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Service Manual Models G10-55A G12-55A 3126019 Revised January 5, 2011
An Oshkosh Corporation Company
EFFECTIVITY PAGE December, 2003 - A - Original Issue Of Manual July 16, 2004 - B - Revised Manual March 11, 2005 - C - Added Main Pump Information July 7, 2006 - D - Revised Manual April 19, 2007 - E - Revised pages 2.7, 3.16, 5.11, 6.3, 6.4, 7.10, 8.4, 8.6, 8.20, 9.18 & 9.22. August 8, 2007 - F - Revised pages 2.7, 7.4, 7.5, 7.6, 7.14, 9.4, 9.9, 9.12, 9.15 & 9.17. May 1, 2008 - G - Revised Danger, Warning & Caution text and pages 1.4, 2.10, 3.14, 3.15, 3.16, 3.17 & 3.19. January 5, 2011 - H - Revised page numbers and pages 2-3 thru 2-10, 2-13 thru 2-19, 3-4 thru 3-29, 4-6 thru 4-10, 5-4, 5-5, 5-9 thru 5-11, 6-3, 6-6, 7-6 thru 7-9, 7-11 thru 7-15, 8-3 thru 8-12, 8-14 thru 8-25, 9-5 thru 9-12, 9-15 thru 9-21, 9-23, 9-25 thru 9-28, 9-31, 9-32, 9-34 thru 9-36 & 9-42 thru 9-54.
3126019
G10-55A, G12-55A
i
EFFECTIVITY PAGE
ii
G10-55A, G12-55A
3126019
SECTION CONTENTS Section
Subject
Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7
Page
1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 1-2 1-2 1-2 1-2 1-3 1-4
Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1 2.2 2.3 2.4 2.5 2.6
Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 2-3 2-11 2-15 2-17 2-20
...........................................................
3-1
Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Carrier Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 3-4 3-4 3-5 3-6 3-16 3-18 3-20 3-23 3-24 3-24 3-25 3-29 3-30
Section 4 Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Section 3 Boom 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14
4.1 4.2 4.3 4.4 4.5
G10-55A, G12-55A
Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 4-3 4-3 4-8 4-9
i
Section
Subject
Page
Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.6 5.7
5-1
Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 5-3 5-3 5-9 5-10 5-11 5-11
Section 6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1 6.2 6.3 6.4 6.5 6.6
Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications And Maintenance Information. . . . . . . . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 6-3 6-3 6-3 6-6 6-7
...........................................................
7-1
Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2 7-4 7-6 7-8 7-10 7-10 7-12 7-13 7-14 7-17
Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
Section 7 Engine 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10
8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8
Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2 8-3 8-3 8-4 8-13 8-14 8-15 8-21
Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9.1 9.2 9.3 9.4 9.5 9.6
ii
Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3 9-6 9-6 9-6 9-10 9-22
G10-55A, G12-55A
Section 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15
G10-55A, G12-55A
Subject Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . . . . . .
Page 9-26 9-28 9-30 9-30 9-37 9-38 9-40 9-42 9-43
iii
Section
iv
Subject
Page
G10-55A, G12-55A
Section 1 Safety Practices
Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6
1.7
G10-55A, G12-55A
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4
1-1
Safety Practices
1.1
INTRODUCTION
1.4
DO NOT OPERATE TAGS
This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.
Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.
1.5
These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local distributor. Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.
SAFETY INFORMATION
To avoid possible death or injury, carefully read, understand and comply with all safety messages. In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.
Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.
1.5.1
Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
1.2
DANGER
WARNING
DISCLAIMER
All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.
1.3
Safety Alert System and Signal Words
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
OPERATION & SAFETY MANUAL
The mechanic must not operate the machine until the Operation & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
An Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult the local distributor before proceeding.
1-2
G10-55A, G12-55A
Safety Practices
1.6
SAFETY INSTRUCTIONS
Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding.
1.6.1
Personal Hazards
PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat. LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.
1.6.2
Equipment Hazards
LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached. NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip. DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.
1.6.3
General Hazards
SOLVENTS: Only use approved solvents that are known to be safe for use. HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.). FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it. CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service. When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off. It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure the machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, JLG recommends a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in. (30,5 cm) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation, Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.
HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.
G10-55A, G12-55A
1-3
Safety Practices 1.6.4
Operational Hazards
ENGINE: Stop the engine before performing any service unless specifically instructed otherwise. VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation. SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service. FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding. FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury. Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.
PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result. LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine. TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires. NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications. MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine. BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.
1.7
SAFETY DECALS
Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.
RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury. FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials. NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion. DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.
1-4
G10-55A, G12-55A
Section 2 General Information and Specifications
Contents PARAGRAPH 2.1 2.2
2.3
2.4 2.5
2.6
G10-55A, G12-55A
TITLE
Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Engine Performance Specifications - John Deere . . . . . . . . . . . . . . . . . . 2.3.5 Engine Performance Specifications - Perkins . . . . . . . . . . . . . . . . . . . . . . 2.3.6 Engine Performance Specifications - Cummins . . . . . . . . . . . . . . . . . . . . Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3 1000 & 1500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2-2 2-3 2-3 2-7 2-10 2-11 2-11 2-11 2-12 2-12 2-12 2-13 2-15 2-17 2-17 2-18 2-19 2-20
2-1
General Information and Specifications
2.1
REPLACEMENT PARTS AND WARRANTY INFORMATION
1
MY1000
Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure. Note: The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts. A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use. Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.
2-2
G10-55A, G12-55A
General Information and Specifications
2.2 2.2.1
TORQUE CHARTS SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque (Dry)
Tensile Clamp Load Stress Area
Torque Lubricated
Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
IN-LB
[N.m]
4
40 48 32 40 32 36 24 32 20 28
0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500
0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364
380 420 580 610 900 940 1120 1285 2020 2320
8 9 16 18 30 31 43 49 96 120
0.9 1.0 1.8 2.0 3.4 3.5 4.8 5.5 10.8 13.5
6 7 12 13 22 23 32 36 75 86
0.7 0.8 1.4 1.5 2.5 2.6 3.5 4 9 10
105 135
12 15
18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12
In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB 3340 3700 4940 5600 6800 7550 9050 10700 11600 12950 14400 16300 21300 23800 29400 32400 38600 42200 42300 47500 53800 59600 64100 73000 78000 87700
FT-LB 17 19 30 35 50 55 75 90 110 120 150 170 260 300 430 470 640 700 800 880 1120 1240 1460 1680 1940 2200
[N.m] 23 26 41 47 68 75 102 122 149 163 203 230 353 407 583 637 868 949 1085 1193 1518 1681 1979 2278 2630 2983
FT-LB 13 14 23 25 35 40 55 65 80 90 110 130 200 220 320 350 480 530 600 660 840 920 1100 1260 1460 1640
[N.m] 18 19 31 34 47 54 75 88 108 122 149 176 271 298 434 475 651 719 813 895 1139 1247 1491 1708 1979 2224
FT-LB 19 21 35 40 55 60 85 100 120 135 165 190 285 330 475 520 675 735 840 925 1175 1300 1525 1750 2025 2300
[N.m] 26 29 48 54 75 82 116 136 163 184 224 258 388 449 646 707 918 1000 1142 1258 1598 1768 2074 2380 2754 3128
6 8 10 1/4
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
NOTES:
Torque Loctite® 262™ OR Vibra-TITE™ 131
IN-LB
[N.m]
FT-LB 16 17 28 32 45 50 68 80 98 109 135 153 240 268 386 425 579 633 714 802 1009 1118 1322 1506 1755 1974
[N.m] 22 23 38 43 61 68 92 108 133 148 183 207 325 363 523 576 785 858 968 1087 1368 1516 1792 2042 2379 2676
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
G10-55A, G12-55A
JLG P/N
Loctite® P/N
ND Industries P/N
0100011 0100019 0100071
242TM 271TM 262TM
Vibra-TITE TM 121 Vibra-TITE TM 140 Vibra-TITE TM 131
Description Medium Strength (Blue) High Strength (Red) Medium - High Strength (Red)
MY4650J
2-3
General Information and Specifications 2.2.1
SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque (Dry or Loctite® 263) K= 0.20
Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K=.18
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
4
40 48 32 40 32 36 24 32 20 28
0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500
0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364
1320 1580 1800 2860 3280
43 60 68 143 164
5 7 8 16 19
129 148
15 17
18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12
In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
[N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 770 895 1160 1300 1635 1810 2145 2435 2845 3200
[N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1045 1215 1580 1770 2225 2460 2915 3310 3870 4350
6 8 10 1/4
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
NOTES:
2-4
Tensile Clamp Load Stress Area
Torque Loctite® 262™ OR Vibra-TITE™ 131 K=0.15 IN-LB
[N.m]
FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665
[N.m 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER MY4660J
G10-55A, G12-55A
General Information and Specifications 2.2.1
SAE Fastener Torque Chart (Continued)
SOCKET HEAD CAP SCREWS Magni Coating* Tensile Stress Area
Clamp Load See Note 4
Torque (Dry) K = .17
Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 OR Precoat 85® K=0.16
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
4
40 48 32 40 32 36 24 32 20 28
0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500
0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364
2860 3280
122 139
14 16
114 131
13 15
18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12
In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
FT-LB 20 25 35 40 60 65 90 100 130 145 180 205 320 355 515 570 730 845 1095 1225 1545 1710 2025 2300 2690 3020
[N.m] 25 35 50 55 80 90 120 135 175 195 245 280 435 485 700 775 995 1150 1490 1665 2100 2325 2755 3130 3660 4105
FT-LB 20 20 35 40 55 60 85 95 125 135 170 190 300 335 485 535 685 795 1030 1155 1455 1610 1905 2165 2530 2845
[N.m] 25 25 50 55 75 80 115 130 170 185 230 260 410 455 660 730 930 1080 1400 1570 1980 2190 2590 2945 3440 3870
6 8 10 1/4
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
Torque Loctite® 262™ OR Vibra-TITE™ 131 K=0.15 IN-LB
[N.m]
FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665
[N.m] 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4670J
G10-55A, G12-55A
2-5
General Information and Specifications 2.2.1
SAE Fastener Torque Chart (Continued)
SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners* Tensile Stress Area
Clamp Load See Note 4
Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18
Torque (Dry) K = .20
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
4
40 48 32 40 32 36 24 32 20 28
0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500
0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364
2860 3280
143 164
16 19
129 148
15 17
18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12
In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
[N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 775 895 1160 1300 1635 1810 2145 2435 2845 3200
[N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1055 1215 1580 1770 2225 2460 2915 3310 3870 4350
6 8 10 1/4
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
Torque (Loctite® 262TM TM or Vibra-TITE 131) K=0.15 IN-LB
[N.m]
FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665
[N.m] 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4680J
2-6
G10-55A, G12-55A
General Information and Specifications 2.2.2
Metric Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS
Size
PITCH
Tensile Stress Area
Sq mm
Clamp Load
Torque (Dry or Loctite® 263TM)
Torque (Lub)
KN
[N.m]
[N.m]
Torque Loctite® Torque Loctite® 262™ 242™ or 271™ OR OR Vibra-TITE™ 131 Vibra-TITE™ 111 or 140 [N.m]
[N.m]
3
0.5
5.03
2.19
1.3
1.0
1.2
1.4
3.5
0.6
6.78
2.95
2.1
1.6
1.9
2.3
4
0.7
8.78
3.82
3.1
2.3
2.8
3.4
5
0.8
14.20
6.18
6.2
4.6
5.6
6.8
6
1
20.10
8.74
11
7.9
9.4
12
7
1
28.90
12.6
18
13
16
19
8
1.25
36.60
15.9
26
19
23
28
10
1.5
58.00
25.2
50
38
45
55
12
1.75
84.30
36.7
88
66
79
97
14 16
2 2
115 157
50.0 68.3
140
105
126
154
219
164
197
241
18
2.5
192
83.5
301
226
271
331
20
2.5
245
106.5
426
320
383
469
22
2.5
303
132.0
581
436
523
639
24
3
353
153.5
737
553
663
811
27
3
459
199.5
1080
810
970
1130
30
3.5
561
244.0
1460
1100
1320
1530 2090
33
3.5
694
302.0
1990
1490
1790
36
4
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4690J
G10-55A, G12-55A
2-7
General Information and Specifications 2.2.2
Metric Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Size
PITCH
Tensile Stress Area
Clamp Load
Torque Lube OR Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K= 0.18
Torque Loctite® 262™ OR Vibra-TITE™ 131
[N.m]
[N.m]
[N.m]
Torque Dry or Loctite® 263™ K = 0.20
Sq mm
KN
K=0.15
3
0.5
5.03
3.13
3.5
0.6
6.78
4.22
4
0.7
8.78
5.47
5
0.8
14.20
8.85
6
1
20.10
12.5
7
1
28.90
18.0
25.2
22.7
18.9
8
1.25
36.60
22.8
36.5
32.8
27.4
10
1.5
58.00
36.1
70
65
55
12
1.75
84.30
52.5
125
115
95
14 16
2 2
115 157
71.6 97.8
200
180
150
315
280
235
18
2.5
192
119.5
430
385
325
20
2.5
245
152.5
610
550
460
22
2.5
303
189.0
830
750
625
24
3
353
222.0
1065
960
800
27
3
459
286.0
1545
1390
1160
30
3.5
561
349.5
2095
1885
1575
33
3.5
694
432.5
2855
2570
2140
36
4
817
509.0
3665
3300
2750
42
4.5
1120
698.0
5865
5275
4395
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, MY4700J ADDITIONAL TESTING IS REQUIRED.
