31200728 G10-55A,G12-55A 3
4 G10-55A,G12-55A 31200728
31200728 G10-55A,G12-55A 5
6 G10-55A,G12-55A 31200728
TABLE OF CONTENTS
31200728 G10-55A,G12-55A 7
SECTION 1 - FRAME AND ATTACHING PARTS.............................................................................................................................. 11
FIGURE 1-1. FRAME AND ATTACHING PARTS .......................................................................................................................... 12
FIGURE 1-2. COVERS ................................................................................................................................................................... 14
FIGURE 1-3. OUTRIGGER INSTALLATION .................................................................................................................................. 18
FIGURE 1-4. PINTLE HOOK .......................................................................................................................................................... 20
SECTION 2 - BOOM .......................................................................................................................................................................... 23
FIGURE 2-1. BOOM INSTALLATION............................................................................................................................................. 24
FIGURE 2-2. FIRST BOOM SECTION G10-55A............................................................................................................................ 26
FIGURE 2-3. FIRST BOOM SECTION G12-55A............................................................................................................................ 28
FIGURE 2-4. SECOND BOOM SECTION G10-55A....................................................................................................................... 30
FIGURE 2-5. SECOND BOOM SECTION G12-55A....................................................................................................................... 34
FIGURE 2-6. THIRD BOOM SECTION G10-55A ........................................................................................................................... 38
FIGURE 2-7. THIRD BOOM SECTION G12-55A ........................................................................................................................... 42
FIGURE 2-8. FOURTH BOOM SECTION G10-55A ....................................................................................................................... 46
FIGURE 2-9. FOURTH BOOM SECTION G12-55A ....................................................................................................................... 48
FIGURE 2-10. EXTEND CHAINS G10-55A.................................................................................................................................... 50
FIGURE 2-11. EXTEND CHAINS G12-55A.................................................................................................................................... 52
FIGURE 2-12. RETRACT CHAINS G10-55A ................................................................................................................................. 54
FIGURE 2-13. RETRACT CHAINS G12-55A ................................................................................................................................. 56
FIGURE 2-14. MANUAL QUICK ATTACH ..................................................................................................................................... 60
SECTION 3 - ATTACHMENTS .......................................................................................................................................................... 63
FIGURE 3-1. STANDARD CARRIAGE (Prior to SN 0160052000) ................................................................................................. 64
FIGURE 3-2. STANDARD CARRIAGE (SN 0160052000 to Present) ............................................................................................ 66
FIGURE 3-3. SIDE TILT CARRIAGE.............................................................................................................................................. 68
FIGURE 3-4. 50 IN SIDE SHIFT CARRIAGE ................................................................................................................................. 70
FIGURE 3-5. DUAL FORK POSITIONING CARRIAGE ................................................................................................................. 72
FIGURE 3-6. 90, SWING CARRIAGE ............................................................................................................................................ 74
FIGURE 3-7. 180, SWING CARRIAGE .......................................................................................................................................... 76
FIGURE 3-8. SHEET HANDLER CARRIAGE ................................................................................................................................ 80
FIGURE 3-9. FORKS AND ATTACHING PARTS........................................................................................................................... 82
FIGURE 3-10. FORK MOUNTED PLATFORM............................................................................................................................... 84
FIGURE 3-11. FORK MOUNTED HOOK ....................................................................................................................................... 86
FIGURE 3-12. GENERAL PURPOSE BUCKET ............................................................................................................................. 88
FIGURE 3-13. GRAPPLE BUCKET................................................................................................................................................ 90
FIGURE 3-14. TRUSS BOOM ........................................................................................................................................................ 92
FIGURE 3-15. TRUSS BOOM WITH WINCH ................................................................................................................................. 94
FIGURE 3-16. ADJUSTABLE TRUSS BOOM ................................................................................................................................ 96
FIGURE 3-17. 8 FOOT STANDARD MAST ................................................................................................................................... 98
FIGURE 3-18. 8 FT SIDE TILT ELECTRIC MAST ....................................................................................................................... 102
SECTION 4 - ENGINE AND ATTACHING PARTS .......................................................................................................................... 107
