JLG G12-55A Parts Manual

4.3 (6)

An Oshkosh Corporation Company

Illustrated Parts Manual

Models G10-55A G12-55A

S/N 0160045636 & After including

0160045082, 0160045094, 0160045209, 0160045295,

0160045296 & 0160045449

31200728

Revised

March 4, 2014

May 1, 2012 - A - Original Issue of Manual

January 4, 2013 - B - Revised Manual

January 29, 2013 - C - Revised Manual

April 3, 2013 - D - Revised Manual

August 2, 2013 - E - Revised Manual

January 10, 2014 - F - Revised Manual

March 4, 2014 - G - Revised Manual

EFFECTIVITY PAGE

31200728 G10-55A, G12-55A i

EFFECTIVITY PAGE

G10-55A, G12-55A 31200728ii

Machine Configuration

OY2700

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387 A

REAR VIEW OF CAB

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

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.

General Information

1. MACHINE IDENTIFICATION Machines are identified by model & in some cases a combination of model, serial number (S/N) or regional standard (CE, AUS, ANSI). Components may also be identified by S/N or manufacturer. Common components that may be identified by these characteristics are attachments, engine, transmission & hydraulic components.

2. PARTS MANUAL ORGANIZATION Product information in this manual is organized under section titles. Frame & Attaching Parts, Drive Train & Electrical are a few examples. Each section is organized by Figure & page number. The information within the Figure is then organized by item number, part number, description & corresponding illustration(s).

3. TABLE OF CONTENTS A table of contents (TOC) is found toward the beginning of the manual. Figure number, description & page number are provided for quick reference to the page containing the related information.

4. RECOMMENDED SPARE PARTS The Recommended Spare Parts, located near the end of the manual, references most frequently used maintenance parts.

5. PART NUMBER INDEX A numerical index listing all part numbers & the corresponding page number(s) appears at the back of the manual.

6. NON-SERVICED PARTS In some instances it is necessary to display non-serviced parts, assemblies or installations. In the case of assemblies & installations there will be a Ref in the Qty column & a note after the item description stating what is available for service within. In the case of parts that are not available for service within assemblies or components there will be a NSS (Not Sold Separately) listed in the part number column of the manual.

7. PARTS LIST ITEM NUMBERS Numbers shown in the Item column correspond to numbers used in the associated illustration(s). Item numbers which are missing from sequence & are not shown in the illustration(s) are not used on that page.

8. INDENTED PART DESCRIPTION An indented part description is included in the item under which it is indented.

9. ABBREVIATIONS & SYMBOLS

AC.................................................................... Air Conditioning

ANSI ............................. American National Standards Institute

AR..........................................................................As Required

ASME.................... American Society of Mechanical Engineers

ASSY ......................................................................... Assembly

AUS..............................................................................Australia

AUX..............................................................................Auxiliary

CE............................................................European Conformity

DIA..............................................................................Diameter

EURO.........................................................................European

FT ...................................................................................... Foot

GA...................................................................................Gauge

GR ...................................................................................Grade

HD.....................................................................................Head

HYD ............................................................................Hydraulic

ID ..................................................................... Inside Diameter

IN ........................................................................................Inch

ISO............................. International Organization for Standards

ITSDF ..... Industrial Truck Standards Development Foundation

KG............................................................................... Kilogram

kW.................................................................................Kilowatt

10. ILLUSTRATION REFERENCE LETTERS When necessary, illustrations may contain reference letters that are intended to track information from one point to another in the illustration such as harnesses & hoses or any other information that has been separated in the illustration.

LB ....................................................................................Pound

LH.............................................................................. Left Hand

LS ............................................................................. Low Sulfur

MAX........................................................................... Maximum

MM .............................................................................Millimeter

N....................................................................................Newton

NA ...................................................................... Not Applicable

NLA ...........................................................No Longer Available

NSS ........................................................... Not Sold Separately

OD ................................................................. Outside Diameter

OZ .................................................................................. Ounce

P/N ........................................................................Part Number

QTY ..............................................................................Quantity

REF ...........................................................................Reference

REQ............................................................................ Required

RH ...........................................................................Right Hand

S/N ..................................................................... Serial Number

SAE ....................................... Society of Automotive Engineers

STD ............................................................................ Standard