2-8
G10-55A, G12-55A
General Information and Specifications 2.2.2
Metric Fastener Torque Chart (Continued)
Magni Coating* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Size
PITCH
Tensile Stress Area
Clamp Load See Note 4
Sq mm
kN
Torque Lube OR Loctite® Torque Torque Dry 242™ or 271™ Loctite® 262™ or OR OR Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131 111 or 140 K = .17 K = .16 K = .15 [N.m]
[N.m]
[N.m]
3
0.5
3.5
0.6
5.03 6.78
4
0.7
8.78
5
0.8
14.20
6
1
20.10
12.5
13
12
11
7
1
28.90
18.0
21
20
19 27
8
1.25
36.60
22.8
31
29
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14 16
2 2
115 157
71.6
170
160
150
97.8
265
250
235
18
2.5
192
119.5
365
345
325
20
2.5
245
152.5
520
490
460
22
2.5
303
189.0
705
665
625
24
3
353
220.0
900
845
790
27
3
459
286.0
1315
1235
1160
30
3.5
561
349.5
1780
1680
1575
33
3.5
694
432.5
2425
2285
2140
36
4
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4710J
G10-55A, G12-55A
2-9
General Information and Specifications 2.2.3
Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart
Size
ORFS
JIC
Flats Method
4
13 lb-ft (18 Nm)
13 lb-ft (18 Nm)
1.5 to 1.75
6
23 lb-ft (31 Nm)
23 lb-ft (31 Nm)
1 to 1.5
8
40 lb-ft (54 Nm)
40 lb-ft (54 Nm)
1.5 to 1.75
10
60 lb-ft (81 Nm)
60 lb-ft (81 Nm)
1.5 to 1.75
12
74 lb-ft (100 Nm)
85 lb-ft (115 Nm)
1.0 to 1.5
16
115 lb-ft (156 Nm)
115 lb-ft (156 Nm)
0.75 to 1.0
20
170 lb-ft (230 Nm)
170 lb-ft (230 Nm)
0.75 to 1.0
24
200 lb-ft (271 Nm)
200 lb-ft (271 Nm)
0.75 to 1.0
32
N/A
270 lb-ft (366 Nm)
0.75 to 1.0
Flats Method: 1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm). 2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it’s connecting to. 3. Use the double wrench method while tightening to avoid hose twist. 4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots indicating that the connection has been properly tightened.
Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible. Torque Wrench: 1. Identify the appropriate application and refer to the above chart for the correct torque value. 2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm). 3. Use the double wrench method while tightening to avoid hose twist. 4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks. 5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.
2-10
G10-55A, G12-55A
General Information and Specifications
2.3
SPECIFICATIONS
2.3.1
Travel Speeds FUNCTION
G10-55A
G12-55A
First Gear
3.4 mph (5,4 km/h)
3.5 mph (5,6 km/h)
Second Gear
6.1 mph (9,8 km/h)
6.3 mph (10,1 km/h)
Third Gear
13.8 mph (22,2 km/h)
14.1 mph (22,7 km/h)
Fourth Gear
20.0 mph (32,2 km/h)
20.4 mph (32,8 km/h)
2.3.2
Hydraulic Cylinder Performance
Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature.
FUNCTION
APPROXIMATE TIMES (seconds) G10-55A
G12-55A
Boom Extend (Boom Level)
17.3
16.5
Boom Retract (Boom Level)
16.8
16.0
Boom Lift
14.6
15.8
Boom Lower
15.8
18.3
Attachment Tilt Forward
6.0
8.0
Attachment Tilt Rearward
7.1
6.4
Sway - Full Right to Left
10.4
9.8
Sway - Full Left to Right
12.2
10.0
Outrigger - Down
5.0
4.9
Outrigger - Up
4.1
4.1
G10-55A, G12-55A
2-11
General Information and Specifications 2.3.3
Electrical System Battery
Type, Rating
12 BCI, Negative (-) Ground, Maintenance Free
Quantity
1
Reserve Capacity
1,000 Cold Cranking Amps @ 0° F (-18° C)
Group/Series
Group 31
Alternator
12V, 95 Amps
2.3.4
Engine Performance Specifications - John Deere Description
G10-55A
G12-55A
John Deere PE 4045HF275
John Deere PE 4045HF275
276 in³ (4,5 liters)
276 in³ (4,5 liters)
Low Idle
900 rpm
900 rpm
High Idle
2,400 to 2,650 rpm
2,400 to 2,650 rpm
Horsepower
125 HP (93 kW) @ 2400 rpm
140 HP (104 kW) @ 2400 rpm
Peak Torque
341 lb-ft (483 Nm) @ 1400 rpm
367 lb-ft (497 Nm) @ 1400 rpm
Fuel Delivery
Fuel Injection
Fuel Injection
4.1 gal/hr (15.5 l/hr)
4.3 gal/hr (16.2 l/hr)
Dry Type, Replaceable Primary and Safety Elements
Dry Type, Replaceable Primary and Safety Elements
Engine Make/Model Displacement
Average Fuel Consumption (depending on load/duty) Air Cleaner
2.3.5
Engine Performance Specifications - Perkins Description
G10-55A
G12-55A
Perkins 1104D - 125HP
Perkins 1104D - 142HP
276 in³ (4,5 liters)
276 in³ (4,5 liters)
Low Idle
1000 rpm
900 rpm
High Idle
2,400 to 2,650 rpm
2,400 to 2,650 rpm
Horsepower
125 HP (93 kW) @ 2400 rpm
142 HP (104 kW) @ 2400 rpm
Peak Torque
Not Available at Publication
410 lb-ft (556 Nm) @ 1400 rpm
Fuel Delivery
Fuel Injection
Fuel Injection
Dry Type, Replaceable Primary and Safety Elements
Dry Type, Replaceable Primary and Safety Elements
Engine Make/Model Displacement
Air Cleaner
2-12
G10-55A, G12-55A
General Information and Specifications 2.3.6
Engine Performance Specifications - Cummins Description
Engine Make/Model Displacement
G10-55A & G12-55A Cummins QSB - 130HP 276 in³ (4,5 liters)
Low Idle
900 rpm
High Idle
2,500 to 2,700 rpm
Horsepower
130 HP (97 kW) @ 2500 rpm
Peak Torque
459 lb-ft (622 Nm) @ 1500 rpm
Fuel Delivery
Fuel Injection
Air Cleaner
G10-55A, G12-55A
Dry Type, Replaceable Primary and Safety Elements
2-13
General Information and Specifications 2.3.7
Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm). Note: Pressure for foam filled tires are for initial fill ONLY. a. G10-55A Size
Tire Type
Minimum Ply/ Star Rating
14.00 x 24
G-2/L-2 Bias Ply Traction
12 Ply
14.00 x 24
G-3/L-3 Bias Ply Rock
12 Ply
14.00 x 24
G-2/L-2 Radial
1 Star
14.00 x 24
Fill Type
Pressure
Pneumatic
65 psi (4,5 bar)
Foam - Approx 720 lb (327 kg)
62 psi (4,3 bar)
Pneumatic
65 psi (4,5 bar)
Foam - Approx 720 lb (327 kg)
62 psi (4,3 bar)
Pneumatic
70 psi (4,8 bar)
Foam - Approx 720 lb (327 kg)
70 psi (4,8 bar)
Solid - 1038 lb (470 kg)
17.50 x 25
G-2/L-2 Bias Ply Traction
12 Ply
17.50 x 25
G-3/L-3 Bias Ply Rock
12 Ply
17.50 x 25
G-2/L-2 Radial
1 Star
400/75-28
Duraforce
16 Ply
Size
Tire Type
Minimum Ply/ Star Rating
17.50 x 25
G-2/L-2 Bias Ply Traction
12 Ply
17.50 x 25
G-3/L-3 Bias Ply Rock
12 Ply
17.50 x 25
G-2/L-2 Radial
1 Star
400/75-28
Duraforce
16 Ply
Pneumatic
65 psi (4,5 bar)
Foam - Approx 785 lb (356 kg)
51 psi (3,5 bar)
Pneumatic
65 psi (4,5 bar)
Foam - Approx 785 lb (356 kg)
51 psi (3,5 bar)
Pneumatic
70 psi (4,8 bar)
Foam - Approx 785 lb (356 kg)
73 psi (5,0 bar)
Pneumatic
76 psi (5,2 bar)
Foam - Approx 570 lb (259 kg)
73 psi (5,0 bar)
Fill Type
Pressure
Pneumatic
65 psi (4,5 bar)
Foam - Approx 785 lb (356 kg)
51 psi (3,5 bar)
Pneumatic
65 psi (4,5 bar)
Foam - Approx 785 lb (356 kg)
51 psi (3,5 bar)
Pneumatic
70 psi (4,8 bar)
Foam - Approx 785 lb (356 kg)
73 psi (5,0 bar)
Pneumatic
76 psi (5,2 bar)
Foam - Approx 570 lb (259 kg)
73 psi (5,0 bar)
b. G12-55A
2-14
G10-55A, G12-55A
General Information and Specifications
2.4
FLUID AND LUBRICANT CAPACITIES
Engine Crankcase Oil Capacity with Filter Change John Deere (G10-55A)
14.3 quarts (13,5 liters)
John Deere (G12-55A)
15.8 quarts (15,0 liters)
Perkins Cummins
7 quarts (6,5 liters) 13.5 quarts (12,8 liters)
Type of Oil 0° to 104° F (-20° to 40° C)
15W-40 CH
-40° to 0° F (-40° to 20° C)
0W-40 CH
Fuel Tank Capacity
38 gallons (144 liters)
Type of Fuel 0° to 104° F (-20° to 40° C)
#2 Diesel
-40° to 0° F (-40° to 20° C)
#1 Diesel
Anti-Gel Fluid -40° to 0° F (-40° to 20° C)
16 oz (0,5 liters)
Cooling System System Capacity John Deere
20.5 quarts (19,4 liters)
Perkins
22.25 quarts (21 liters)
Cummins No Heater With Heater
22.8 quarts (21,6 liters) 24.3 quart (23 liters)
Overflow Bottle Capacity Before S/N 0160039451 excluding 0160039394 & 0160039397 S/N 0160039451 & After including 0160039394 & 0160039397
3 quarts (2,8 liters) 2.5 quarts (2,4 liters)
Type of Coolant 0° to 104° F (-20° to 40° C)
50/50 ethylene glycol & water
-40° to 0° F (-40° to 20° C)
60/40 ethylene glycol & water
Coolant Conditioner Before S/N 0160039451 excluding 0160039394 & 0160039397
0.5 quarts (0,47 liters)
S/N 0160039451 & After including 0160039394 & 0160039397
Not Required
G10-55A, G12-55A
2-15
General Information and Specifications
Hydraulic System System Capacity G10-55A
63 gallons (238 liters)
G12-55A
65 gallons (246 liters)
Reservoir Capacity
38 gallons (144 liters)
Type of Fluid 0° to 104° F (-20° to 40° C)
Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C)
Exon Univis HVl All Season Hyd Fluid
Auxiliary Hydraulic Circuit Max Flow
10 gpm (37,9 lpm)
Transmission Capacity with Filter Change
4 gallons (16 liters)
Type of Fluid 0° to 104° F (-20° to 40° C)
Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C)
Mobilfluid LT® Hydraulic Fluid (75W-80)
Transfer Case Capacity
1.5 quarts (1,4 liters)
Type of Fluid 0° to 104° F (-20° to 40° C)
Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C)
Mobilfluid LT® Hydraulic Fluid (75W-80)
Axles Differential Housing Capacity Front
15.8 quarts (15 liters)
Rear
16.9 quarts (16 liters)
Wheel End Capacity
2 quarts (1,9 liters)
Type of Fluid 0° to 104° F (-20° to 40° C)
Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C)
Mobilfluid LT® Hydraulic Fluid (75W-80)
Air Conditioning System (if equipped) System Capacity Type of Fluid
2-16
2.5 lb (1134 g) Refrigerant R-134a - Tetrafluorethane
G10-55A, G12-55A
General Information and Specifications
2.5
2.5.1
SERVICE AND MAINTENANCE SCHEDULES 10, 1st 50 & 50 Hour
EVERY
10
Air Filter Restriction Indicator
Check Fuel Level
Check Engine Oil Level
Check Hydraulic Oil Level
Check Tire Condition & Pressure
Check Washer Fluid Level (if equipped)
Lubrication Schedule
A Check Check Hydraulic Return Check Auto-Sway Transmission Filter Indicator (Before Function (Before S/N 0160038592) Oil Level S/N 0160039451)
1st
50 LB/F T (N m)
Check Wheel Lug Nut Torque
EVERY
50
Drain Fuel/ Water Separator
Check Engine Coolant Level
Check Battery
MY4740
G10-55A, G12-55A
2-17
General Information and Specifications 2.5.2
1st 250, 250 & 500 Hour
1st
250
Change Axle Oil
Change Transmission Oil & Filter
Change Wheel End Oil
Change Transfer Case Oil
EVERY
250
Change Engine Oil and Filter* (Before S/N 0160039451)
Check Axle Oil Level
Check Wheel End Oil Levels
Air Filter Vacuator Valve
Check Fan Belt
Check Boom Extend Chains
Check Boom Wear Pads
Check Transfer Case Oil Level
Check Rear Axle Stabilization
Lubrication Schedule
EVERY
500
LB/F T (N m)
Change Fuel Check Wheel Change Engine Oil Change Fuel Filter & Strainer Filter Lug Nut and Filter* (S/N (Before S/N 0160032082) Torque 0160039451 & After) MY4750
Note: Engine oil & filter service interval can be extended. See Engine Manual for details. 2-18
G10-55A, G12-55A
General Information and Specifications 2.5.3
1000 & 1500 Hour
EVERY
1000
Change Transmission Oil & Filter
Change Transfer Case Oil
Check Boom Retract Chains
Lubrication Schedule
Change Axle Oil
Change Wheel End Oil
Check Air Intake System
EVERY
1500
Change Engine Coolant
Change Hydraulic Fluid & Filters
Change Hydraulic Tank Breather MY4760
G10-55A, G12-55A
2-19
General Information and Specifications
2.6
LUBRICATION SCHEDULES
a. 50 Hour
EVERY
50
OAL0450
2-20
G10-55A, G12-55A
General Information and Specifications b. 250 Hour
EVERY
250
OW1211
G10-55A, G12-55A
2-21
General Information and Specifications c. 1000 Hour
EVERY
1000
OY2080
2-22
G10-55A, G12-55A
Section 3 Boom
Contents PARAGRAPH 3.1 3.2 3.3 3.4
3.5
3.6
3.7 3.8
3.9
G10-55A, G12-55A
TITLE
Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Complete Boom Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Second, Third & Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . 3.5.2 Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.4 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.5 Fourth Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.7 Third Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.9 Second Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.10 Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.11 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2 Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.4 Extend Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Carrier Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Assembling the Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Hose Carrier-Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.4 Boom Hose Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.3 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.4 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 3-3 3-4 3-4 3-4 3-5 3-5 3-5 3-6 3-6 3-8 3-9 3-10 3-10 3-11 3-12 3-12 3-13 3-14 3-15 3-16 3-16 3-17 3-17 3-18 3-18 3-20 3-20 3-21 3-21 3-22 3-23 3-23 3-23 3-23 3-23
3-1
Boom 3.10
3.11
3.12
3.13 3.14
3-2
Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Boom Head-Mounted Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-24 3-24 3-24 3-24 3-24 3-24 3-25 3-25 3-26 3-28 3-28 3-29 3-30
G10-55A, G12-55A
Boom
3.1
BOOM SYSTEM COMPONENT TERMINOLOGY
The following illustrations identify the components that are referred to throughout this section.
THIRD BOOM SECTION FOURTH BOOM SECTION
EXTEND CHAINS
SECOND BOOM SECTION
FIRST BOOM SECTION
AUXILIARY HYDRAULIC CONNECTIONS
TILT CYLINDER QUICK SWITCH
HOSE CARRIER ASSEMBLY (INSIDE BOOM) RETRACT CHAINS
EXTEND/RETRACT CYLINDER (UNDERSIDE OF BOOM)
HOSE SHEAVE
PIVOT PIN MY0101
G10-55A, G12-55A
3-3
Boom
3.2 3.2.1
BOOM SYSTEM - FOUR SECTION Boom System Operation
The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chain and a single fourth section retract chain. As the extend/retract cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section. The boom sections are connected by extend and retract chains. These chains are routed around sheaves on the second and third boom sections. As the second section is forced out hydraulically, the third and fourth boom sections are pulled out by the extend chains. As hydraulic pressure is applied to the retract port on the extend/retract cylinder, the second boom section is pulled back into the first boom section, and the retract chain pulls the third and fourth boom sections back into the second boom section.
3.3
BOOM ASSEMBLY MAINTENANCE
These instructions provide the complete boom assembly removal and installation or the second, third and fourth boom sections removal and installation. Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.The boom assembly consists of the first, second and third section booms and supporting hardware. Note: Before removing the boom or boom section, the carriage or any other attachment must be removed from the quick switch. Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions. During service of the boom, perform the following: 1. Check wear pads. (Refer to Section 3.11, “Boom Wear Pads.”)
This mechanical linkage formed by the chains and supporting hardware, extends and retracts the third and fourth boom sections at the same rate.
2. Check hose sheaves and chain rollers.
The boom section lifts and lowers via action of the lift/ lower cylinder.
4. Check for proper operation by operating all boom functions through their full ranges of motion several times.
3. Apply grease at all lubrication points (grease fittings). (Refer to Section 2.6, “Lubrication Schedules.”)
Depending on your particular circumstance, the following procedures explain the removal/installation of individual boom sections or removal/installation of the complete boom.
WARNING NEVER weld or drill the boom unless approved in writing by the manufacturer. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling.
3-4
G10-55A, G12-55A
Boom
3.4
3.4.1
COMPLETE BOOM REMOVAL/ INSTALLATION Complete Boom Removal
1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual. 2. Remove the quick switch assembly. Refer to Section 3.9.1, “Quick Switch Removal.” 3. If equipped, remove the Boom Head Mounted Winch. Refer to Section 3.10.1, “Boom HeadMounted Winch Removal.” 4. Park the machine on a hard, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 5. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 6. Open the engine cover. Allow the system fluids to cool. 7. Properly disconnect the battery. 8. Support the front of the boom by placing a sling behind the boom head. 9. Label, disconnect and cap all hydraulic hoses for the extend/retract and tilt circuits. Cap all fittings and openings to keep dirt & debris from entering the hydraulic system. 10. Support the lift/lower cylinder on the left side of the machine. Remove the lock bolt and rod end pin. Lower the lift/lower cylinder onto the frame rails. Repeat this step for the right side lift/lower cylinder. 11. Support the compensation cylinder. Remove the lock bolt and rod end pin. Lower the compensation cylinder onto the frame rails. 12. Lower the boom to a level position and place a suitable support under the boom head. Reposition the slings to each end of the boom. 13. Remove the bolt securing the boom pivot pin. Pull out the boom pivot pin. 14. Lift the complete boom off machine and set on level ground or supports.
3.4.2
Complete Boom Installation
the park brake, chock the wheels and shut the engine OFF. 2. Using suitable slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bore with the boom assembly pivot bore. 3. Install the boom pivot pin. 4. With the sling still in place, install the compensation cylinder, pins and bolts. 5. With the sling still in place, install the rod end of the left lift/lower cylinder, pin and lock bolt. Repeat for the right side lift/lower cylinder. Note: Raising the boom up or down with the sling may be necessary so the boom, compensation and lift/lower cylinder bores can be aligned for easier pin installation. Note: Grease the boom pivot bore, compensation cylinder rod ends, lift/lower cylinder rod end and pins before installing. 6. Uncap and reconnect the previously labeled hydraulic hoses to the extend/retract cylinder. 7. Uncap and connect any remaining hydraulic fittings to their appropriate locations. 8. Recheck the wear pad gaps to ensure they meet the minimum gap requirement. Shim if necessary. 9. Ensure that the boom chains are properly adjusted. Refer to Section 3.7, “Boom Section Separation Adjustment.” 10. Properly connect the battery. 11. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid level in the reservoir; add fluid if required. 12. Install the quick switch assembly. Refer to Section 3.9.2, “Quick Switch Installation.” 13. If equipped, install the Boom Head Mounted Winch. Refer to Section 3.10.2, “Boom Head-Mounted Winch Installation.” 14. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine. 15. Close and secure the engine cover. 16. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 17. Install the previously remove attachment to the quick switch assembly. Refer to the appropriate operation and safety manual.
1. Park the machine on a hard, level surface, place the transmission control lever in (N) NEUTRAL, engage
G10-55A, G12-55A
3-5
Boom
3.5
3.5.1
BOOM SECTION REMOVAL/ INSTALLATION Second, Third & Fourth Boom Section Removal
1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual.
8. Using a suitable lifting device, secure the tilt cylinder barrel with a nylon strap. 9. Remove both retaining clips (4) from each side of the tilt cylinder mounting pin (5). 10. Remove the tilt cylinder mounting pin (5). 11. Lower tilt cylinder from the boom head. 12. Support the front of the boom by placing a sling behind the boom head.
2. Remove the quick switch assembly. Refer to Section 3.9.1, “Quick Switch Removal.” 3. If equipped, remove the Boom Head Mounted Winch. Refer to Section 3.10.1, “Boom HeadMounted Winch Removal.” 4. Park the machine on a hard, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
7
6
8
MY4130
5. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
13. Loosen the jam nut and lock nut (6) to release tension from the hoses on the hose take-up weldment (7).
6. Open the engine cover. Allow the system fluids to cool.
14. Loosen the hydraulic hoses (8) and electrical cables if equipped on the hose take-up weldment (7). Plug the hose ends and tube ends to prevent dirt and debris from entering the hydraulic system.
3
13
12
11 10
9
1
4 5 MY3580
2
15. At the top front of the boom, measure and note the distance from the end of the three extend chain clevises (9) to the face of the lock nut (10). 16. Loosen and remove the lock nuts (10), adjusting nuts (11), washers (12) and springs (13) from the three extend chain clevises (9).
MY3770
7. Label and remove both tilt cylinder hoses (1) between the tilt cylinder (2) and the hose carrier (3). Label, cap and plug the hose carrier tube ends and cylinder ports to prevent dirt and debris from entering the hydraulic system.
3-6
G10-55A, G12-55A
Boom
21
19
14
24
9 22
23 23
20 MY3540
MY3440
17. Pull the three extend chain clevises (9) off of each chain roller (14) and lay each assembly on the third and fourth boom sections respectively. Note: It may be necessary to remove the extend chain rollers to help in the removal of the top wear pads. 18. Verify all fittings, tubes and hoses are properly capped and /or plugged. 19. Extend the second boom section to access the retract chain adjusting block.
25. Remove the adjusting nut and lock nut (19), retract chain & clevis (20), spring stop (21) and spring (22). Loosen bolts (23) and adjusting block (24). 26. Properly disconnect the battery. 30
30 31
31
27 26
28 32
29
25
25
MY3420
17
18
15
16
MY4120
20. Remove the extend/retract cylinder support (15) from the front of the first boom section. 21. Support the extend/retract cylinder (16) with a suitable sling. 22. Remove the retaining clips (17) from each side of the extend/retract cylinder rod. 23. Remove the extend/retract cylinder rod mounting pin (18). 24. Lower the front of the extend/retract cylinder to a secured block on top of the frame. Do Not use the engine hood for support.
27. At the rear of the boom, remove both hose sheave covers (25). 28. Unbolt the hose carrier bracket (26) from the rear of the second boom section and the hose carrier. 29. Pull the hose carrier (27) back to gain access to the tilt hose (28) and the auxiliary hose (29) connections. 30. Disconnect the tilt hoses, auxiliary hoses and if equipped, the electrical connector at the rear of the hose carrier. Label, plug and cap all hydraulic connections to prevent dirt and debris from entering the hydraulic system. 31. Push hose carrier (27) as far forward as possible. Note: Tag each wear pad, spacer, shim and hardware from each location. Note the location of any grease fitting (if equipped) on each wear pad.
G10-55A, G12-55A
3-7
Boom 32. Remove the top rear wear pads, spacers, shims and hardware (30) from the rear of the second boom section. 33. Remove the left (or right) side rear wear pad, spacer, shims and hardware (31) from the rear of the second boom section.