FIGURE 4-1. ENGINE INSTALLATION ........................................................................................................................................ 108
FIGURE 4-2. ENGINE .................................................................................................................................................................. 110
FIGURE 4-3. ENGINE .................................................................................................................................................................. 112
FIGURE 4-4. FUEL TANK AND LINES ........................................................................................................................................ 114
FIGURE 4-5. RADIATOR INSTALLATION ................................................................................................................................... 116
FIGURE 4-6. AIR CLEANER INSTALLATION .............................................................................................................................. 120
FIGURE 4-7. AIR CLEANER INSTALLATION .............................................................................................................................. 122
FIGURE 4-8. EXHAUST INSTALLATION ..................................................................................................................................... 124
FIGURE 4-9. EXHAUST INSTALLATION..................................................................................................................................... 126
SECTION 5 - DRIVE TRAIN ............................................................................................................................................................ 129
FIGURE 5-1. DRIVETRAIN COMPONENTS (Prior to SN 0160054609) ...................................................................................... 130
FIGURE 5-2. DRIVETRAIN COMPONENTS (SN 0160054609 to Present) ................................................................................. 134
FIGURE 5-3. FRONT AXLE ......................................................................................................................................................... 138
FIGURE 5-4. FRONT AXLE (SN 0160063540 to Present) ........................................................................................................... 140
FIGURE 5-5. FRONT AXLE - CENTRAL HOUSING AND STEERING (Prior to SN 0160046229, SN 0160046235 through
0160063539, Excluding 0160045209, 0160045296, 0160045449 and 0160045636) ................................................................... 142
TABLE OF CONTENTS
8 G10-55A,G12-55A 31200728
FIGURE 5-6. FRONT AXLE - CENTRAL HOUSING AND STEERING (SN 0160046229 through 0160046235, Including
0160045209, 0160045296, 0160045449 and 0160045636).......................................................................................................... 144
FIGURE 5-7. FRONT AXLE - CENTRAL HOUSING (SN 0160063540 to Present) ...................................................................... 146
FIGURE 5-8. FRONT AXLE - DIFFERENTIAL ............................................................................................................................. 148
FIGURE 5-9. FRONT AXLE - DIFFERENTIAL (SN 0160063540 to Present) ............................................................................... 150
FIGURE 5-10. FRONT AXLE - HUB REDUCTION (Prior to SN 0160046229, SN 0160046235 through 0160063539, Excluding
0160045209, 0160045296, 0160045449 and 0160045636).......................................................................................................... 152
FIGURE 5-11. FRONT AXLE - HUB REDUCTION (SN 0160046229 through 0160046235, Including 0160045209, 0160045296,
0160045449 and 0160045636) ..................................................................................................................................................... 156
FIGURE 5-12. FRONT AXLE - HUB REDUCTION (SN 0160063540 to Present)......................................................................... 160
FIGURE 5-13. FRONT AXLE - BRAKES (Prior to SN 0160046229, SN 0160046235 through 0160063539, Excluding
0160045209, 0160045296, 0160045449 and 0160045636).......................................................................................................... 162
FIGURE 5-14. FRONT AXLE - BRAKES (SN 0160046229 through 0160046235, Including 0160045209, 0160045296,
0160045449 and 0160045636) ..................................................................................................................................................... 164
FIGURE 5-15. FRONT AXLE - BRAKES (SN 0160063540 to Present) ........................................................................................ 166
FIGURE 5-16. FRONT AXLE - STEERING (SN 0160063540 to Present) .................................................................................... 168
FIGURE 5-17. FRONT AXLE - TRUNION (SN 0160063540 to Present) ...................................................................................... 170
FIGURE 5-18. REAR AXLE .......................................................................................................................................................... 172
FIGURE 5-19. REAR AXLE (SN 0160063541 to Present) ............................................................................................................ 174
FIGURE 5-20. REAR AXLE - CENTRAL HOUSING AND STEERING (Prior to SN 0160054609) ............................................... 176
FIGURE 5-21. REAR AXLE - CENTRAL HOUSING AND STEERING (SN 0160054609 through 0160063540) .......................... 178
FIGURE 5-22. REAR AXLE - CENTRAL HOUSING (SN 0160063541 to Present) ...................................................................... 180
FIGURE 5-23. REAR AXLE - DIFFERENTIAL (Prior to SN 0160054609) .................................................................................... 182
FIGURE 5-24. REAR AXLE - DIFFERENTIAL (SN 0160054609 through 0160063540) ............................................................... 184
FIGURE 5-25. REAR AXLE - DIFFERENTIAL (SN 0160063541 to Present) ............................................................................... 186
FIGURE 5-26. REAR AXLE - HUB REDUCTION (Prior to SN 0160054609) ................................................................................ 188
FIGURE 5-27. REAR AXLE - HUB REDUCTION (SN 0160054609 through 0160063540) .......................................................... 190
FIGURE 5-28. REAR AXLE - HUB REDUCTION (SN 0160063541 to Present) ........................................................................... 192
FIGURE 5-29. REAR AXLE - BRAKES (Prior to SN 0160054609) ............................................................................................... 194
FIGURE 5-30. REAR AXLE - BRAKES (SN 0160054609 through 0160063540).......................................................................... 196