ULS ..................................................................Ultra Low Sulfur

V ..........................................................................................Volt

Note: Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

This Page Intentionally Left Blank

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1 Frame & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-3 Outrigger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1-4 Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

SECTION 2 –

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-4 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-5 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-6 Extend Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 2-7 Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2-8 Manual Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

SECTION 3 –

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Standard Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-3 50 In Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-4 Dual Fork Positioning Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3-5 90 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-6 180 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-7 Sheet Handler Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 3-8 Forks & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 3-9 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-10 Fork Mounted Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 3-11 General Purpose Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 3-12 Grapple Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 3-13 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 3-14 Truss Boom with Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 3-15 8 Foot Standard Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 3-16 8 Ft Side Tilt Electric Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

SECTION 4 –

ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4-3 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4-4 Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4-5 Air Cleaner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

31200728 G10-55A, G12-55A 5

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

4-6 Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

SECTION 5 –

DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 Drivetrain Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-2 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5-3 Front Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5-4 Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5-5 Front Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5-6 Front Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5-7 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 5-8 Rear Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 5-9 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 5-10 Rear Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 5-11 Rear Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 5-12 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 5-13 Transmission - Converter & Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 5-14 Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 5-15 Transmission - Forward Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 5-16 Transmission - Reverse Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 5-17 Transmission - 1st Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62 5-18 Transmission - 2nd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 5-19 Transmission - 3rd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66 5-20 Transmission - 4th Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 5-21 Transmission - Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70 5-22 Transmission - Control Unit & Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72 5-23 Transmission - Gearshift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74 5-24 Transmission - Oil Pump, Filter & Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76 5-25 Transmission - Transfer Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78 5-26 Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80 5-27 Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

SECTION 6 –

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-2 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-3 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6-4 Cab Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6-5 Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6-6 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6-7 Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6-8 Air Conditioning Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

G10-55A, G12-55A 312007286

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 7 –

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-2 Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7-3 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7-4 Boom Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 7-5 Outrigger & Frame Level/Auxiliary Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

SECTION 8 –

HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-2 Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8-3 Steer Select Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8-4 Service Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8-5 Boom Joystick Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 8-6 Frame Level/Auxiliary Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 8-7 Outrigger Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 8-8 Lift Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 8-9 Extend/Retract Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 8-10 Tilt Cylinder & Compensation Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 8-11 Boom Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 8-12 Auxiliary Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26 8-13 Frame Level Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 8-14 Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

SECTION 9 –

HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1 Lift Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-2 Extend/Retract Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9-3 Tilt Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9-4 Compensation Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9-5 Frame Level Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9-6 Outrigger Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 9-7 Stabilizer Cylinder & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 9-8 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 9-9 50 In Side Shift Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 9-10 Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20 9-11 Grapple Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 9-12 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 9-13 Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 9-14 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32 9-15 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 9-16 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36 9-17 Hydraulic Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40

31200728 G10-55A, G12-55A 7

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

9-18 Decompression Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42

SECTION 10 –

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1 Engine Compartment Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10-2 Arctic Package Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 10-3 Boom & Frame Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 10-4 Cab Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 10-5 Cab Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 10-6 Clearsky Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 10-7 Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 10-8 Drive Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 10-9 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 10-10 Transmission Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 10-11 Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 10-12 VEC Options Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 10-13 Transmission Relay Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 10-14 Enclosed Cab Options Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 10-15 Dash Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 10-16 Instrument Panel Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 10-17 Frame Road Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 10-18 Boom Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 10-19 Cab Road Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58 10-20 Cab Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 10-21 A/C Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 10-22 VEC Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64

SECTION 11 –

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-1 Cab & Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

SECTION 12 –

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

SECTION 13 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

G10-55A, G12-55A 312007288

SECTION 1

FRAME & ATTACHING PARTS

31200728 G10-55A, G12-55A

FRAME & ATTACHING PARTS

Figure 1-1 Frame & Attaching Parts

G10-55A, G12-55A 312007281-2

FRAME & ATTACHING PARTS

Figure 1-1 Frame & Attaching Parts

Item Part Number Qty. Description Rev.