3.5.2
Third & Fourth Boom Section Removal
1
1
2
2
34. Pull each boom section slightly forward to relieve the tension in retract chain (32). 35. Remove the snap rings and pin connecting the rear retract chain (32) from the chain clevis at the rear of the boom. Allow chain to hang out over the rear of the boom. 36. Place a sling around the second boom section. With a suitable lifting device, slowly pull the second, third and fourth boom sections approximately 25% out of the first boom section. 29
29 28
28
2
2
MY4150
Note: Tag each wear pad, spacer, shim and hardware from each location. Note the location of any grease fitting (if equipped) on each wear pad. 1. Remove the top rear wear pads, spacers, shims and hardware (1) from the rear of the third boom section. 2. Remove the left (or right) side rear wear pad, spacer, shims and hardware (2) from the rear of the third boom section.
28
28 30
30
3. Verify all disconnected hoses, tubes and fittings are capped and/or plugged.
3 MY4140
37. With the second, third and fourth boom section still connected to a suitable lifting device, remove all wear pads, spacers, shims, and hardware (28) from the front sides of the first boom section. 38. Remove both wear pads, spacers, shims, blocks and hardware (29) from the front top of the first boom section. 39. Remove both wear pads, spacers, shims and hardware (30) from the front bottom of the first boom section. 40. Adjust sling(s) around the second boom section to help balance the second, third and fourth boom sections. 41. Remove the remainder of the second, third and fourth boom sections from the first boom section and set on suitable supports.
3-8
MY3590
4. Pull each boom section slightly forward to relieve the tension on the retract chain (3). 5. Remove the snap rings and pin connecting the rear retract chain (3) from the chain clevis at the rear of the boom. Allow chain to hang out over the rear of the boom.
G10-55A, G12-55A
Boom 6. Place a sling around the third boom section. With a suitable lifting device, slowly pull the third and fourth boom sections approximately 25% out of the second boom section.
5
5
4
4
4
4
6 7
6 MY3450
7. With the third and fourth boom section still connected to a suitable lifting device, remove all wear pads, spacers, shims, and hardware (4) from the front sides of the second boom section. 8. Remove both wear pads, spacers, shims, blocks and hardware (5) from the front top of the second boom section. 9. Remove both wear pads, spacers, shims and hardware (6) from the front bottom of the second boom section. 10. Loosen and remove the wear pad support plate (7) from the bottom front of the second boom section. 11. Adjust sling(s) around the third boom section to help balance the third and fourth boom sections. 12. Remove the remainder of the third and fourth boom sections from the second boom section and set on suitable supports.
G10-55A, G12-55A
3.5.3
Fourth Boom Section Removal
1. Place a sling around the fourth boom section and slowly pull the fourth boom section approximately 25% out of the third boom section. Lower the fourth section boom head onto a suitable support.
9
9
8
8
8
8
9
9
10
MY3510
2. With the fourth boom section still connected to a suitable lifting device, remove all wear pads, spacers, shims, and hardware (8) from the front sides of the third boom section. 3. Remove top and bottom front wear pads, shims and blocks (9) from the third boom section. 4. Loosen and remove the wear pad support plate (10) from the bottom front of the third boom section. 5. Adjust the sling(s) around the fourth boom section for stability. Balance the fourth boom section and slowly pull the fourth boom section out of the third boom section being careful not to damage any surrounding components. 6. Lower the fourth boom section onto a suitable support.
3-9
Boom
3.5.4
Hose Carrier Removal 1
2
C
11 12
13
13 MY3630 MY3470
1. Remove the guide bracket (11) at the front of the hose carrier (12). Reuse the existing hardware. 2. Loosen and remove the front two mounting bolts (13) holding the hose carrier in place. Tag all hardware. 3. Remove the hose carrier through the front of the fourth boom section. 4. When the hose carrier is approximately 25% free of the fourth boom section, fasten the two hose carriers together (using nylon tie-wraps or nylon straps) to prevent separation.
2. Install the previously removed extend chain assembly and clevis (1) at the top rear of the fourth boom section. Allow 0.250 in (6,35 mm)(C) between the end of the clevis (1) and the face of the lock nut (2). Torque lock nut to 100 lb-ft (135 Nm). 5
5
4
4
3
3
5. Continue to remove the hose carrier, fastening the hose carriers together as they are being removed. 6. When the hose carrier is approximately 75% tied together, pull the assembly free of the boom section. 7. Lower the hose carrier onto a suitable support.
MY3490
3. Install the previously removed wear pads, spacers and shims at the bottom rear of the fourth boom section (3). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
14
FRONT OF BOOM
MY3610
8. Remove the hose carrier guide bracket from the inside of the fourth boom section (14).
3.5.5
Fourth Boom Section Assembly
1. Place the fourth boom section onto suitable supports. 3-10
4. Install the previously removed wear pads and spacers at the top rear of the fourth boom section (4). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 5. Install the previously removed wear pad and spacer on each side of the fourth boom section (5). Snug mounting bolts. Shim as needed AFTER boom section is installed.
G10-55A, G12-55A
Boom 3.5.6
Hose Carrier Installation 14
6
6
13
MY3610
FRONT OF BOOM
MY3480
1. Inspect the hose carrier track (6) for any broken or missing clips. Repair or replace as needed. 2. Remove the caps from the tubes on the hose carrier. 10
11
8
9. Install the previously removed hose carrier guide bracket (13). Torque as required. 10. Install the hose carrier (14) into the front of the fourth boom section. Remove each nylon tie or nylon strap as the hose carrier is installed. 11. Align the hose carrier (14) to the hose carrier guide bracket (13).
9
7
12
12
15 MY3750
MY3470
Note: Connect the tilt cylinder hoses and the auxiliary hoses to the hose carrier bulkhead before installing the hose carrier in the fourth boom section. 3. Install tilt cylinder hose (7) to the bottom left fitting on the hose carrier tube (8).
12. Align the hose carrier mounting bracket and install the previously removed hardware to mounting bracket at the front of the fourth boom section (15). Torque as required.
4. Install tilt cylinder hose (9) to the top left fitting on the hose carrier tube (10). 5. Install adaptors (11) to each auxiliary tube at the front right of the hose carrier. 6. Install auxiliary hoses (12) to each adaptor (11) no the auxiliary tubes at the front right of the hose carrier. 7. Orient each auxiliary hose (12) as shown above. 8. Torque each fitting and hose as required. G10-55A, G12-55A
3-11
Boom 4. Install the previously removed wear pads (3) at the bottom rear of the third boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
17 16
5. Install the previously removed wear pads and spacers (4) at top rear of the third boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
MY3480
6. Shims may be required to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap at the top rear of the third boom section.
13. Install guide bracket (16) P/N using the previously removed hardware (17). Torque as required.
3.5.7
C
5
6
Third Boom Section Assembly
Note: Inspect and lubricate all extend and retract chains before re-assembly. Refer to Section 3.12.1, “Boom Chain Inspection,” for detailed information. Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section. 1. Place the third boom section onto suitable supports. 4
4
2
2
1
MY3630
7. Install the previously removed extend chain assemblies and clevises (5) at the top rear of the third boom section. Allow 0.250 in (6,35 mm) between the end of the clevis (5) and the face of the lock nut (6). Torque lock nut to 100 lb-ft (135 Nm).
3.5.8
Fourth Boom Section Installation
Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section. 3
3 MY3500
2. Install the previously removed chain roller (1) at the rear of the third boom section. Insert the mounting pin, retainer plate and hardware. Torque as required. 3. Install the previously removed wear pads and spacers (2) at each side rear of the third boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
3-12
1. Clean and lubricate the bottom of the fourth boom section where the wear pads of the third boom section contact the fourth boom section. 2. Place the sling, or two slings for better stability, around the fourth boom section and slowly insert the fourth boom section into the third boom section being careful not to damage any surrounding components.
G10-55A, G12-55A
Boom 6. Install the previously removed wear pads, spacers and shims at the bottom front of the third boom section (11). Snug mounting bolts. 7
7
8
8
Note: Longer bolts (12) may be required to fully engage the threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to page 6, Wear Pad Installation and Lubrication for detailed information.
3.5.9 8
8
MY3510
1. Place the second boom section onto suitable supports. 14
14
15
15
3. Install the previously removed wear pad support plates and spacers (7) with existing hardware at the inside top front of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 4. Install the previously removed wear pads, spacers and shims on each side at the front of the third boom section (8). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
Second Boom Section Assembly
13
16
16 MY4160
2. Install the previously removed chain roller (13) at the rear of the second boom section. Insert the mounting pin, retainer plate and hardware. Torque as required. 3. Install the previously removed wear pads and spacers (14) at the top rear of the second boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
9
11
11 MY3510
12
10
10
12
5. Install the previously removed wear pad support (9) at the front inside of the third boom section. Use the previously removed hardened washers and bolts (10). Torque as required.
G10-55A, G12-55A
4. Install the previously removed wear pads and spacers (15) at each side rear of the second boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 5. Install the previously removed wear pads and spacers (16) at the bottom rear of the second boom section. Snug mounting bolts. Shim as needed AFTER all boom sections are installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 6. Shims may be required to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap at the top rear of the second boom section 3-13
Boom 3.5.10
6. Retract the second boom section pulling both retract chains at the same time.
Third & Fourth Boom Section Installation
Note: Refer to Section 2.2, “Torque Charts,” for standard bolt torque information. Note: Refer to Section 2.2.3, “Hydraulic Hose Torque Chart,” for standard hose torque information. Note: Apply Loctite® 242 to all boom assembly bolts.
25
25
26
26
Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section. 1. Place the sling or using two slings for better stability, around the third boom section and slowly insert the third and fourth boom sections into the second boom section being careful not to damage any surrounding components. 21 22
17
20 18
MY3450
7. Install the previously removed wear pad support plates and spacers (25) with existing hardware at the inside top front of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. Note: Longer bolts may be required to fully engage the threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication.”
18
19 MY3540
2. Install adjusting block (17) using existing hardware (18). Torque as required. 3. Install chain & clevis (19), spring (20), spring stop (21), adjusting nut and lock nut (22). A
8. Install the previously removed wear pads, spacers and shims on each side at the front of the second boom section (26). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections.
24
23
27
MY3650
4. Allow 0.50 in (1,27 mm)(A) between the end of the clevis (23) and the face of the lock nut (24). Torque lock nut to 100 lb-ft (135 Nm).
28
28
29
29
5. Properly connect the battery.
MY3450
30
3-14
30
G10-55A, G12-55A
Boom 9. Install the wear pad support plate (27) with existing hardware at the inside front of the second boom section.
3 2
3
2 1
2
2
10. Install the previously removed wear pads, spacers and shims at the bottom front of the second boom section (28 & 29). Snug mounting bolts. Note: Longer bolts (30) may be required to fully engage the threaded inserts in the wear pads without allowing bolts to protrude past the chamfer on the wear pads. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication.”
1
11. Manually retract the boom sections as required to connect the retract chains. MY4140
31
2. Install the previously removed wear pads, spacers and shims at the bottom front of the first boom section (1). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 3. Install the previously removed wear pads, spacers and shims on each side at the front of the first boom section (2). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. MY3590
12. Install the bracket and clevis assembly (31) at the rear of the fourth boom section. Torque mounting bolts.
3.5.11
Second, Third and Fourth Boom Section Installation
Note: Using a straight bar approximately 40 in (1041 mm) long will aid in the installation of the wear pads located on the inside front of each boom section.
4. Install the previously removed wear pads, spacers and shims at the top front of the first boom section (3). Snug mounting bolts. Shim as needed AFTER boom section is installed to maintain a 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the boom sections. 5. Re-adjust the sling(s) and push the second, third and fourth boom assembly the remainder of the way into the first boom section.
1. Place the sling or using two slings for better stability, around the second boom section and slowly insert the second, third and fourth boom sections into the first boom section being careful not to damage any surrounding components and allowing sufficient room to install the wear pads at the front of the first boom section.
G10-55A, G12-55A
3-15
Boom 11. Install both hose sheave covers (9).Torque mounting bolts as required. 10
11
5
4
MY3440
MY3590
6. Connect the rear retract chain (4) to the chain clevis with the previously removed pin at the rear of the third boom section. Secure the pin with the previously removed snap rings. 7. Pull hose carrier from the rear as far as possible to access the hydraulic and if equipped, the electrical connections. 8. If equipped, connect the electrical cable (5) to the fitting on the hose carrier.
12. Connect the fourth boom section extend chain (10) to the clevis at the top front of the third boom section and adjust to the previously measured setting. Do Not tighten the lock nut at this time. 13. Connect the third boom section extend chains (11) to the clevises at the top front of the second boom section and adjust to the previously measured setting. Do Not tighten the lock nut at this time. 14. Grease all wear pad at the rear of the boom using the zerk fittings. 15. Refer to Section 3.7, “Boom Section Separation Adjustment,” for proper boom section adjustments.
