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

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

TABLE OF CONTENTS :

Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Safety Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.6 Safety Instructions
1.7 Safety Decals

Section 2 General Information and Specifications
2.1 Replacement Parts and Warranty Information
2.2 Torques
2.3 Specifications
2.4 Fluid and Lubricant Capacities
2.5 Service and Maintenance Schedules
2.6 Lubrication Schedules

Section 3 Boom
3.1 Boom System Component Terminology
3.2 Boom System – Four Section
3.3 Boom Assembly Maintenance
3.4 Boom Extend and Retract Chains
3.5 Boom Section Separation Adjustment
3.6 Hydraulic Sub-Assembly Removal/Installation
3.7 Boom Wear Pads
3.8 Quick Switch Assembly
3.9 Forks
3.10 Troubleshooting

Section 4 Cab and Covers
4.1 Operator’s Cab and Covers Component Terminology
4.2 Operator’s Cab
4.3 Cab Components
4.4 Cab Removal
4.5 Cab Installation

Section 5 Axles, Drive Shafts, Wheels and Tires
5.1 Axle, Drive Shaft and Wheel Component Terminology
5.2 General Information
5.3 Axle Assemblies
5.4 Drive Shafts
5.5 Wheels and Tires
5.6 Brakes
5.7 Towing a Disabled machine

Section 6 Transmission
6.1 Transmission Assembly Component Terminology
6.2 Transmission Description
6.3 Transmission Serial Number
6.4 Transmission Specifications
6.5 Transmission Replacement
6.6 Troubleshooting

Section 7 Engine
7.1 Introduction
7.2 Engine Cooling System
7.3 Engine Electrical System
7.4 Fuel System
7.5 Engine Exhaust System
7.6 Air Cleaner Assembly
7.7 Engine Replacement
7.8 Torque Convertor Diaphragm
7.9 Troubleshooting

Section 8 Hydraulic System
8.1 Hydraulic Component Terminology
8.2 Safety Information
8.3 Hydraulic Pressure Diagnosis
8.4 Hydraulic Circuits
8.5 Hydraulic System Schematics and Diagrams
8.6 Hydraulic Reservoir
8.7 Engine Implement Pump
8.8 Control Valves
8.9 Hydraulic Piston Accumulator
8.10 Hydraulic Cylinders

Section 9 Electrical System
9.1 Electrical Component Terminology
9.2 Specifications
9.3 Safety Information
9.4 Fuses and Relays
9.5 Control Modules
9.6 Electrical System Schematics And Diagrams
9.7 Engine Start Circuit
9.8 Charging Circuit
9.9 Window Wiper/Washer Windshield Wiper Motor
9.10 Cab Heater and Fan
9.11 Solenoids, Senders and Sensors
9.12 Display Monitor and Gauges
9.13 Dash Switches
9.14 Engine Indicator Lamps
9.15 Hand Held Analyzer

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200452
Total Pages : 230

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31200452_A_G10-55A G12-55A AccuPlace_JLG_Service
Effectivity
Section Contents

Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Safety Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.5.1 Safety Alert System and Signal Words
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals

Section 2 General Information and Specifications
2.1 Replacement Parts and Warranty Information
2.2 Torques
2.2.1 ASTM Fastener Torque Chart (English)
2.2.2 ASTM Fastener Torque Chart (Metric)
2.2.3 Metric Fastener Torque Chart
2.3 Specifications
2.3.1 Travel Speeds
2.3.2 Electrical System
2.3.3 Engine Performance Specifications
2.3.4 Tires
2.4 Fluid and Lubricant Capacities
2.5 Service and Maintenance Schedules
2.5.1 10, 1st 100 & 50 Hour
2.5.2 250, 500, 1000 & 1500 Hour
2.6 Lubrication Schedules