FIGURE 5-31. REAR AXLE - BRAKES (SN 0160063541 to Present) .......................................................................................... 198
FIGURE 5-32. REAR AXLE - STEERING (SN 0160063541 to Present)....................................................................................... 200
FIGURE 5-33. REAR AXLE - TRUNION (SN 0160063541 to Present)......................................................................................... 202
FIGURE 5-34. REAR AXLE - DIFFERENTIAL ASSEMBLY (SN 0160063541 to Present) ........................................................... 204
FIGURE 5-35. REAR AXLE - RING GEAR SUPPORT KIT (SN 0160063541 to Present) ............................................................ 206
FIGURE 5-36. REAR AXLE - PLANET GEAR CARRIER KIT (SN 0160063541 to Present) ........................................................ 208
FIGURE 5-37. REAR AXLE - SUPPORT ASSEMBLY (SN 0160063541 to Present) ................................................................... 210
FIGURE 5-38. TRANSMISSION ................................................................................................................................................... 212
FIGURE 5-39. TRANSMISSION - CONVERTER AND INPUT ..................................................................................................... 214
FIGURE 5-40. TRANSMISSION - GEARBOX HOUSING ............................................................................................................. 216
FIGURE 5-41. TRANSMISSION - FORWARD GEAR GROUP .................................................................................................... 218
FIGURE 5-42. TRANSMISSION - REVERSE GEAR GROUP ...................................................................................................... 220
FIGURE 5-43. TRANSMISSION - 1ST SHAFT GROUP ............................................................................................................... 222
FIGURE 5-44. TRANSMISSION - 2ND SHAFT GROUP .............................................................................................................. 224
FIGURE 5-45. TRANSMISSION - 3RD SHAFT GROUP .............................................................................................................. 226
FIGURE 5-46. TRANSMISSION - 4TH SHAFT GROUP............................................................................................................... 228
FIGURE 5-47. TRANSMISSION - POWER TAKE-OFF ................................................................................................................ 230
FIGURE 5-48. TRANSMISSION - CONTROL UNIT AND PRESSURE REGULATOR ................................................................. 232
FIGURE 5-49. TRANSMISSION - GEARSHIFT SYSTEM ............................................................................................................ 234
FIGURE 5-50. TRANSMISSION - OIL PUMP, FILTER AND DIPSTICK ....................................................................................... 236
FIGURE 5-51. TRANSMISSION - TRANSFER BOX .................................................................................................................... 238
FIGURE 5-52. WHEEL ASSEMBLY.............................................................................................................................................. 240
FIGURE 5-53. FENDER INSTALLATION (Prior to SN 0160052014, SN 0160058370 to Present) ............................................... 242
FIGURE 5-54. FENDER INSTALLATION (SN 0160052014 through 0160058369) ...................................................................... 244
SECTION 6 - CAB ............................................................................................................................................................................ 247
FIGURE 6-1. CAB INSTALLATION ............................................................................................................................................... 248
FIGURE 6-2. CAB ASSEMBLY ..................................................................................................................................................... 252
FIGURE 6-3. CAB DOOR ............................................................................................................................................................. 256
FIGURE 6-4. CAB INTERIOR ....................................................................................................................................................... 258
FIGURE 6-5. WIPERS .................................................................................................................................................................. 260
FIGURE 6-6. SEATS ..................................................................................................................................................................... 262
FIGURE 6-7. HEATER INSTALLATION........................................................................................................................................ 264
FIGURE 6-8. AIR CONDITIONING INSTALLATION ..................................................................................................................... 268
SECTION 7 - CONTROLS ................................................................................................................................................................ 273
TABLE OF CONTENTS
31200728 G10-55A,G12-55A 9
FIGURE 7-1. BRAKE .................................................................................................................................................................... 274
FIGURE 7-2. ACCELERATOR ..................................................................................................................................................... 276
FIGURE 7-3. STEERING COLUMN ............................................................................................................................................. 278
FIGURE 7-4. BOOM JOYSTICK................................................................................................................................................... 280
FIGURE 7-5. OUTRIGGER AND FRAME LEVEL/AUXILIARY CONTROLLER ........................................................................... 282
SECTION 8 - HYDRAULIC CIRCUITS............................................................................................................................................. 285
FIGURE 8-1. SUPPLY CIRCUIT .................................................................................................................................................. 286
FIGURE 8-2. DUMP CIRCUIT ...................................................................................................................................................... 290