3.6
EXTEND/RETRACT CHAIN REMOVAL/INSTALLATION
8 7
6
3.6.1
Retract Chain Removal
The following section explains the removal of the retract chains without removing the boom assemblies.
9
Note: The retract chain on the bottom of the boom must be removed to gain access to the inner retract chain. 9
MY3420
9. Remove any caps and plugs from the tilt and auxiliary hoses at the rear of the boom assembly. Connect and tighten the tilt (6) and auxiliary hoses (7) to their proper fitting locations on the hose carrier. Torque as required. 10. Install the hose carrier bracket (8) at the rear of the third boom section and the hose carrier. Torque mounting bolts as required. 3-16
To remove the retract chain from the third to first boom sections: 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery.
G10-55A, G12-55A
Boom 4. Attach a suitable sling to the extend/retract cylinder. Remove the extend/retract cylinder support. 5. Remove the rod end pin and lower the cylinder onto the frame rails. Lowering the extend/retract cylinder will allow access to the chains. 4
3.6.2
Retract Chain Installation
Inspect and lubricate chains thoroughly before installation. Articulate the chains to make sure all working surfaces are thoroughly lubricated. Note: If the inner retract chain was removed, it must be installed first. 1. Fasten a rope to the end of the 3/4 in. chain in order to pull it back into the boom.
MX0510
1
2
3
6. Remove tension from the chain by backing off the jam nut and adjusting nut (1). 7. Remove the four bolts (2) from the chain adjustment block. 8. Remove the chain from the clevis (3) at the block. 9. Install a nylon tie wrap through the holes of the removed chain, making a loop with a tie wrap and tie a rope to the loop.
2. Attach the chain to the chain clevis at the rear of the boom. 3. Carefully pull the chain into the boom until it can be fastened to the chain clevis. 4. Remove the rope. 5. Fasten the chain into the clevis by installing the pin and retaining ring. 6. Torque the jam nuts to 100 lb-ft (135 Nm). To install the outer retract chain: 1. Fasten a rope to the end of the chain in order to pull it back into the boom.
10. At the rear of the boom, pull the chain to the rear to allow slack for removal.
2. Attach the chain to the chain clevis at the rear of the boom.
11. Remove the chain from the clevis and drop it free from the boom.
3. Carefully pull the chain into the boom until it can be fastened to the chain clevis.
12. Holding a rope at the front adjustment block, carefully pull the chain out through the back of the boom.
4. Remove the rope.
13. Untie the rope and leave it in place for reinstallation of the chain.
6. Install the chain adjustment block and mounting bolts. Torque the chain adjustment block mounting bolts to 360-390 lb-ft (475-530 Nm).
To remove the retract chain from the fourth to second boom sections: 1. Remove the jam nut (4) from the chain clevis installed in the chain adjustment block. 2. Back off the adjusting nut fully on the chain clevis. Do not remove the nut from the clevis.
5. Fastened the chain into the clevis by installing the pin and cotter pin.
7. Install the extend/retract cylinder and cylinder support. 8. Adjust the retract chains as needed. Refer to Section 3.7, “Boom Section Separation Adjustment.” 9. Properly connect the battery.
3. Remove the chain from the clevis, install a nylon tiewrap through the holes in the chain, making a loop with the tie-wrap and tie a rope to the loop.
10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
4. Move to the back of the boom and pull the chain to the rear to allow slack for removal.
3.6.3
5. Remove the chain from the clevis and drop it free from the boom. 6. Holding the rope at the front, carefully pull the chain out through the back of the boom until it’s free. 7. Untie the rope and leave it in place for reinstallation of the chain. G10-55A, G12-55A
Extend Chain Removal
The following section explains the removal of the extend chains without removing the boom assemblies. 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom, extend the boom far enough to access the chain anchor and the clevis through the top rear access hole, shut the engine OFF. 3-17
Boom 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Secure the boom sections together to prevent uncontrolled boom run out when the extend chains are removed. 5. On the chain being removed, loosen and remove the jam nut from the rear chain clevis and back off the adjusting nut on the chain clevis to the end of the threads. Do not completely remove the nut.
9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
3.7
BOOM SECTION SEPARATION ADJUSTMENT
1. Start the machine and verify the boom is in a horizontal (level) position. 2. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract the boom. 3. Shut machine OFF.
6. Remove the chain clevis pin and retaining ring to free the chain. 7. Install the nylon tie wrap through the holes in the chain, making a loop with the tie wrap and tie a rope to the loop. 8. Pull the slack to the chain clevis at the front of the boom. 9. Remove the clevis pin and the retaining ring from the chain and chain clevis. 10. Install a nylon tie wrap through the chain holes, forming a loop and tie a rope to the loop.
D
11. Carefully pull the chain out of the boom. 12. Untie the rope and leave it in place for reinstallation of the chain.
3.6.4
1
Extend Chain Installation
The following section explains the installation of the retract chains without removing the boom assemblies. Inspect and lubricate chains thoroughly before installation. 1. Fasten the previously used rope to the end of the extend chain. 2. Carefully pull the chain into the boom to the chain clevis anchor. 3. Fasten the chain to clevis with a pin and cotter pin. 4. At the other end of the chain, connect the chain to the clevis fastening the chain to the clevis with a pin and retaining ring. 5. Install the chain clevis fastening and adjusting hardware on both ends. 6. Remove any clamping devises being used to keep the boom sections from moving. 7. Properly connect the battery. 8. Adjust the extend chains as needed. Refer to Section 3.7, “Boom Section Separation Adjustment.”
3-18
1
MY3800
4. Measure the gap (D) between the flat washer at the extend chain anchor on the top front of the first boom section and the second boom section. If the gap is greater that 0.375 in (9.52 mm), the boom chains will need to be adjusted. Adjust the extend chain as follows: 1. Loosen the lock nut (1) on each of the extend chains. 2. Tighten the adjusting nuts on the first boom section until the gap (D) between the flat washers and boom is 0.375 in (9,52 mm) maximum. The gap must be equal on both chains. Torque the lock nut to 100 lb-ft (135 Nm). Note: Verify the exposed threads on both extend chain clevises are kept equal. 3. Tighten the adjusting nut on the second boom section until the gap (D) between the washer and boom is 0.375 in (9,52 mm) maximum. Torque the lock nut to 100 lb-ft (135 Nm). G10-55A, G12-55A
Boom
3
2 4
Note: BOTTOM OF BOOM SHOWN WITH EXTEND/RETRACT CYLINDER REMOVED FOR CLARITY MY3810
MY3820
4. After adjusting, check to see that the boom sections and access holes (2) are aligned. If they are not, the retract chain will need to be adjusted as well. Adjust the retract chain as follows:
3. Loosen the second to third boom section retract chain lock nut and adjusting nut (3) as far as possible. 4. Loosen the third to fourth boom section retract chain lock nut and adjusting nut (4) as far as possible.
1. Fully retract the boom.
5. Tighten the retract chain adjusting nut (3) until the proper distance (E) is obtained and proper access hole alignment (2) is obtained.
F
6. Torque the lock nut to 100 lb-ft (135 Nm). 7. Recheck the extend chain adjustments and readjust if necessary. 8. Measure the distance between the third boom section and fourth boom section (F). The dimension should be: G10-55A - 17.5-17.75 in (444,5-451,3 mm) G12-55A - 18.5-18.75 in (469,9-476,7 mm) 9. Tighten the retract chain adjusting nut (4) until the proper distance (F) is obtained and proper access hole alignment (2) is obtained. 10. Torque the lock nuts to 100 lb-ft (135 Nm). E
MY3790
11. Re-adjust the extend chains as needed.
2. Measure the distance between the second boom section and the third boom section (E). The dimension should be 0.50-0.75 in (12,7-19,5 mm).
G10-55A, G12-55A
3-19
Boom
3.8
HOSE CARRIER ASSEMBLY REMOVAL/INSTALLATION 3
The hose carrier assembly locates primarily in the fourth boom section. It is fastened at the bottom front of the fourth boom section and at the rear of the third boom section.
3.8.1
Hose Carrier Assembly Removal
1
1. Remove any attachment from the quick switch assembly. Refer to the appropriate operation and safety manual. Note: Allow adequate room in front of the machine when removing and installing the hose carrier assembly. 2. Park the machine on a hard, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
MY2710
2
9. Loosen and remove both cap screws and locknuts (2) from the hose carrier bracket at the front of the fourth boom section. 10. Loosen and remove the guide bracket (3) from the front of the fourth boom section.
3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the engine cover. Allow the system fluids to cool. 4
5. Properly disconnect the battery. 1
MY2720
1 MY2690
6. Loosen and remove both compression springs (1) from the hose take-up weldment at the bottom of the first boom section.
11. Loosen and remove the hose carrier bracket (4) at the rear of the third boom section. FRONT
7. Label and disconnect the tilt and auxiliary hydraulic hoses attached to the hose carrier at the rear of the boom and at the front of the boom head. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system. 8. If equipped, label and disconnect any electrical connections at the front and rear of the boom assembly. Note: Tag or identify each hose to the corresponding fitting it was removed from.
3-20
MY2700
5
12. Install a sling around the hose carrier at the front of the boom. With a suitable lifting device, slowly pull the hose carrier loose from the bottom bracket (5) located approximately halfway in the fourth boom section.
G10-55A, G12-55A
Boom 13. When the hose carrier is pulled approximately 25% out of the boom, fasten the two hydraulic carriers together using plastic tie wraps or nylon straps to keep them from separating. Note: Do Not wrap the hose carrier since it will not prevent the two hydraulic carriers from moving apart sideways.
3.8.3
Hose Carrier-Assembly Installation
1. Clean and lubricate the side surfaces where the hose carrier rides. 2. Fully collapse the hose carriers and secure together using plastic tie wraps or nylon straps to keep them from separating.
14. Continue withdrawing the hose carrier, fastening the two hydraulic carriers together.
3. Install a sling around the balance point of the hose carrier. With a suitable lifting device, slowly insert the hose carrier into the front of the fourth boom section.
15. With the two hose assemblies tied together, remove the hose carrier and set on the ground or proper supports.
4. Remove the first plastic tie wrap or nylon strap as the hose carrier is being inserted into the front of the fourth boom section.
3.8.2
Assembling the Hose Carrier Assembly
5. Continue inserting the hose carrier and removing the plastic tie wraps or nylon straps until the hose carrier is fully inserted into the boom.
The following procedure is described with the assumption that all components have been removed and assembly proceeding from the beginning. 1
MY2740
6. Install the guide bracket (1) on the front of the hose carrier. MY2730
FRONT
1. Place both sections on a suitable stand or support. 2. Install the wear pad to the bottom of the upper hydraulic carrier. 3. Install the bulkhead fittings to the each hydraulic carrier. 4. Install the tube assemblies to the bulkhead fittings on each hydraulic carrier. 5. Install the cushion clamps to the tube assemblies and secure to each hydraulic carrier. 6. Install the hose carrier to each hydraulic carrier and install each tilt hose and auxiliary hose to the proper fitting or tube connection. 7. Tie wrap the hydraulic hoses together where they extend from each end of the hose carrier. 8. Fasten the two hydraulic carriers together using plastic tie wraps or nylon straps for stability.
G10-55A, G12-55A
2
3
MY2700
7. Verify that the bottom bracket (2) on the hose carrier is in place on the bottom plate (3) of the fourth boom section. 8. Install the cap screws, washers and nuts to the hose carrier bracket at the rear of the third boom section. 9. Install both cap screws and locknuts to the hose carrier bracket at the front of the fourth boom section. 10. Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the rear of the hose carrier.
3-21
Boom 11. Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the front of the fourth boom section. 12. If equipped, reconnect any electrical connections at the front and rear of the boom assembly.
87 6
12
11
4
MY4470
5 9
MY2691
5
13. Install the hose take-up compression spring (4) on each hose take-up bracket (5) at the bottom of the first boom section. Install the washer (6), adjusting nut (7) and jam nut (8). Tighten the adjusting nut (7) to compress the hose take-up compression spring to measure 3 in (76,20 mm)(9). Refer to Section 3.8.4, “Boom Hose Adjustment,” if required. 14. Torque the jam nut (8) against the adjusting nut (7) to 100 ft-lbs (135,5 Nm). 15. Properly connect the battery. 16. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
3.8.4
5. Verify the auxiliary hoses and/or tilt hoses are NOT touching the bottom of the second boom section by viewing the auxiliary hoses and/or tilt hoses through the access hole (10) in each side of the second boom section.