Section 3 Boom
3.1 Boom System Component Terminology
3.2 Boom System – Four Section
3.2.1 Boom System Operation
3.3 Boom Assembly Maintenance
3.3.1 Boom Removal
3.3.2 Second, Third & Fourth Boom Section Removal
3.3.3 Third & Fourth Boom Section Removal
3.3.4 Fourth Boom Section Removal
3.3.5 Fourth Boom Section Installation
3.3.6 Third & Fourth Boom Section Installation
3.3.7 Second Boom Section Installation
3.3.8 Boom Installation
3.4 Boom Extend and Retract Chains
3.4.1 Boom Chain Inspection
3.4.2 Inspection Guidelines
3.4.3 Expose Chains for Inspection
3.4.4 Chain Lubrication
3.4.5 Retract Chain Removal
3.4.6 Retract Chain Installation
3.4.7 Extend Chain Removal
3.4.8 Extend Chain Installation
3.5 Boom Section Separation Adjustment
3.6 Hydraulic Sub-Assembly Removal/Installation
3.6.1 Hydraulic Sub-Assembly Removal
3.6.2 Assembling the Hydraulic Sub- Assembly
3.6.3 Hydraulic Sub-Assembly Installation
3.7 Boom Wear Pads
3.7.1 Wear Pad Inspection
3.7.2 Boom Wear Pad Replacement
3.7.3 Boom Wear Pad Lubrication
3.8 Quick Switch Assembly
3.8.1 Quick Switch Removal
3.8.2 Quick Switch Installation
3.9 Forks
3.10 Troubleshooting

Section 4 Cab and Covers
4.1 Operator’s Cab and Covers Component Terminology
4.2 Operator’s Cab
4.2.1 Cab Safety
4.2.2 Serial Number Decal
4.3 Cab Components
4.3.1 Steering Column and Orbitrol Valve
4.3.2 Service Brake Pedal
4.3.3 Throttle Pedal
4.3.4 Boom Joystick Assembly
4.3.5 Frame Level, Auxiliary Hydraulic and Outrigger Joysticks
4.3.6 Windshield Wiper Assembly
4.3.7 Heater/Defroster System (If equipped)
4.4 Cab Removal
4.5 Cab Installation

Section 5 Axles, Drive Shafts, Wheels and Tires
5.1 Axle, Drive Shaft and Wheel Component Terminology
5.2 General Information
5.3 Axle Assemblies
5.3.1 Axle Serial Number Plate
5.3.2 Axle Specifications
5.3.3 Axle Internal Service
5.3.4 Axle Maintenance
5.3.5 Axle Removal
5.3.6 Axle Installation
5.3.7 Axle Assembly and Drive Shaft Troubleshooting
5.4 Drive Shafts
5.4.1 Drive Shaft Inspection and Service
5.4.2 Drive Shaft Maintenance
5.4.3 Drive Shaft Removal
5.4.4 Drive Shaft Cleaning and Drying
5.4.5 Drive Shaft Installation
5.5 Wheels and Tires
5.5.1 Removing Wheel and Tire Assembly from Machine
5.5.2 Installing Wheel and Tire Assembly onto Machine
5.6 Brakes
5.7 Towing a Disabled machine
5.7.1 Manually Releasing the Park Brake
5.7.2 Manually Resetting the Park Brake

Section 6 Transmission
6.1 Transmission Assembly Component Terminology
6.2 Transmission Description
6.3 Transmission Serial Number
6.4 Transmission Specifications
6.4.1 Transmission Maintenance
6.4.2 Transmission Maintenance Schedule
6.5 Transmission Replacement
6.5.1 Transmission Removal
6.5.2 Transmission Inspection and Internal Repair
6.5.3 Transmission Installation
6.5.4 After Transmission Service or Replacement
6.6 Troubleshooting
6.6.1 Transmission Troubleshooting

Section 7 Engine
7.1 Introduction
7.1.1 Disclaimer and Scope
7.1.2 Component Terminology
7.1.3 Engine Serial Number
7.1.4 Specifications and Maintenance Information
7.2 Engine Cooling System
7.2.1 Radiator Pressure Cap
7.2.2 Thermostat Replacement
7.2.3 Radiator Replacement
7.3 Engine Electrical System
7.4 Fuel System
7.4.1 Diesel Fuel
7.4.2 Fuel Tank
7.4.3 After Fuel System Service
7.5 Engine Exhaust System
7.5.1 Exhaust System Removal
7.5.2 Exhaust System Installation
7.6 Air Cleaner Assembly
7.6.1 Air Cleaner Assembly Removal
7.6.2 Air Cleaner Assembly Installation
7.7 Engine Replacement
7.7.1 Engine Removal
7.7.2 Engine Installation
7.8 Torque Convertor Diaphragm
7.8.1 Torque Convertor Diaphragm Removal
7.8.2 Torque Convertor Diaphragm Installation
7.9 Troubleshooting