1001130125 Ref ENGINE POD INSTALLATION, (if equipped for ULS), (not available to order,

see items 1 thru 24 for service)

1001136089 Ref ENGINE POD INSTALLATION, (if equipped for LS), (not available to order, see

items 1 thru 24 for service) 1 0682018 2 HEX HD CAPSCREW, 5/8-11X2-1/4 2 0682032 2 HEX HD CAPSCREW, 5/8-11X4 4 0811606 7 SCREW, 3/8-16X3/4 5 4892000 4 WASHER, 5/8 6 1001121031 1 POD WELDMENT SUPPORT 7 1001121047 1 BOTTOM COVER PLATE 8 1001128248 1 COOLER ACCESS COVER PLATE

15 1001132796 2 HOSE GUIDE BRACKET 16 0811610 4 SCREW, 3/8-16X1-1/4 18 0641640 4 HEX HD CAPSCREW, 3/8-16X5 19 1001143653 4 SPACER TUBE 20 1001123654 2 HOSE GUIDE PLATE

24 1001150299 2 HOSE, 3/4 101 NSS 1 FRAME WELDMENT 223 83201147 4 HEX HD CAPSCREW, 1-8X8-1/2, GR8, (torque to 860 lb-ft/1170 Nm) 224 80241137 4 WASHER 251 91140001 1 COUNTERWEIGHT, (if equipped)

1001097095 1 COUNTERWEIGHT WITH PINTLE HITCH ASSY, (if equipped),

(includes items 303 & 304) 303 Ref PINTLE HOOK, (not shown), (see Figure 1-4 for details) 304 1001091458 1 COUNTERWEIGHT 401 Ref HYDRAULIC TANK, (see Figure 9-14 for details) 402 Ref CAB WELDMENT, (see Figure 6-1 for details) 501 90206202 11 in TRIM-LOK 502 4060918 39 in TRIM-LOK, (not shown) 503 1001125491 1 FOAM GASKET SEAL

31200728 G10-55A, G12-55A 1-3

FRAME & ATTACHING PARTS

PAP25591

201

202

17 26

203

Figure 1-2 Covers

G10-55A, G12-55A 312007281-4

PAP25600

5 11 13

108

107

110

111

101

103

104

FRAME & ATTACHING PARTS

Figure 1-2 Covers (Continued)

31200728 G10-55A, G12-55A 1-5

FRAME & ATTACHING PARTS

Figure 1-2 Covers

Item Part Number Qty. Description Rev.

1001129636 Ref COVERS INSTALLATION, (not available to order, see items 1 thru 28

for service) 1 0641405 10 HEX HD CAPSCREW, 1/4-20X5/8, GR5 3 0641610 5 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 4 0791410 2 SCREW, 1/4-20X1-1/4 5 0791608 6 SCREW, 3/8-16X1 6 0811606 5 SCREW, 3/8-16X3/4 7 3311405 2 HEX LOCKNUT, 1/4-20 8 3520176 2 PLUG

10 4751400 12 WASHER, 1/4 11 4751600 7 WASHER, 3/8 12 8866348 1 RH MIRROR, (includes washer & locknut) 13 88501006 2 HEX NUT, 3/8-16 14 88662523 5 TINNERMAN NUT 15 1001121332 1 LATCH MOUNT BRACKET 16 1001121337 1 LATCH CATCH BRACKET 17 1001149900 1 FRONT COVER 18 1001129637 1 HINGE COVER 19 1001129639 1 MIRROR BRACKET 20 1001144114 1 HINGE MOUNT SUPPORT 21 1001131147 1 ENGINE ASSY COVER, (includes items 101 thru 111) F 23 1001131247 2 GAS SPRING 24 0811608 6 SCREW, 3/8-16X1 25 4761600 5 LOCKWASHER, 3/8 26 90206198 3 in TRIM-LOK 27 1001146367 1 INSULATE

28 1001146371 1 INSULATE 101 3290605 4 HEX LOCKNUT, M6X1 103 4811700 4 WASHER, 6mm 104 1001122219 1 COMPRESSION LATCH 107 1001129358 1 ENGINE COVER HINGE 108 1001129638 1 ENGINE COVER 110 3300492 5 LOCKING NUT 111 4751600 5 WASHER, 3/8 201 1001144101 15.5 in SPLIT CONDUIT 202 90206203 13.5 in TRIM-LOK 203 88671001 2 GREASE FITTING, 1/8

G10-55A, G12-55A 312007281-6

FRAME & ATTACHING PARTS

Figure 1-2 Covers (Continued)

Item Part Number Qty. Description Rev.