Boom Hose Adjustment
1. Park the machine on a hard, level surface, level the machine, fully extend the boom, lower the boom head to the ground, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Verify any trapped hydraulic pressure in the auxiliary circuit and the tilt circuit is relieved. 4. Open the engine cover. Allow the system fluids to cool.
6. Verify that 4 in (101,6 mm) of slack (11) is present between the hose take-up bracket (5) and the first hose clamp (12). 7. Verify the hose take-up bracket (5) is not bent and is at an 85° angle to the hose. Note: Replace both auxiliary hoses and/or tilt hoses if the hoses are touching the bottom of the second boom section AND 4 in (101,6 mm) of slack is present between the hose take-up bracket and the first hose clamp. 8. Refer to Section 3.8.3, “Hose Carrier-Assembly Installation,” step 13 and 14 for hose take-up bracket adjustment. 9. Measure the slack (11) at the lowest point between the hose take-up bracket (5) and the first hose clamp (12). The 4 in (101,6 mm) measurement is from the bottom of the first boom section to the top of the hose. 10. If necessary, loosen the hose clamp (12), pull the auxiliary hoses and/or the tilt hoses, tighten the hose clamp for additional clearance. 11. Replace the auxiliary hoses and/or the tilt hoses if the proper slack, 4 in (101,6 mm)(11) cannot be achieved. 12. Start the machine, raise the boom to level, cycle the extend/retract cylinder, fully extend the boom. 13. Cycle the auxiliary circuit and/or the tilt circuit, verifying the auxiliary hoses and the tilt hoses are NOT touching the bottom of the second boom section and the proper slack, 4 in (101,6 mm) is maintained. 14. Retract the boom and shut engine OFF. 15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
10
3-22
MY4480
G10-55A, G12-55A
Boom
3.9
QUICK SWITCH ASSEMBLY
3.9.3
Quick Switch Removal
S/N 0160037689 & After
3.9.1
Quick Switch Removal 14
Before S/N 0160037689 7
9 13
8
2 6 1
11 12 10 4
5 3
MY5080
1. Remove the lock bolt (1) holding the tilt cylinder rod end pin (2) to the quick switch assembly (3). Remove the Tilt Cylinder pin. 2. Support the quick switch assembly (3).Remove the capscrew (4) and locknut (5) securing the head pin (6) to the boom head (7). 3. Inspect the above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired the pin must be replaced.
3.9.2
Quick Switch Installation
1. Assemble the quick switch assembly (3) to the boom head (7). Line up the quick switch between the mounts on the boom head. The quick switch should be centered in the boom head. 2. Coat the quick switch head pin (6) with an anti-seize compound. Insert the quick switch head pin through the quick switch and boom head. Secure with the previous capscrew (4) and locknut (5). 3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin (2). Align the tilt cylinder pin and screw in the locking bolt (1). Torque as required.
G10-55A, G12-55A
MY5090
1. Remove the lock bolt (8) holding the tilt cylinder rod end pin (9) to the quick switch assembly (10). Remove the Tilt Cylinder pin. 2. Support the quick switch assembly (10).Remove the capscrew (11) and locknut (12) securing the head pin (13) to the boom head (14). 3. Inspect the above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired the pin must be replaced.
3.9.4
Quick Switch Installation
1. Assemble the quick switch assembly (10) to the boom head (14). Line up the quick switch between the mounts on the boom head. The quick switch should be centered in the boom head. 2. Coat the quick switch head pin (13) with an antiseize compound. Insert the quick switch head pin through the quick switch and boom head. Secure with the previous capscrew (11) and locknut (12). 3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin (9). Align the tilt cylinder pin and screw in the locking bolt (8). Torque as required.
3-23
Boom
3.10
BOOM HEAD - MOUNTED WINCH
3.10.1
3.11
Boom Head-Mounted Winch Removal 3
BOOM WEAR PADS
The wear pads on this machine are flat rectangular wear pads with metal inserts. A total of 42 wear pads are installed on the boom sections of the G10-55A and the G12-55A machines.
3.11.1 6
Wear Pad Inspection
1
1
4 5 Ma2070
MY3710
1. Using a suitable lifting device, secure the winch assembly (4) with a nylon strap. 2. Disconnect the hydraulic hoses (5). 3. Loosen and remove the mounting bolts, washers and nuts (6)(not shown). 4. Lower the winch assembly (4) onto a suitable skid or table.
3.10.2
Boom Head-Mounted Winch Installation
Inspect all wear pads for wear. If the angle indicators (1) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.
3.11.2
Wear Pad Installation and Lubrication
Note: Inspect all wear pads. Replace as necessary. The following wear pad procedure must be followed to insure the proper wear pad installation: • The wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Loctite® 242 and installing mounting bolts. • Apply Loctite® 242 to all wear pad mounting bolts. 4
1. Using a suitable lifting device, secure the winch assembly (4) with a nylon strap. 2. Raise the winch assembly (4) into position behind the boom head.
3 2
Loctite®
242 to the previously removed 3. Apply mounting bolts. 4. Install the mounting bolts, washers and nuts (6)(not shown). Torque to 200 lb-ft (271 Nm). 5. Connect the hydraulic hoses (5). MAM1390
• A spacer (2) with holes must be used before any shim (3) is used. • A shim (3) must be inserted between the spacer (2) and wear pad support plate, block or boom section (4). • The number of shims can vary at each shim point. • The bottom wear pads must be shimmed equally on each side.
3-24
G10-55A, G12-55A
Boom
5
BOOM EXTEND AND RETRACT CHAINS
3.12
5
3.12.1
Boom Chain Inspection
WARNING MY5510
• Maintain a total boom section clearance (5) of 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and vertical directions. A
B
MY3620
• The length of the wear pad bolt depends on the number of shims, spacers and washers being used. • The thickness of each threaded wear pad insert is 0.312 in (7,92 mm)(A). • The bolt length should be determined by measuring the distance from the face of the insert to the face of the boom (B) including any spacer, shim(s) and washer(s). • Bolt thread engagement in the wear pad insert should be 0.275 ± 0.040 in (6,98 ± 1,0 mm). • One or two hardened washers are to be used on each wear pad bolt except where noted otherwise. DO NOT use more than two hardened washers. • Use only one hardened washer if mounting bolts are recessed. • Wear Pad Bolt Torque: 3/8 - 24 Bolt, 32 - 37 lb-ft (43 - 50 Nm) 3/8 - 24 Hollow Bolt, 15 - 17 lb-ft (20 - 23 Nm) 1/2 - 20 Bolt, 76 - 86 lb-ft (103 - 116 Nm) 1/2 - 20 Hollow Bolt, 45 - 50 lb-ft (61 - 68 Nm) • Torque wear pad bolts after shimming is completed. • Lubricate the face and pockets of each wear pad after being installed.
Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or machine instability. Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains need to be exposed and inspected every 1000 hours of operation. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions and require more frequent inspection intervals. Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows: • Moisture - Corrosive rusting reduces chain strength by pitting and cracking. • Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation. • Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time. • Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins an d plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.
Boom Section Wear Pad Pathway Lubrication: • Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease. 6. Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.
G10-55A, G12-55A
3-25
Boom Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain.
Edge Wear
• High velocity movement of load, followed by sudden, abrupt stops. • Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. • Attempting to “inch” loads which are beyond the rated capacity of the vehicle. The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted. The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3%. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation.
3.12.2
Inspection Guidelines
1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park brake switch. 2. Fully extend the boom until the extend chain is taut. Shut the engine off. 3. The extend chains will be visible for inspection with the vehicle in this state. 4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.
2
1
MZ1463
Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave. If the measured plate height (1) is 5% less than the normal plate height (2), discard and replace the chain. Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as the middle of the chains. It is best to measure in 12 pin increments from pin center to pin center. For example, if the links are one inch from pin center to pin center, the distance should be 12 in (305 mm). If the links are 3/4 in (19,0 mm) apart, the distance after 12 pins should be 9 in (228,6 mm). 4 3
5. Inspect the retract chains every 1000 hours of operation. 6. Inspect the chains for the following conditions:
MY1360
If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain.
3-26
G10-55A, G12-55A
Boom Cracked Plates
Distorted or Battered Link Plates
Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety.
85
It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself. The types of cracks are:
MZ1466
Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing. Turning or Protruding Pins Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.
7
6
8 MZ1465
Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (6). Chain with rotated/displaced heads (7) or abnormal pin protrusion (8) should be replaced immediately. DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored. Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.
G10-55A, G12-55A
• Fatigue Cracking Fatigue cracks (9) are a result of repeated cyclic loading beyond the chain’s endurance limit. • Stress Corrosion Cracking - The 10 outside link plates are particularly susceptible to stress corrosion cracking (10).
9 MZ1467
MZ1468
• Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress. Other Modes of Failure • Ultimate Strength Failure These types of failures are 11 caused by overloads far in excess of the design load. Either fractured plates (11) 12 or enlarged holes (12) can occur. If either of these failures occurs, the chain should be replaced immediately.
MZ1469
MZ1470
• Tight Joints - All joints in the chain should flex freely. Tight MZ1471 13 joints (13) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain.
3-27
Boom 3.12.3
Expose Chains for Inspection
d. Extend Chains 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom until both extend chains are taut. Shut the engine OFF. The extend chains will be visible for inspection with the machine in this state. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevises be replaced at the same time. e. Retract Chains The three retract chains are only partially visible through the rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary.
3.12.4
Chain Lubrication
After inspection and before being returned to service, chains must be lubricated with Mystik Tetrimoly Grease. The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links. To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces. Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation. Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often. Refer to Section 2.5, “Service and Maintenance Schedules,” and Section 2.6, “Lubrication Schedules,” for detailed information. Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. Contact the local distributor for guidance.
Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis’ be replaced at the same time.
3-28
G10-55A, G12-55A
Boom
3.13
FORKS
Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. Daily Inspection 3 6 7
5
4
2 1
9 8 11
10
MH6460
1. Inspect forks (1) for cracks, paying special attention to heel (2) and mounting tubes (3). 2. Inspect forks for broken or bent tips (4) and twisted blades (5) and shanks (6). Yearly Inspection 1. Straightness of the upper face of blade (5) and the front face of shank (6) should not exceed 0.5 percent of the length of blade or height of shank. 2. Angle (7) between upper face of blade and front face of shank should not exceed 93 degrees. 3. Thickness of blade (8) and shank (9) should not be reduced to 90 percent of original thickness. Note: Contact the local distributor with the fork part number to find the manufactured dimensions of the fork blade. 4. Ensure fork length (10) is adequate for intended loads. 5. Fork markings should be legible, re-stamp if required. 6. Compare fork tips (11) when mounted on a carriage. Maximum difference in height of fork tips is 3 percent of the length of the blade (10).
G10-55A, G12-55A
3-29
Boom
3.14
TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that occur during operation of the boom.
Problem 1. Boom will not extend or retract
Cause
Remedy
1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.
1. Locate break, replace hose(s) or tube(s), tighten connections.
2. Extend/retract hydraulic system not operating properly.
2. Refer to Section 8.4, “Hydraulic Circuits.”
3. Faulty extend/retract cylinder.
3. Repair cylinder, Refer to Section 8.8, “Hydraulic Cylinders.”
2. Boom shifts to right or left when extending.
1. Boom side wear pads improperly shimmed or worn.
1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.11, “Boom Wear Pads.”
3. Excessive boom pivot pin noise and/or wear.
1. Insufficient lubrication.
1. Lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.” Replace worn pins as needed.
2. Worn bearing(s).
2. Replace bearing(s) and lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.”
1. Insufficient lubrication.
1. Lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.” Replace worn pins as needed.
2. Worn bushing(s).
2. Replace bushing(s) and lubricate at regular intervals.
4. Excessive Compensation cylinder pivot pin noise and/ or wear.
3-30
G10-55A, G12-55A
Boom
Problem 5. Drooping chain, or jerky boom extend or retract functions.
6. Boom will not raise or lower.
7. Excessive Lift/Lower cylinder pivot pin noise and/or wear.
G10-55A, G12-55A
Cause
Remedy
1. Chain(s) tension not properly adjusted.
1. Adjust chain(s).
2. Chain(s) stretched or binding.
2. Replace chains as needed. Refer to Section 3.7, “Boom Section Separation Adjustment.”
3. Wear pads loose, contaminated, excessively worn or damaged.
3. Replace wear pad. Refer to Section 3.11, “Boom Wear Pads.”
4. Contaminated, corroded or rusted wear pad sliding surfaces.
4. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).