Section 8 Hydraulic System
8.1 Hydraulic Component Terminology
8.2 Safety Information
8.3 Hydraulic Pressure Diagnosis
8.3.1 Pressure Checks and Adjustments
8.4 Hydraulic Circuits
8.4.1 Hydraulic Pressures
8.5 Hydraulic System Schematics and Diagrams
8.5.1 Chassis Schematic
8.5.2 Boom Schematic
8.5.3 Hydraulic Diagram
8.6 Hydraulic Reservoir
8.6.1 Hydraulic Oil Reservoir Draining
8.6.2 Hydraulic Oil Reservoir Filling
8.6.3 Hydraulic Oil Reservoir Removal/ Installation
8.7 Engine Implement Pump
8.7.1 Pump Description
8.7.2 Pump Failure Analysis
8.7.3 Pump Replacement
8.8 Control Valves
8.8.1 Lift Valve
8.8.2 ISP Valve
8.8.3 Stabilizer Valve
8.8.4 Auxiliary Valve
8.8.5 Telescope Valve
8.8.6 Tilt Valve
8.8.7 Service Brake Valve
8.8.8 Brake Test
8.8.9 Steering Orbitrol Valve
8.8.10 Steer Select Valve
8.8.11 Valve Controllers
8.9 Hydraulic Piston Accumulator
8.9.1 Accumulator Removal
8.9.2 Accumulator Pre-Charge & Check Procedure
8.10 Hydraulic Cylinders
8.10.1 General Cylinder Removal Instructions
8.10.2 Cylinder Pressure Checking
8.10.3 Steering Cylinders
8.10.4 Cylinder Torque Specifications

Section 9 Electrical System
9.1 Electrical Component Terminology
9.1.1 General Overview
9.2 Specifications
9.3 Safety Information
9.4 Fuses and Relays
9.4.1 Engine Compartment
9.4.2 Cab
9.4.3 Power Distribution Unit (VEC)
9.4.4 Optional Power Distribution Unit (VEC)
9.5 Control Modules
9.5.1 CAN Distribution Module
9.5.2 Universal Ground Control Module (UGM)
9.5.3 Frame Level, Auxiliary Hydraulic and Outrigger Joysticks Module
9.6 Electrical System Schematics And Diagrams
9.6.1 Cab Schematic
9.6.2 Options Schematic
9.6.3 CAN Distribution Schematic
9.6.4 Chassis Schematic
9.6.5 Power Unit Schematic
9.6.6 Boom Schematic
9.6.7 CAN Diagram
9.7 Engine Start Circuit
9.7.1 Starter
9.8 Charging Circuit
9.8.1 Alternator
9.9 Window Wiper/Washer Windshield Wiper Motor
9.9.1 Windshield/Rear Window Washer Reservoir
9.10 Cab Heater and Fan
9.10.1 Cab Heater Controls
9.11 Solenoids, Senders and Sensors
9.11.1 Intelligent Control Valves (INCOVA) Solenoids
9.11.2 Park Brake Solenoid Valve
9.11.3 Sway Solenoid Valve
9.11.4 Pump Solenoid Valve
9.11.5 Boom Ride Control Solenoid Valve
9.11.6 Lift Isolation Solenoid Valves
9.11.7 Steer Solenoid Valves
9.11.8 Transmission Solenoid Valves
9.11.9 Transmission Temperature Sender
9.11.10 Engine Coolant Temperature Sender / Switch
9.11.11 Fuel Level Sender
9.11.12 Boom Angle Sensors
9.11.13 Boom Length Sensor
9.12 Display Monitor and Gauges
9.12.1 3-N-1 Digital Gauge
9.13 Dash Switches
9.13.1 Ignition Key Switch
9.13.2 Dash Switches
9.14 Engine Indicator Lamps
9.15 Hand Held Analyzer
9.15.1 Analyzer Description
9.15.2 Debug Functionality
9.15.3 Personality Settings
9.15.4 Machine Setup
9.15.5 Calibrations
9.15.6 Emergency Boom Lowering Procedure
9.15.7 Diagnostics
9.15.8 Diagnostic Trouble Code (DTC) Table

 

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JLG G10-55A & G12-55A AccuPlace Telehandlers Service Manual (ANSI).pdf

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