder - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
8-22 Crowd Cylinder - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
8-23 Crowd Cylinder - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
8-24 Tilt & Tilt Compensating Cylinders - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
8-25 Tilt & Tilt Compensating Cylinders - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . 8-64
8-26 Auxiliary Function - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
8-27 Auxiliary Function - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
8-28 Boom Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
8-28 Boom Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
8-28 Boom Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
8-29 Sway Cylinder - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80
8-30 Sway Cylinder - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
8-31 Sway Cylinder - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
8-32 Outrigger Cylinders - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
8-33 Outrigger Cylinders - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
8-34 Outrigger Cylinders - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90
SECTION 9 –
HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9-2 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9-3 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9-4 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9-5 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
9-6 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9-7 Outrigger Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-76
9-8 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
9-9 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88
9-10 Hydraulic Pump - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
9-11 Hydraulic Tank Assembly - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
9-12 Hydraulic Tank Assembly - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
9-13 Hydraulic Tank Assembly - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
9-14 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100
9-15 Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-108
9-16 Steer Select Valve - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110
9-17 Steer Select Valve - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-112
9-18 180 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-114
9-19 Grapple Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-116
9-20 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-118
9-21 72” 90 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-120
9-22 50 in Side Shift Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-122
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
3126020 G10-55A, G12-55A vii
SECTION 10 –
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10-1 Battery & Cables - John Deere & Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10-2 Battery & Cables - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10-3 Engine Harness - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10-4 Engine Harness - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10-5 Engine Harness - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10-6 Vec Grid Htr Pwr Harness- Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10-7 Chassis Harness - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10-8 Chassis Harness - Perkins & Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
10-9 Dash Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
10-10 Transmission Relay Harness - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
10-11 Transmission Relay Harness - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
10-12 Enclosed Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
10-13 VEC Options Harness - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
10-14 VEC Options Harness - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
10-15 Auxiliary Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
10-16 Power Distribution Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
10-17 Cab Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
10-18 Auxiliary Electric Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
10-19 A/C Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
SECTION 11 –
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11-1 Cab & Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
SECTION 12 –
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1 Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12-2 Cold Start Installation - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
12-3 Block Heater Assembly - John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
12-4 Block Heater Assembly - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
12-5 Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
12-6 Fuel/Water Separator Installation - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
12-7 Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20
12-8 Truss Boom Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24
12-9 Winch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28
12-10 Sway Cylinder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
12-11 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
12-12 Road Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
12-13 Pintle Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-38
12-14 Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40
12-15 Top Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-42
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
3126020 G10-55A, G12-55A viii
12-16 Front Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44
12-17 Boom Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
12-18 Work Light Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
12-19 Road Light & Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50
12-20 Road Light & Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-52
12-21 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-54
12-22 Arctic Package - Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-56
12-23 Arctic Package - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-58
SECTION 13 –
RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
3126020 G10-55A, G12-55A
SECTION 1
FRAME & ATTACHING PARTS
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-2
Figure 1-1 Frame Shrouding & Trim
PAP2000
49
50
29
50
22
43
42
44
38
35
50
31
38
28
30
38
39
36
33
38
26
38
1
41
51
46
38
27
10
219
11
12
18
80
81
82
16
17
15
85
15
13
48
33
38
27
34
40
8
45
2
4
5
7
6
52
32
9
37
25
20
3
68
69
70
70
71
76
83
300
84
14
86
93
88
87
3
90
91
92
94
33
38
95
45
2
G10-55A S/N 0160016099 & AFTER
G10-55A BEFORE S/N 0160016099
G12-55A S/N 0160016095 & AFTER
G12-55A BEFORE S/N 0160016095
G10-55A S/N 0160016099 & AFTER
G12-55A S/N 0160016095 & AFTER
G10-55A BEFORE S/N 0160016099
G12-55A BEFORE S/N 0160016095
Before S/N 0160039451
excluding 0160039394 & 0160039397
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-3
Figure 1-1 Frame Shrouding & Trim (Continued)
PAP3580
K1
K2
79
78
77
103
102
109
108
111
101
107
106
105
109
108
101
102
103
104
67
66
55
63
65
64
62
57
59
58
56
61
59
60
75
74
73
72
19
23
21
53
53
54
24
23
21
CAB
WALL
LOWER CAB
MOUNT
SHOWN WITH
WOK LIGHT
G10-55A S/N 0160032454 & AFTER
FRAME
MOUNT
WELDMENT
UPPER CAB
MOUNT
G12-55A S/N 0160032458 & AFTER
CAB
MOUNT
WELDMENT
FRAME
MOUNT
WELDMENT
Before S/N 0160039451
excluding 0160039394 & 0160039397
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-4
Figure 1-1 Frame Shrouding & Trim
Item Part Number Qty. Description Rev.
