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 3126020)
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Description
This comprehensive parts manual is specifically designed for the JLG Telehandlers G10-55A G12-55A ANSI. It provides easy access to essential information, making it suitable 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
- Section 12: Options
With step-by-step instructions and detailed exploded diagrams, this manual covers all parts and ensures efficient completion of any required job. The instant file delivery eliminates shipping costs and waiting time, allowing you to access the manual immediately upon payment. Compatible with all versions of Windows and Mac, this manual is available in English and requires Adobe Reader and Win for viewing and printing.