31200728 G10-55A, G12-55A 1-7

FRAME & ATTACHING PARTS

Figure 1-3 Outrigger Installation

G10-55A, G12-55A 312007281-8

FRAME & ATTACHING PARTS

Figure 1-3 Outrigger Installation

Item Part Number Qty. Description Rev.

1001143633 Ref OUTRIGGER INSTALLATION, (includes items 1 thru 13) A 1 0641634 2 HEX HD CAPSCREW, 3/8-16X4-1/4, GR5 2 0641808 4 HEX HD CAPSCREW, 1/2-13X1, GR5 3 3300143 4 HEX LOCKNUT, 3/8-16 4 3931672 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8 5 4761800 4 LOCKWASHER, 1/2 6 88671001 4 LUBE FITTING, STRAIGHT, 1/8 7 91081313 2 KEEPER 8 1001001211 2 OUTRIGGER CYLINDER ASSY, (includes items 101 & 105) B 9 1001141892 2 PAD WELD STABILIZER

10 1001142258 2 OUTRIGGER ARM WELDMENT 11 91563197 2 OUTRIGGER CYLINDER PIN 12 91563198 2 ARM PIN 13 91563199 2 SHOE PIN

101 Ref OUTRIGGER CYLINDER & ATTACHING HARDWARE,

(see Figure 9-6 for details)

105 Ref STRAIGHT FITTING, (see Figure 8-14 for details)

31200728 G10-55A, G12-55A 1-9

FRAME & ATTACHING PARTS

301

303

304

305

PY7310

302

Figure 1-4 Pintle Hook

G10-55A, G12-55A 312007281-10

FRAME & ATTACHING PARTS

Figure 1-4 Pintle Hook

Item Part Number Qty. Description Rev.

301 0100011 AR

LOCTITE 302 0681814 4 HEX HD CAPSCREW, 1/2-13X1-3/4, GR8, (torque to 105 lb-ft/145 Nm) 303 88551013 4 LOCKWASHER, 1/2 304 90200602 1 PINTLE HOOK 305 Ref COUNTERWEIGHT, (see Figure 1-1 for details)

242

31200728 G10-55A, G12-55A 1-11

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

G10-55A, G12-55A 312007281-12

SECTION 2

BOOM

31200728 G10-55A, G12-55A

BOOM

PAP25812

501

602

101

102

103

104

333

332

326

331

307

240 241

601

120

401

BACK OF FRAME

502

501

Figure 2-1 Boom Installation

G10-55A, G12-55A 312007282-2

BOOM

Figure 2-1 Boom Installation

Item Part Number Qty. Description Rev.

1001099663 Ref BOOM INSTALLATION, (G10-55A), (not available to order, see items 3 thru 20

for service)

1001099662 Ref BOOM INSTALLATION, (G12-55A), (not available to order, see items 3 thru 20

for service)

3 3423247 1 PIN 13 88212287 1 SOCKET HD CAPSCREW, 3/4-10X6 14 8310067 1 HEX LOCKNUT, 3/4-10 18 88661002 2 STRAIGHT FITTING 19 84719940 2 HOSE ASSY 20 2160002 2 GREASE FITTING

1001113744B 1 BOOM ASSY, (G10-55A), (includes items 101 thru 106 & 120 thru 241) D

1001114138B 1 BOOM ASSY, (G12-55A), (includes items 101 thru 106 & 120 thru 241) D 101 Ref FIRST BOOM SECTION, (see Figure 2-2 for details) 102 Ref SECOND BOOM SECTION, (see Figure 2-3 for details) 103 Ref THIRD BOOM SECTION, (see Figure 2-4 for details) 104 Ref FOURTH BOOM SECTION, (see Figure 2-5 for details) 105 Ref EXTEND CHAINS, (not shown), (see Figure 2-6 for details) 106 Ref RETRACT CHAINS, (not shown), (see Figure 2-7 for details) 120 91141301 2 BUSHING 125 Ref BOOM HYDRAULICS, (not shown), (see Figure 8-11 for details) 240 8307916 AR SHIM, 2.5X3.875X.075 241 8307917 AR SHIM, 2.5X3.875X.134 307 Ref ANGLE DECAL, (see Figure 11-2 for details) 326 1001098769 1 BOOM ANGLE INDICATOR 331 1001096404 1 BOOM ANGLE SPACER 332 4711600 1 WASHER, 3/8 333 8305645 1 HEX LOCKNUT, 3/8-16 401 Ref MECHANICAL QUICK ATTACH INSTALLATION, (see Figure 2-8 for details) 501 Ref LIFT CYLINDER & HARDWARE, (see Figure 9-1 for details) 502 Ref COMPENSATION CYLINDER & HARDWARE, (see Figure 9-4 for details) 601 Ref TILT CYLINDER & HARDWARE, (see Figure 9-3 for details) 602 Ref EXTEND/RETRACT CYLINDER & HARDWARE, (see Figure 9-2 for details)