1 91563155 1 FRONT COVER
2 91563065 Ref ENGINE COVER, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095), (no longer available, use 1671219 for replacement or items 3
thru 9, 52, 68 thru 71 & 76)
1671219 1 ENGINE COVER, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After), (includes items 84 thru 92)
3 7026420 Ref LATCH BODY ASSY, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095), (no longer available, use Kit K1 for replacement)
7300364 1 LATCH BODY ASSY, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After), (includes key)
8342813 1 KEY
4 0721006 4 SCREW, #10-24X3/4, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
5 4751000 4 FLAT WASHER, #10, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
6 80963149 1 ROD CLIP, LEFT, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
7 80963150 1 ROD CLIP, RIGHT, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
8 7026421 1 STRICKER BOLT, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
9 7026422 1 TWO-ROTOR LATCH, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
10 83201147 4 HEX HD CAPSCREW, 1-8X8-1/2, GR8
11 80241137 4 SPECIAL WASHER
12 91140001 1 COUNTER WEIGHT, (no pintle hook)
1001091458 1 COUNTER WEIGHT, (with pintle hook)
13 0682216 8 HEX HD CAPSCREW, 3/4-10X2, GR8, (torque to 240-255 lb-ft)
14 0642232 2 HEX HD CAPSCREW, 3/4-10X4, GR5, (torque to 240-255 lb-ft)
15 4892200 12 HARDENED WASHER, 3/4
16 3312206 4 HEX NUT, 3/4-10
17 91561175 2 BACKING PLATE
18 8270621 1 BACK-UP ALARM
19 91143357 1 HORN
20 91566027 1 ENGINE POD WELDMENT AA
21 0641506 3 HEX HD CAPSCREW, 5/16-18X3/4, GR5
22 4751500 2 FLAT WASHER, 5/16
23 4761500 3 LOCKWASHER, 5/16
24 3311501 2 HEX NUT, 5/16-18
25 0641412 4 HEX HD CAPSCREW, 1/4-20X1-1/2, GR5, (G10-55A Before S/N 0160016099;
G12-55A Before S/N 0160016095)
26 0641608 8 HEX HD CAPSCREW, 3/8-16X1, GR5
27 0641610 3 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5, (G10-55A Before S/N 0160016099;
G12-55A Before S/N 0160016095)
0641610 1 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5, (G10-55A S/N 0160016099 & After;
G12-55A S/N 0160016095 & After)
28 0641622 6 HEX HD CAPSCREW, 3/8-16X2-3/4, GR5
29 0700610 2 HEX HD CAPSCREW, M6X20
30 1321384 5 ROUND TUBE CLAMP
31 2600262 2 OFFSET HINGE
Before S/N 0160039451
excluding 0160039394 & 0160039397
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-5
32 3311405 4 HEX LOCKNUT, 1/4-20, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
33 3311605 8 HEX LOCKNUT, 3/8-16
34 3331205 1 HEX NUT, M12X1.75, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
35 3900280 8 BUTTON HD CAPSCREW, 3/8-16X5/8
36 4160194 2 GAS SPRING
37 4711400 4 FLAT WASHER, 1/4, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
38 4711600 32 HEX HD CAPSCREW, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
4711600 34 HEX HD CAPSCREW, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
39 0641607 5 HEX HD CAPSCREW, 3/8-16X7/8, GR5
40 4751800 1 FLAT WASHER, 1/2, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
41 88662523 6 TINNERMAN NUT