FIGURE 8-3. STEER SELECT CIRCUIT...................................................................................................................................... 292
FIGURE 8-4. SERVICE BRAKE CIRCUIT.................................................................................................................................... 294
FIGURE 8-5. BOOM JOYSTICK CIRCUIT ................................................................................................................................... 296
FIGURE 8-6. FRAME LEVEL/AUXILIARY CONTROLLER .......................................................................................................... 298
FIGURE 8-7. OUTRIGGER CONTROLLER ................................................................................................................................. 300
FIGURE 8-8. LIFT CYLINDER CIRCUIT ...................................................................................................................................... 302
FIGURE 8-9. EXTEND/RETRACT CYLINDER CIRCUIT ............................................................................................................. 304
FIGURE 8-10. TILT CYLINDER AND COMPENSATION CYLINDER CIRCUIT .......................................................................... 306
FIGURE 8-11. BOOM HYDRAULIC ASSEMBLY ......................................................................................................................... 308
FIGURE 8-12. AUXILIARY HYDRAULIC CIRCUIT ...................................................................................................................... 310
FIGURE 8-13. FRAME LEVEL CIRCUIT ...................................................................................................................................... 314
FIGURE 8-14. OUTRIGGER CIRCUIT ......................................................................................................................................... 316
FIGURE 8-15. QUICK ATTACH INSTALLATION ......................................................................................................................... 318
SECTION 9 - HYDRAULIC COMPONENTS .................................................................................................................................... 321
FIGURE 9-1. LIFT CYLINDER AND HARDWARE ....................................................................................................................... 322
FIGURE 9-2. LIFT CYLINDER AND HARDWARE ....................................................................................................................... 324
FIGURE 9-3. EXTEND/RETRACT CYLINDER AND HARDWARE .............................................................................................. 326
FIGURE 9-4. TILT CYLINDER AND HARDWARE ....................................................................................................................... 328
FIGURE 9-5. COMPENSATION CYLINDER AND HARDWARE ................................................................................................. 330
FIGURE 9-6. FRAME LEVEL CYLINDER AND HARDWARE ...................................................................................................... 332
FIGURE 9-7. OUTRIGGER CYLINDER AND HARDWARE ......................................................................................................... 334
FIGURE 9-8. STABILIZER CYLINDER AND HARDWARE .......................................................................................................... 336
FIGURE 9-9. SIDE TILT CARRIAGE CYLINDER (Prior to SN 0160066379) ............................................................................... 338
FIGURE 9-10. SIDE TILT CARRIAGE CYLINDER (SN 0160066379 to Present) ........................................................................ 340
FIGURE 9-11. 50 IN SIDE SHIFT CARRIAGE CYLINDER .......................................................................................................... 342
FIGURE 9-12. SWING CARRIAGE CYLINDER ........................................................................................................................... 344
FIGURE 9-13. GRAPPLE BUCKET CYLINDER........................................................................................................................... 348
FIGURE 9-14. MAIN CONTROL VALVE ...................................................................................................................................... 350
FIGURE 9-15. PISTON PUMP ..................................................................................................................................................... 352
FIGURE 9-16. HYDRAULIC TANK ............................................................................................................................................... 356
FIGURE 9-17. STEER SELECT VALVE....................................................................................................................................... 358
FIGURE 9-18. BRAKE VALVE ..................................................................................................................................................... 360
FIGURE 9-19. HYDRAULIC MANIFOLD VALVE ......................................................................................................................... 364
FIGURE 9-20. DECOMPRESSION VALVE .................................................................................................................................. 366
FIGURE 9-21. QUICK ATTACH VAVLE ....................................................................................................................................... 368
FIGURE 9-22. QUICK ATTACH INSTALLATION, G SERIES ...................................................................................................... 370
FIGURE 9-23. CYLINDER - QUICK ATTACH ASSEMBLY .......................................................................................................... 372
FIGURE 9-24. QUICK COUPLER CYLINDER ............................................................................................................................. 374
FIGURE 9-25. DIVERTOR VALVE ............................................................................................................................................... 376
SECTION 10 - ELECTRICAL ........................................................................................................................................................... 379
FIGURE 10-1. ENGINE COMPARTMENT ELECTRICAL INSTALLATION .................................................................................. 380
FIGURE 10-2. ENGINE COMPARTMENT ELECTRICAL INSTALLATION .................................................................................. 384