5. Extend/Retract hydraulic system not operating properly.
5. Refer to Section 8.4, “Hydraulic Circuits.”
6. Damaged boom section.
6. Replace the damaged boom section. Refer to Section 3.3, “Boom Assembly Maintenance.”
1. Broken hydraulic hoses or tubes and/or connection leaks.
1. Locate break, replace hose(s) or tube(s), tighten connections.
2. Lift/lower hydraulic system not operating properly.
2. Refer to Section 8.4, “Hydraulic Circuits.”
3. Faulty lift/lower cylinder.
3. Repair cylinder. Refer toSection 8.8, “Hydraulic Cylinders.”
4. Seized boom pivot pin bearing.
4. Replace bearing.
1. Insufficient lubrication.
1. Lubricate at regular intervals. Refer to Section 2.5, “Service and Maintenance Schedules.” Replace worn pins as needed. Refer to Section 8.8, “Hydraulic Cylinders.”
2. Worn self-aligning bushing(s).
2. Replace bushing(s) and lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.”
3-31
Boom
Problem 8. Rapid boom pad wear.
9. Auxiliary hydraulics will not operate. 10. Excessive chain wear.
3-32
Cause
Remedy
1. Incorrect wear pad gap.
1. Check wear pad gaps and correct as needed. Refer to Section 3.11, “Boom Wear Pads.”
2. Rapid cycle times with heavy loads.
2. Reduce cycle times.
3. Contaminated, corroded or rusted wear pad sliding surfaces.
3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).
4. Operating in extremely dusty/ abrasive conditions.
4. Clean equipment frequently.
1. Auxiliary hydraulic system not operating properly.
1. Refer to Section 8.4, “Hydraulic Circuits.”
1. Improper chain adjustment.
1. Adjust to correct tension. Refer to Section 3.7, “Boom Section Separation Adjustment.”Replace chains as needed.
2. Chain sheave(s) not properly lubricated.
2. Lubricate chain sheave. (Refer to Section 2.5, “Service and Maintenance Schedules.”
3. Chain sheave(s) not rotating freely.
3. Lubricate chain sheave. Refer to Section 2.5, “Service and Maintenance Schedules.” Repair or replace chain sheave(s) as needed.
4. Improper chain lubrication.
4. Lubricate at regular intervals. Refer to Section 2.5, “Service and Maintenance Schedules.” Replace chains as needed.
G10-55A, G12-55A
Section 4 Cab and Covers
Contents PARAGRAPH 4.1 4.2
4.3
4.4 4.5
G10-55A, G12-55A
TITLE
Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Sway, Auxiliary and Outrigger Control Joysticks . . . . . . . . . . . . . 4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.7 Heater/Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-5 4-5 4-6 4-6 4-6 4-8 4-9
4-1
Cab and Covers
4.1
OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.
FRAME LEVEL INDICATOR STEERING WHEEL
HEATER AND A/C CONTROLS (OPTIONAL) BOOM CONTROL JOYSTICK
INSTRUMENT PANEL
SWAY CONTROL JOYSTICK AUXILIARY CONTROL JOYSTICK
TRANSMISSION CONTROL LEVER OUTRIGGER CONTROL JOYSTICK
IGNITION SWITCH
FUEL TANK
SERVICE BRAKE PEDAL ACCELERATOR PEDAL
4-2
MY0930
G10-55A, G12-55A
Cab and Covers
WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual.
4.2 4.2.1
OPERATOR’S CAB Cab Safety
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. Note: It may be necessary to remove the main dash panel to gain access to the appropriate hydraulic hoses. Refer to Section 9.11.1, “Analog Gauges.”
WARNING
2
The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value.
3
WARNING DO NOT weld, grind, drill, repair or modify the cab in any way. Any modification or damage to cab structural components requires cab replacement. Refer to page 2-9 in the Operators & Safety Manual.
4
To help ensure optimum safety, protection and performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.
4.2.2
Serial Number Decal
The cab serial number decal is located on the left side of the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.
4.3 4.3.1
CAB COMPONENTS Steering Column and Orbitrol Valve
a. Orbitrol Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF.
G10-55A, G12-55A
1 MY0121
5. Label, disconnect and cap the four hoses from the side of the steering valve (1). Cap the fittings on the steering valve. Label, disconnect and plug the load sense hose at the front of the steering valve. Cap the fitting on the steering valve. 6. Remove the steering wheel (2), disconnect and remove the travel select lever (3), disconnect the instrument panel harness connector (4). 7. Remove the steering assembly through the dash panel opening. 8. Support the steering valve, and remove the four hexhead capscrews and four lockwashers. Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective. 4-3
Cab and Covers b. Orbitrol Valve Installation 1. Secure the steering valve to the steering column with four hex-flange capscrews and four lockwashers. 2. Install the steering column through the dash panel opening. Position steering valve to its original orientation in the cab. 3. Install the travel select lever, connect the instrument panel harness connector, install the steering wheel assembly. Torque the steering wheel nut to 29-34 lb-ft (39-46 Nm). 4. Install new o-rings into the steering valve fittings. Lubricate the o-rings with clean hydraulic oil.
c. Service Brake Pedal Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
5. Uncap and connect the previously labeled load sense hose to the steering valve. 6. Uncap and connect the remaining previously labeled four hoses to the steering valve. Note: If necessary, install the main dash panel. Refer to Section 9.11.1, “Analog Gauges.” 7. Properly connect the battery 8. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.
3 1
9. Close and secure the engine cover. c. Steering Test Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.3.1, “Pressure Checks and Adjustments.”
4.3.2
Service Brake Pedal
a. Brake Valve Removal Refer to Section 8.7.3, “Service Brake Valve,” for removal information. b. Brake Valve Installation Refer to Section 8.7.3, “Service Brake Valve,” for installation information.
2 MY0140
5. Remove the bolt and lockwasher (1) securing the service brake pedal pivot pin (2). 6. Pull the pivot pin from the service brake pedal bracket (3). 7. Remove the service brake pedal from the cab. d. Service Brake Pedal Installation 1. Position the service brake pedal in its mounting location within the cab. 2. Secure the brake pedal into position with the pivot pin. 3. Be sure the brake pedal has the correct range of motion. Secure pivot pin with bolt and lockwasher. 4. Properly connect the battery. 5. Close and secure the engine cover.
4-4
G10-55A, G12-55A
Cab and Covers 4.3.3
4.3.4
Throttle Pedal
a. Throttle Pedal Removal
Boom Joystick Assembly
a. Boom Joystick Assembly Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.
3. Properly disconnect the battery.
3. Properly disconnect the battery.
7 6 5 4 MY0950
4. Lift the joysticks rubber sleeve, remove the bolts securing the boom joystick to the cab console (7). 5. Lift the boom joystick from its mounting position. 6. Label, disconnect and cap the hydraulic hoses attached to the boom joystick. 7. Disconnect the electrical harness connector from the joystick. MY0940
4. Disconnect the electrical harness connector (4). 5. Remove the bolts (5) securing the throttle pedal to the throttle pedal bracket (6). 6. Remove the throttle pedal assembly from the cab. b. Throttle Pedal Installation
8. Remove the boom joystick assembly. b. Boom Joystick Assembly Installation 1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 2. Connect the electrical harness connector to the joystick.
1. Position the throttle pedal in its mounting location within the cab.
3. Install the bolts securing the boom joystick to the cab console.
2. Secure the throttle pedal into position with the pivot pin.
4. Properly connect the battery.
3. Install the throttle pedal ball joint to the throttle pedal.
5. Test the boom extend/retract and boom lift/lower joystick function:
4. Connect the battery negative (-) cable to the battery negative (-) terminal. 5. Close and secure the engine cover.
G10-55A, G12-55A
4-5
Cab and Covers a. Move the joystick handle rearward, activating the boom lift function. The boom should RISE. b. Move the joystick handle forward, activating the boom lower function. The boom should LOWER. c. Move the joystick handle to the right, activating the boom extend function. The boom should EXTEND.
b. Joystick Installation 1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 2. Install the bolts securing the joystick to the cab. 3. Install the dash panel to its original position with the previously used hardware.
d. Move the joystick handle to the left, activating the boom retract function. The boom should RETRACT.
4. Properly connect the battery.
e. Depress the left side of the switch (optional) to activate the tilt up function. The attachment should TILT UP.
6. Close and secure the engine cover.
f. Depress the right side of the switch (optional) to activate the tilt down function. The attachment should TILT DOWN. 6. Close and secure the engine cover.
4.3.5
5. Test the complete range of the joystick functions:
4.3.6
Refer to Section 9.8, “Window Wiper/Washer Windshield Wiper Motor,” for removal and installation information.
4.3.7
Frame Sway, Auxiliary and Outrigger Control Joysticks
a. Joystick Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery.
Windshield Wiper Assembly
Heater/Air Conditioning System (if equipped)
Note: If machine is equipped with air conditioning, DO NOT loosen or disconnect any air conditioning hoses until the air conditioning system has been properly drained by the local distributor or certified air conditioning service center. a. Heater Assembly Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool.
9
4. Properly disconnect the battery. 5. Place a suitable container beneath the radiator. Slowly turn the radiator cap to the first stop, allow any pressure to escape. Remove the radiator cap. 8 MY0960
4. Remove the screws (8) securing the dash panel (9) to the cab. Remove the dash panel. 5. Remove any hardware securing the joystick to the cab. 6. Label, disconnect and cap the hydraulic fittings attached to the joystick. 7. Remove the joystick from the cab.
4-6
6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain petcock and allow the coolant to drain. 7. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility. 8. Tighten the radiator drain petcock. 9. Remove the bolts that secure the seat to the cab. Remove the seat.
G10-55A, G12-55A
Cab and Covers
HEATER WITH AIR CONDITIONING SHOWN
14
15
MY4390
11 10
MY0190
10. Remove the bolts securing the front plate (10) to the seat riser weldment (11). 11. Remove the bolts securing the seat riser weldment to the cab. Remove the riser weldment.
16
14
16
13
13. Loose the hose clamps securing the heater hoses (13). 14. Label and remove both heater hoses. 15. Label and disconnect any electrical connections (14). 16. Label and disconnect both air conditioning hoses (15). 17. Remove the bolts (16) securing the heater assembly to the cab. Remove the heater assembly. b. Heater Assembly Installation Note: If machine is equipped with air conditioning, the air conditioning system must be charged by the local JLG dealer or certified air conditioning service center. 1. Position the heater assembly to its original orientation in the cab. Secure with the previous hardware. 2. Connect the previously labeled electrical connections.
12 MAL0420
12. Loosen the hose and disconnect the heater air duct hoses (12).
3. Connect the previously labeled heater hoses to their appropriate locations. 4. Connect the previously labeled air conditioning hoses to their appropriate locations. 5. Install the seat riser weldment. 6. Install the front plate to the seat riser weldment. 7. Install the cab seat. 8. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluid and Lubricant Capacities.” 9. Properly connect the battery.
G10-55A, G12-55A
4-7
Cab and Covers
4.4
CAB REMOVAL
WARNING The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value. Note: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information. Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact the local distributor with any questions about the suitability or condition of a cab. Note: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine. 1. Park the machine on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF. 2. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab removal. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain petcock and allow the coolant to drain.
9. Remove the necessary dash panels to gain access to the electrical wiring connections. Label and disconnect the harnesses. Push the harness connectors through the opening in the cab. 10. Remove the boom joystick from is mounting position. Refer to Section 4.3.4, “Boom Joystick Assembly.” Label, disconnect and cap all hydraulic hoses attached to the boom joystick. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. 11. Remove the frame level and attachment tilt and auxiliary control joystick. Refer to Section 4.3.5, “Frame Sway, Auxiliary and Outrigger Control Joysticks.” Label, disconnect and cap all hydraulic hoses attached to the joystick. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. 12. Label, disconnect and cap all hydraulic hoses attached to the steering orbitrol valve. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. 13. Label, disconnect and cap all hydraulic hoses attached to the steering orbitrol valve. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. 14. Label, disconnect and cap all hydraulic hoses attached to the service brake valve. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. 15. Push all the hydraulic hoses through the opening in the cab. 16. Disconnect the throttle cable from the throttle assembly. Refer to Section 4.3.3, “Throttle Pedal.” 17. Disconnect the engine air filter and hydraulic oil reservoir breather from their brackets at the top of the cab. Move the air filter and breather clear from the cab so they do not become damaged during cab removal. 18. Remove the fuel tank from the cab. Refer to Section 7.6.2, “Fuel Tank.”
6. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility. 7. Tighten the radiator drain petcock. 8. Disconnect the cab heater hoses. Refer to Section 4.3.7, “Heater/Air Conditioning System (if equipped).”
4-8
G10-55A, G12-55A
Cab and Covers
13
24. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.
14
25. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame. Readjust the position of the sling as needed to help balance the cab during removal. 26. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is being removed from the machine.