42 80363195 1 MIRROR
43 91513194 1 MIRROR BRACKET
44 91566053 1 ENGINE COVER WELDMENT, (G10-55A Before S/N 0160016099; G12-55A
Before S/N 0160016095)
4341070 1 ENGINE COVER WELDMENT, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
45 91563132 1 STRIKER BOLT MOUNT BRACKET, (G10-55A Before S/N 0160016099;
G12-55A Before S/N 0160016095)
91561297 1 LATCH CATCH BRACKET, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
46 91561262 1 COVER MOUNT BRACKET
48 91561242 1 OIL PAN COVER
49 0641809 6 HEX HD CAPSCREW, 1/2-13X7/8, GR5
50 0100011 AR
LOCTITE
®
242
TM
51 NSS 1 FRAME WELDMENT
52 7026476 Ref LINKAGE ROD, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095), (no longer available, use Kit K1 for replacement)
53 91563241 2 INCLINOMETER SWITCH
54 Ref CHASSIS HARNESS, (see Figure 10-7 for details)
55 Ref CAB ASSY, (see Figure 6-1 for details)
56 0682652 2 HEX HD CAPSCREW, 1-8X6-1/2, (torque to 680-720 lb-ft)
57 83201058 4 HEX HD CAPSCREW, 3/4-10X3-3/4, (torque to 280-305 lb-ft)
58 91563060 2 FLAT WASHER
59 91563061 4 MOUNT, CENTER BONDED
60 91563062 2 FLAT WASHER
61 88501016 2 HEX NUT, 1-8
62 90027473 4 HARDENED WASHER, 3/4
63 91403097 4 MOUNT, CENTER BONDED
64 91403098 4 TAIL WASHER
65 88501012 4 HEX NUT, 3/4-10
66 1001145702 1 CAB FENDER
67 0791608 4 WHIZ-LOCK BOLT, 3/8-16X1
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
Before S/N 0160039451
excluding 0160039394 & 0160039397
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-6
68 91404275 1 ENGINE COVER KEY, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
69 91564002 1 PLEATED SCREEN, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
70 7027772 1 ADHESIVE KIT, (includes 3 tubes and applicator), (G10-55A Before
S/N 0160016099; G12-55A Before S/N 0160016095)
71 91564001 1 8 PIECE SCREEN KIT, (G10-55A Before S/N 0160016099; G12-55A Before
S/N 0160016095)
72 91033120 Ref TILT GAUGE, (G10-55A Before S/N 0160005747; G12-55A Before
S/N 0160005741), (no longer available, order 8466306 for replacement)
8466306 1 TILT GAUGE, (with adhesive), (G10-55A S/N 0160005747 & After; G12-55A
S/N 0160005741 & After)
73 88201005 1 HEX HD CAPSCREW, 1/4-20X1, (G10-55A Before S/N 0160005747; G12-55A
Before S/N 0160005741)
74 88561107 1 FLAT WASHER, 1/4, (G10-55A Before S/N 0160005747; G12-55A Before
S/N 0160005741)
75 88521204 1 LOCKNUT, 1/4-20, (G10-55A Before S/N 016000574; G12-55A Before
S/N 0160005741)
76 3960418 90 in BULB SEAL
1001096344 1 LH MIRROR INSTALLATION, (Before S/N 0160032454), (includes items 101
thru 111)
B
1001097149 Ref LH MIRROR INSTALLATION, (S/N 0160032454 thru 0160042299), (no longer
available, order 1001115153 for replacement or items 102, 103, 108 & 109 for
service)
B
1001115153 1 LH MIRROR INSTALLATION, (S/N 0160042300 & After), (includes items 102,
103, 108 & 109)
B
77 0641405 4 HEX HD CAPSCREW, 1/4-20X5/8
78 4751400 4 FLAT WASHER, 1/4
79 3311401 4 HEX NUT, 1/4-20
80 0641406 2 HEX HD CAPSCREW, 1/4-20X3/4
81 4711400 2 FLAT WASHER, 1/4
82 8305624 2 HEX LOCKNUT, 1/4-20
83 91143220 7.3 ft TRIM-LOCK