FIGURE 10-3. ARCTIC PACKAGE INSTALLATION .................................................................................................................... 388
FIGURE 10-4. BOOM AND FRAME ELECTRICAL INSTALLATION............................................................................................ 390
FIGURE 10-5. CAB ELECTRICAL INSTALLATION ..................................................................................................................... 394
FIGURE 10-6. CAB SWITCHES ................................................................................................................................................... 396
FIGURE 10-7. CLEARSKY INSTALLATION ................................................................................................................................ 398
FIGURE 10-8. WORK LIGHTS (Prior to SN 0160059446) ........................................................................................................... 400
FIGURE 10-9. WORK LIGHTS (SN 0160059446 to Present) ...................................................................................................... 404
FIGURE 10-10. REVERSE SENSING SYSTEM INSTALLATION ................................................................................................ 406
FIGURE 10-11. DRIVE LIGHTS ................................................................................................................................................... 408
FIGURE 10-12. ENGINE HARNESS ............................................................................................................................................ 410
FIGURE 10-13. ENGINE HARNESS ............................................................................................................................................ 414
TABLE OF CONTENTS
10 G10-55A,G12-55A 31200728
FIGURE 10-14. TRANSMISSION HARNESS ............................................................................................................................... 418
FIGURE 10-15. FRAME HARNESS .............................................................................................................................................. 420
FIGURE 10-16. VEC OPTIONS HARNESS .................................................................................................................................. 424
FIGURE 10-17. TRANSMISSION RELAY HARNESS .................................................................................................................. 428
FIGURE 10-18. ENCLOSED CAB OPTIONS HARNESS ............................................................................................................. 430
FIGURE 10-19. DASH HARNESS ................................................................................................................................................ 432
FIGURE 10-20. INSTRUMENT PANEL HARNESS ...................................................................................................................... 434
FIGURE 10-21. FRAME ROAD LIGHT HARNESS ....................................................................................................................... 436
FIGURE 10-22. BOOM WORK LIGHT HARNESS ........................................................................................................................ 438
FIGURE 10-23. CAB ROAD LIGHT HARNESS ............................................................................................................................ 440
FIGURE 10-24. CAB WORK LIGHT HARNESS (Prior to SN 0160059446).................................................................................. 442
FIGURE 10-25. CAB WORK LIGHT HARNESS (SN 0160059446 to Present) ............................................................................. 444
FIGURE 10-26. CAB WORK LIGHT HARNESS ........................................................................................................................... 446
FIGURE 10-27. A/C HARNESS .................................................................................................................................................... 448
FIGURE 10-28. VEC HARNESS ................................................................................................................................................... 450
FIGURE 10-29. TELEMATICS INSTALLATION, UNITED RENTALS, (WITH SHORT JUMPER HARNESS) .............................. 452
FIGURE 10-30. TELEMATICS INSTALLATION, UNITED RENTALS, (WITH LONG JUMPER HARNESS) ................................ 454
FIGURE 10-31. REVERSE SENSOR HARNESS ......................................................................................................................... 456
SECTION 11 - DECALS ................................................................................................................................................................... 459
FIGURE 11-1. CAB AND FRAME DECALS .................................................................................................................................. 460
FIGURE 11-2. BOOM DECALS .................................................................................................................................................... 464
SECTION 12 - RECOMMENDED SPARE PARTS ........................................................................................................................... 467
FIGURE 12-1. RECOMMENDED SPARE PARTS ........................................................................................................................ 468
PART NUMBER INDEX .................................................................................................................................................................... 471
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JLG Telehandlers G10-55A G12-55A ANSI Illustrated Master Parts List Manual ! (P/N 31200728)
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Description
This comprehensive parts manual is designed for the JLG Telehandlers G10-55A G12-55A ANSI. It provides easy access to a wide range of parts, making it an essential resource for both professional mechanics and DIY enthusiasts.
- Section 1: Frame & Attaching Parts
- Section 2: Boom
- Section 3: Attachments
- Section 4: Engine & Attaching Parts
- Section 5: Drive Train
- Section 6: Cab
- Section 7: Controls
- Section 8: Hydraulic Circuits
- Section 9: Hydraulic Components
- Section 10: Electrical
- Section 11: Decals
With step-by-step instructions and detailed exploded diagrams, this manual facilitates the correct and efficient completion of any job. It is available in a printable PDF format, compatible with all versions of Windows and Mac, and can be viewed on a PC or laptop. There are no shipping costs or waiting time, as the manual is accessible instantly upon payment via a secure processor. Accepted payment methods include all major credit/debit cards and PayPal.