31200728 G10-55A, G12-55A 2-3

BOOM

PY8310

121 129 201

74 76

201

131 201

107 113 201

62 201

133

G10-55A

Note: Wear Pad Shimming:

Whenever a shim is used with a pad, a spacer with holes must be inserted between pad & shim. The wear pad or wear pad insert must not sit directly on the slotted surface of shims. Add wear pad shims & spacers as required to shim boom to maintain a total minimum gap of 0.070 to 0.130 in (1,8 to 3,3 mm) in both horizontal & vertical directions. Wear pad bolts require one hardened washer. However, up to (2) hardened washers may be used except where noted otherwise. Under no circumstances should more than (2) hardened washers ever be used. The length of pad bolts depends on the number of the shims used. The bolt cannot extend past chamfer on wear pad. Add Mystik Tetrimoly Grease (14404793) to all wear pads & all wear pad slide pathways. If applicable, this includes all pad grease fittings at the rear of boom.

Figure 2-2 First Boom Section

G10-55A, G12-55A 312007282-4

BOOM

Figure 2-2 First Boom Section

Item Part Number Qty. Description Rev.

1 1001113588 1 FIRST BOOM SECTION WELDMENT 13 91561156B 1 EXTEND/RETRACT CYLINDER SUPPORT PLATE 38 91161171 2 WEAR PAD SUPPORT 41 91161167 2 WEAR PAD SUPPORT 43 91033189 2 WEAR PAD 44 1001117653 2 WEAR PAD 45 91033186 4 WEAR PAD 52 91031236 6 SPACER 53 91161183 2 SPACER 54 91161184 AR SHIM, 0.0598 55 90205870 AR SHIM, 0.0598 62 0641818 2 HEX HD CAPSCREW, 1/2-13X2-1/4, GR5, (torque to 85 lb-ft/116 Nm) 74 0651607 AR HEX HD CAPSCREW, 3/8-24X.88, GR5, (torque to 32-37 lb-ft/43-50 Nm) 76 0651606 AR HEX HD CAPSCREW, 3/8-24X3/4, GR5, (torque to 32-37 lb-ft/43-50 Nm) 81 4761800 4 SPRING LOCKWASHER 86 3311801 2 HEX NUT, 1/2-13 95 4891600 14 WASHER, 3/8

107 0651612 AR HEX HD CAPSCREW, 3/8-24X1-1/2, GR5, (torque to 32-37 lb-ft/43-50 Nm) 113 0651614 AR HEX HD CAPSCREW, 3/8-24X1-3/4, GR5, (torque to 32-37 lb-ft/43-50 Nm) 121 0651820 AR HEX HD CAPSCREW, 1/2-20X2-1/2, GR5, (torque to 76-86 lb-ft/103-117 Nm) 129 0651822 AR HEX HD CAPSCREW, 1/2-20X2-3/4, GR5, (torque to 76-86 lb-ft/103-117 Nm) 131 0641810 2 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5, (torque to 76-86 lb-ft/103-117 Nm) 133 4711800 2 WASHER, 1/2

201 0100011 AR

LOCTITE

242

™

31200728 G10-55A, G12-55A 2-5

BOOM

PY7080

75 101 128 201

92 130 131 201

106 201

61 76 77 201

62 201

143

G12-55A

Note: Wear Pad Shimming:

Figure 2-2 First Boom Section

G10-55A, G12-55A 312007282-6

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