84 3960477 1 FOAM SEAL
85 0642236 2 HEX HD CAPSCREW, 3/4-10 X 4 1/2
86 3900395 4 BUTTON HD CAPSCREW, M4X.7X25
87 4811400 4 FLATWASHER, M4, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
88 3290401 4 HEX NUT, M4X.7, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
90 0902956 1 HOOD BRACKET, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
91 0902955 1 HOOD MOUNTING BRACKET, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
92 3340877 5 RUBBER PAD, (G10-55A S/N 0160016099 & After; G12-55A S/N 0160016095
& After)
93 0100081 AR
LOCTITE
®
454
TM
, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
94 0902746 4 MOUNTING BRACKET, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
Before S/N 0160039451
excluding 0160039394 & 0160039397
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-7
95 0791610 2 SCREW, 3/8-16, (G10-55A S/N 0160016099 & After; G12-55A
S/N 0160016095 & After)
101 1001096327 1 MIRROR BRACKET
102 8866530 Ref MIRROR ARM, (Before S/N 0160042300), (no longer available, order Kit K1 for
replacement)
1001114675 1 MIRROR ARM, (S/N 0160042300 & After)
103 8866514 1 MIRROR, (Before S/N 0160042300)
3140007 1 MIRROR, (S/N 0160042300 & After)
104 4420060 AR DOUBLE SIDED TAPE
105 1001096728 1 BOLT, 1/2-13
106 4751800 1 WASHER, 1/2
107 4761800 1 LOCKWASHER, 1/2
108 8303799 2 HEX HD CAPSCREW, 6X1X14mm, GR8.8, (Before S/N 0160042300)
0700610 2 HEX HD CAPSCREW, M6X20, GR8.8, (S/N 0160042300 & After)
109 8307024 2 LOCKWASHER, M6
110 88501008 1 HEX NUT, 1/2-13
111 91403503 1 SPACER
219 0100019 AR
LOCTITE
®
271
TM
300 4060608 AR FLEXIBLE TRIM SHIELD
K1 1001125007 1 MIRROR ARM KIT, (Before S/N 0160042300), (includes items 102 &108)
K2 91565093 1 HOOD LATCH REPLACEMENT KIT
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
Before S/N 0160039451
excluding 0160039394 & 0160039397
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-8
Figure 1-1 Frame Shrouding & Trim
PAP2140
705
716
11
4
12
8
6
3
18
1106
104
21
2
26
5
20
2
5
25
7
1
14
22
2
5
9
19
107
109
108
105
106
103
102
101
110
203
507
507
543
542
909
915
909
915
1101
1104
1102
1103
1105
1301
640
703
707
723
717
1011
1017
1019
581
5
2
7
1
23
24
S/N 0160039451 & After
including 0160039394 & 0160039397
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-9
Figure 1-1 Frame Shrouding & Trim (Continued)
S/N 0160039451 & After
including 0160039394 & 0160039397
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-10
Figure 1-1 Frame Shrouding & Trim
Item Part Number Qty. Description Rev.
1001116650 1 HOOD INSTALLATION, (includes items 1 thru 26) E
1 0641409 8 HEX HD CAPSCREW, 1/4-20X1-1/8, GR5
2 0641608 16 HEX HD CAPSCREW, 3/8-16X1, GR5
3 0791610 2 SCREW, 3/8-16X1-1/4
4 0791612 4 SCREW, 3/8-16X1-1/2
5 4711600 16 WASHER, 3/8
6 4751600 2 WASHER, 3/8
7 4761400 8 LOCKWASHER, 1/4
8 88501006 2 HEX NUT, 3/8-16
9 88662523 6 TINNERMAN NUT
11 1001108965 1 LATCH MOUNT BRACKET
12 1001108966 1 LATCH CATCH BRACKET
14 1001109338 1 ENGINE COVER, (includes items 101 thru 109) H
18 1001116461 1 RH MIRROR INSTALLATION, (includes items 1101 thru 1106) A
19 1001116907 1 FRONT COVER
20 1001120554 2 ENGINE HOOD SHIM
21 1001120550 1 HOOD HINGE SUPPORT PLATE
22 1001120639 AR BULB SEAL
23 1001121965 1 GAS STRUT REAR BRACKET
24 1001121659 1 HOOD HINGE MOUNT PLATE
25 1001121964 1 GAS STRUT FRONT BRACKET
26 0100011 AR
LOCTITE
®
242
TM
101 1001122219 1 COMPRESSION LATCH
102 3290605 4 HEX LOCKNUT, 6X1mm
103 4811700 4 WASHER, 6mm
104 4711600 8 WASHER, 3/8
105 3900316 8 BUTTON HD CAPSCREW, 3/8-16X1
106 1001114294 2 GAS SPRING
107 1001114295 1 ENGINE COVER HINGE, FRONT
108 1001114296 1 ENGINE COVER HINGE, REAR
109 1001114297 1 ENGINE COVER SUPPORT BAR
110 8342813 1 ENGINE COVER KEY
91569003 Ref CAB INSTALLATION, (not available to order, see items 201 thru 213 for service) D
201 NSS 1 FRAME WELDMENT
202 Ref CAB WELDMENT, (see Figure 6-2 for details)
203 Ref HYDRAULIC TANK ASSY, (see Figure 9-13 for details)
204 91563061 4 CAB MOUNT ISOLATOR
205 91403097 4 CENTER BONDED MOUNT
206 0682652 2 HEX HD CAPSCREW, 1-8X6-1/2, GR8, (torque to 680-720 lb-ft)
207 83201058 4 HEX HD CAPSCREW, 3/4-10X3-3/4, GR8, (torque to 280-305 lb-ft)
208 88501016 2 HEX NUT, 1-8
209 88501012 4 HEX NUT, 3/4-10
210 1001106614 2 TAIL WASHER
211 91563062 2 WASHER
212 91403098 4 TAIL WASHER
213 90027473 4 HARD WASHER, 3/4
S/N 0160039451 & After
including 0160039394 & 0160039397
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-11
1001097149 Ref LH MIRROR INSTALLATION, (S/N 0160032454 thru 0160042299), (no longer
available, order 1001115153 for replacement or items 301 thru 304 for service)
B
1001115153 1 LH MIRROR INSTALLATION, (S/N 0160042300 & After),
(includes items 301 thru 304)
B
301 8866530 Ref MIRROR ARM, (Before S/N 0160042300), (no longer available, order Kit K1
for replacement)
1001114675 1 MIRROR ARM, (S/N 0160042300 & After)
302 8866514 1 MIRROR, (Before S/N 0160042300)
3140007 1 MIRROR, (S/N 0160042300 & After)
303 8307024 2 LOCKWASHER, 6mm
304 8303799 2 HEX HD CAPSCREW, 6X1X14mm, GR8.8, (Before S/N 0160042300)
0700610 2 HEX HD CAPSCREW, M6X20, GR8.8, (S/N 0160042300 & After)
507 0791506 6 WHIZ-LOCK SCREW, 5/16-18X3/4
542 1001118101 1 ENGINE DRAIN COVER
543 1001118102 1 COOLER HOSE COVER
581 1001127174 1 FILTER COVER PLATE
640 91140001 1 COUNTERWEIGHT, (with out pintle hook)
1001091458 1 COUNTERWEIGHT, (with pintle hook)
703 8270621 1 BACK-UP ALARM
704 10713707 1 HORN
705 Ref PROXIMITY SENSOR, (see Figure 10-7 for details)
707 4711400 2 WASHER, 1/4
716 0641406 2 HEX HD CAPSCREW, 1/4-20X3/4, GR5
717 8305624 2 LOCKNUT, 1/4-20
723 1001116274 1 MOULDED RESISTOR
724 Ref CAB WORK LIGHT HARNESS, (see Figure 10-17 for details)
823 8466306 1 TILT ANGLE GAUGE
909 0682420 8 HEX HD CAPSCREW, 7/8-9X2-1/2, GR8, (torque to 530-565 lb-ft)
915 4892400 8 WASHER, 7/8
921 91143220 AR TRIM-LOCK
1011 83201147 4 HEX HD CAPSCREW, 1-8X8-1/2
1017 80241137 4 SPECIAL WASHER
1019 0100019 AR
LOCTITE
®
271
TM
1101 0641409 2 HEX HD CAPSCREW, 1/4-20X1-1/8, GR5
1102 3311405 2 HEX LOCKNUT, 1/4-20
1103 3520176 2 PLUG
1104 4751400 4 WASHER, 1/4
1105 8866348 1 MIRROR
1106 1001116318 1 MIRROR BRACKET
1201 Ref HEX HD CAPSCREW, (see Figure 8-34 for details)
1301 1001100961 1 ENGINE POD
91565067 Ref CAB FENDER INSTALLATION, (no longer available, order 1001145754 for
replacement or items 1401 thru 1404 for service)
B
1001145754 1 THERMOFORMED FENDER ASSY, (includes items 501 thru 504) A
1401 0641006 4 HEX HD CAPSCREW, 3/8-16X3/4, GR5
1402 4891700 4 WASHER, 7/16
1403 1001145702 1 THERMOFORMED FENDER
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
S/N 0160039451 & After
including 0160039394 & 0160039397
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-12
1404 1001145753 1 FENDER PLATE
K1 1001125007 1 MIRROR ARM KIT, (Before S/N 0160042300), (includes items 301 & 304)
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
S/N 0160039451 & After
including 0160039394 & 0160039397
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-13
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
S/N 0160039451 & After
including 0160039394 & 0160039397
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-14
Figure 1-2 Axle & Wheel Mounting
5
6
3
4
1
3
4
2
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-15
Figure 1-2 Axle & Wheel Mounting
Item Part Number Qty. Description Rev.
1 Ref FRONT AXLE ASSY, (see Figure 5-1 for details)
2 Ref REAR AXLE ASSY, (see Figure 5-6 for details)
3 0682444 16 HEX HD CAPSCREW, 7/8-9X5-1/2, GR5, (torque to 530-565 lb-ft)
4 4892400 16 HARDENED FLATWASHER, 7/8
5 91403193 40 LUG NUT, (torque to 350-400 lb-ft)
6 Ref TIRE & RIM ASSY, (see Figure 5-12 for details)
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-16
Figure 1-3 Outrigger Mounting
13
12
14
6
7
7
2
13
11
4
9
8
3
10
5
1
1
1
1
PY0410
FRAME & ATTACHING PARTS
3126020 G10-55A, G12-55A 1-17
Figure 1-3 Outrigger Mounting
Item Part Number Qty. Description Rev.
1 88671001 4 LUBE FITTING, STRAIGHT, 1/8
2 Ref OUTRIGGER CYLINDER & VALVE, (see Figure 9-7 for details)
3 0641808 4 HEX HD CAPSCREW, 1/2-13X1, GR5
4 91563199 2 SHOE PIN
5 4761800 4 LOCKWASHER, 1/2, (old)
4751800 4 FLAT WASHER, 1/2, (new)
6 91563198 2 ARM PIN
7 91163014 4 BUSHING
8 91566050 2 ARM WELDMENT
9 91566051 2 OUTRIGGER SHOE
10 91081313 2 KEEPER
11 0641634 2 HEX HD CAPSCREW, 3/8-16X4-1/4, GR5
12 91563197 2 OUTRIGGER CYLINDER PIN
13 3300143 4 HEX LOCKNUT, 3/8-16
14 3931672 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8
FRAME & ATTACHING PARTS
G10-55A, G12-55A 31260201-18
This Page Intentionally Left Blank
3126020 G10-55A, G12-55A
SECTION 2
BOOM
BOOM
G10-55A, G12-55A 31260202-2
Figure 2-1 First Boom Section
PAP2830
4
27
15
18
6
28
11
28
11
28
11
26
3
14
12
12
28
11
12
25
17
24
5
1
16
13
23
10
22
20
19
7
21
2
14
13
8
14
13
8
9
10
G10-55A
NOTE:
1. USE LOCTITE
®
242
TM
(0100011) ON ALL BOLT THREADS & JAM NUTS.
2. COAT STATIC, NON-ROTATING, PIN BORES WITH MOLY-PASTE (3020040).
DO NOT COAT THE PIN OR ANY ROTATING PARTS.
3. COAT ALL BUSHINGS, SHEAVES, AND ROTATING PIN BORES WITH MYSTIK
TETRIMOLY GREASE (14404793) PRIOR TO INSTALLATION OF THE PIN.
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