15 MY0610
19. Open Cab: Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) under the inner four braces (13) and behind the center cross support above the wind shield or install two lifting eye bolts (14) in the threaded holes on the roof of the cab above the B pillars (15). 20. Enclosed Cab: Install two lifting eye bolts (14) in the threaded holes on the roof of the cab above the B pillars (15). Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) through the lifting eye bolts.
27. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition. 28. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.
4.5
CAB INSTALLATION
1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation. 13
14
16
16
15
MY0610
MY4170
17
17
21. Remove the two cab side-mount bolts in the cab (16). 22. Remove the four cab-to-frame bolts, flat washers and nuts (17).
2. Open Cab: Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) under the inner four braces (13) and behind the center cross support above the wind shield or install two lifting eye bolts (14) in the threaded holes on the roof of the cab above the B pillars (15). 3. Enclosed Cab: Install two lifting eye bolts (14) in the threaded holes on the roof of the cab above the B pillars (15). Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) through the lifting eye bolts.
23. Remove the mirrors and all other cab components as needed, if not previously removed. G10-55A, G12-55A
4-9
Cab and Covers 4. Use a hoist or overhead crane and sling attached to the cab. Carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation.
14. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluid and Lubricant Capacities.” 15. Properly connect the battery. 16. Start the engine and check the operation of all controls. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required. Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.
16
16
17. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level. 18. Install the mirrors and all other cab components as needed, if removed. 19. Close and secure the engine cover. 20. Unblock the wheels. 21. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
MY4170
17
17
5. Install the four cab-to-frame mount bolts, washers and nuts (17). Torque to 280-305 lb-ft (379-414 Nm). 6. Install the two cab side mount bolts washers and nuts (16). Torque to 680-720 lb-ft (922-976 Nm). 7. Install the engine air filter and hydraulic oil reservoir breather to their brackets at the top of the cab. 8. Install the throttle cable to the throttle pedal assembly. Refer to Section 4.3.3, “Throttle Pedal.” 9. Pull all the hydraulic hoses and electrical wires through the cab. 10. Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations. 11. Reconnect the previously labeled electrical connections to their appropriate locations. 12. For machines equipped with the heater option, reconnect the heater hoses to the cab heater. Refer to Section 4.3.7, “Heater/Air Conditioning System (if equipped).” 13. Install the fuel tank to the cab. Refer to Section 7.6.2, “Fuel Tank.”
4-10
G10-55A, G12-55A
Section 5 Axles, Drive Shafts, Wheels and Tires
Contents PARAGRAPH 5.1 5.2 5.3
5.4
5.5
5.6 5.7
G10-55A, G12-55A
TITLE
Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing a Disabled machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 5-2 5-3 5-3 5-3 5-3 5-3 5-3 5-4 5-4 5-6 5-9 5-9 5-9 5-9 5-9 5-9 5-10 5-10 5-11 5-11 5-11 5-11 5-12
5-1
Axles, Drive Shafts, Wheels and Tires
5.1
AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
REAR STEERING CYLINDER
TRANSMISSION DROP BOX REAR AXLE ASSEMBLY
REAR DRIVE SHAFT
FRONT STEERING CYLINDER
REAR AXLE WHEEL HUBS (2)
FRONT DRIVE SHAFT
FRONT AXLE ASSEMBLY
5-2
FRONT AXLE WHEEL HUBS (2)
MY0570
G10-55A, G12-55A
Axles, Drive Shafts, Wheels and Tires
5.2
GENERAL INFORMATION
WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information. Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace elastic locknuts and any damaged, worn, cracked, seized or otherwise improper parts that could affect the safe and proper functioning of the machine, axles and drive shafts.
5.3 5.3.1
AXLE ASSEMBLIES Axle Serial Number Plate
The front and rear axle serial number plate is located on a mounting pad on the front side of the center section of each axle. Information on the serial number plate is required in correspondence regarding the axle. Supply information from the axle serial number plate when communicating about an axle assembly or axle components.
5.3.2
Axle Specifications
5.3.3
Axle Internal Service
Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the Axle Repair Manual (P/N 31200240).
5.3.4
Axle Maintenance
CLEANING: Clean parts with machined or ground surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces. DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemical to help protect them from corrosion. If storing components for a prolonged period, wrap them in wax paper. PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity. SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary. Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly. If replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set.
General axle specifications are found in Section 2, “General Information and Specifications.”
G10-55A, G12-55A
5-3
Axles, Drive Shafts, Wheels and Tires 5.3.5
Axle Removal
The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly.
9. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal. 10. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.
Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machine. Avoid spraying water or cleaning solution on electrical components. If using a steam cleaner, seal all openings before steam cleaning.
11. Remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.5.1, “Removing Wheel and Tire Assembly from Machine.”)
Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.
Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern “arrows” facing in the direction of forward travel.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the optional fender assembly.
MY4180
2
1
1
2
6. If the axle will be disassembled after removal, place a suitable receptacle under the axle (1) and wheel hubs drain plugs (2). Remove the drain plugs and allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility. 7. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.
12. Remove the drive shaft assembly. Refer to Section 5.4.3, “Drive Shaft Removal.” 13. On the front axle remove the capscrew and locknuts securing the lower position cylinder-mount pin to the front cylinder. Tap the cylinder mount pin out, and move the cylinder to prevent it from interfering with axle removal. 14. Remove the bolts and locknuts securing the axle to the frame. 15. Remove the axles from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axle. Balance the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand.
5.3.6
Axle Installation
1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine. 2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation.
8. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding.
5-4
G10-55A, G12-55A
Axles, Drive Shafts, Wheels and Tires 3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure. 4. Position the axle under the frame, and align the axle housings with the holes in the frame. 5. Install the four axle bolts and nuts. Tighten and torque to 530-565 lb-ft (718-766 Nm). 6. Move the cylinder into position on the axle cylinder anchor. Insert a cylinder-mount pin through the cylinder and cylinder anchor. Secure the cylindermount pin with one capscrew and a new locknut. 7. Apply multi-purpose grease through the self-tapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin. 8. Install the drive shaft assemblies. (Refer to Section 5.4.5, “Drive Shaft Installation.”) 9. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission.
11. Rotate wheel hubs 90 degrees so the drain plug (2) becomes the fill plug (3). Refer to Section 2.4, “Fluid and Lubricant Capacities,” for proper oil and capacities. 12. Install the wheel and tire assemblies. Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto Machine.” 13. Carefully remove the jack, hoist or overhead crane and sling supporting the axle. 14. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground. 15. Remove the blocks from the front and rear of both tires on the other axle. Note: ALWAYS use new o-rings when servicing the machine. 16. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 17. Uncap and connect the steering and brake lines at their axle fittings. 18. Check the hydraulic reservoir oil level. 19. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary. 20. Install the optional fender assembly. 21. Close and secure the engine cover. 22. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
MY4180
2
1
2
1
Note: The service brake and parking brake circuits will need to bled after axle installation. Refer to Section 8.7.4, “Service Brake Bleeding.”
10. Tighten the axle oil drain plug, loosen and remove the axle oil fill plug (1). (Refer to Section 2.4, “Fluid and Lubricant Capacities,” for proper oil and capacities.
3 LEVEL
MY0220
G10-55A, G12-55A
5-5
Axles, Drive Shafts, Wheels and Tires 5.3.7
Axle Assembly and Drive Shaft Troubleshooting
Problem 1. Excessive axle noise while driving.
2. Intermittent noise when traveling.
3. Vibration or intermittent noise when traveling.
5-6
Cause
Remedy
1. Oil level too low.
1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Axle and/or wheel end housings filled with incorrect oil or oil level low.
2. Drain axle and/or wheel end housings and fill to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
3. Incorrect alignment of ring and pinion gears.
3. Correct alignment by adding or removing shims as needed.
4. Incorrect pinion (input) shaft bearing preload.
4. Correct bearing preload by adding or removing shims as needed.
5. Worn or damaged bearings.
5. Replace bearings as needed.
6. Worn or broken gear teeth.
6. Replace gears as needed.
7. Contamination in the axle.
7. Drain axle and/or wheel end housings and fill to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
8. Axle housing damaged.
8. Replace damaged parts.
1. Universal joint(s) worn or damaged.
1. Repair or replace universal joints as needed.
2. Differential ring and/or pinion gears damaged.
2. Determine cause and repair as needed.
1. Drive shaft universal joint assembly(ies) incorrectly tightened.
1. Tighten capscrews to correct torque.
2. Drive shaft universal joint(s) worn or damaged.
2. Repair or replace universal joints as needed.
3. Drive shaft(s) damaged/ unbalanced.
3. Replace drive shaft(s) as needed.
G10-55A, G12-55A
Axles, Drive Shafts, Wheels and Tires
Problem 4. Oil leaking from axle (differential housing and/or axle housings).
5. Oil leaking from wheel end housing (planet carrier).
6. Oil leaking from steering cylinder.
G10-55A, G12-55A
Cause
Remedy
1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.
1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).
2. Hose fittings loose.
2. Tighten fittings.
3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.
3. Replace seal and/or joint coupling fork shaft (axle shaft).
4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.
4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Engine Repair Manual.
5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.
5. Replace o-rings and seals.
6. Axle housing mounting nuts and capscrews loose.
6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm).
7. Differential and/or axle housing(s) damaged.
7. Replace housing(s) as needed.
1. Oil level plugs loose and/or o-rings damaged or missing.
1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).
2. O-ring between hub and housing (planet carrier) damaged or missing.
2. Replace o-ring.
3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.
3. Replace seal and/or fork joint shaft.
4. Housing capscrews loose.
4. Tighten housing capscrews to 41 lb-ft (55 Nm).
5. Housing (planet carrier) damaged.
5. Replace housing (planet carrier).
1. Hose fittings loose.
1. Tighten fittings.
2. Steering cylinder o-rings and/or seals worn or damaged.
2. Replace o-rings and seals.
3. Piston rod seal worn or damaged.
3. Replace piston rod seal.
4. Cylinder tube damaged.
4. Replace cylinder tube.
5-7
Axles, Drive Shafts, Wheels and Tires
Problem 7. Axle overheating.
8. High steering effort required.
9. Slow steering response.
10. Excessive noise when brakes are engaged.
11. Brakes will not engage.
12. Brakes will not hold the machine or braking power reduced.
5-8
Cause
Remedy
1. Oil level too high.
1. Fill oil to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.
2. Drain axle and fill to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
3. Dragging park brake.
3. Adjust park brake cable as needed.
1. Steering (hydraulic) system not operating properly.
1. Refer to Section 8.4, “Hydraulic Circuits.”
2. Excessive joint housing swivel bearing preload.
2. Correct bearing preload by adding or removing shims as needed.
3. Worn or damaged swivel bearings.
3. Replace swivel bearings as needed.
1. Steering (hydraulic) system not operating properly.
1. Refer to Section 8.4, “Hydraulic Circuits.”
2. Steering cylinder leaking internally.
2. Repair or replace steering cylinder as needed.
1. Brake discs worn.
1. Check brake discs for wear. Refer to Section 5.6, “Brakes.”
2. Brake discs damaged.
2. Replace brake discs.
1. Brake (hydraulic) system not operating properly.
1. Refer to Section 8.4, “Hydraulic Circuits.”
2. Brake piston o-rings and seals damaged (leaking).
2. Replace o-rings and seals.
1. Brake discs worn.
1. Check brake discs for wear. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Brake (hydraulic) system not operating properly.
2. Refer to Section 8.4, “Hydraulic Circuits.”
3. Brake piston o-rings and seals damaged (leaking).
3. Replace o-rings and seals.
G10-55A, G12-55A
Axles, Drive Shafts, Wheels and Tires
5.4
DRIVE SHAFTS To Transmission
5.4.1
Drive Shaft Inspection and Service
Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later. Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts. Attempt to turn each drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise.
1 2 To Axle
3 4
MT0350
7. Remove the four bolts (1) and two straps (2) securing the bearing cross to the transmission output shaft flange. Discard bolts.
Note: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.
8. Remove the four bolts (3) and two straps (4) securing the bearing crosses to the axle. Discard bolts.
5.4.2
9. Remove the front drive shaft assembly.
Drive Shaft Maintenance
Refer to Section 2.4, “Fluid and Lubricant Capacities.” for information regarding the lubrication of the grease fittings on the drive shafts.
5.4.3
Drive Shaft Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Block the wheels. 6. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.
10. Repeat the above procedure on the rear drive shaft.
5.4.4
Drive Shaft Cleaning and Drying
1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry. 2. Remove and burrs or rough spots from all machined surfaces. Re-clean and dry as required.
5.4.5
Drive Shaft Installation
1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal. Note: The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. 2. Apply Loctite® 242 to all mounting bolts. 3. Install the two straps (2) and four new bolts (1) securing the bearing crosses to the transmission. Torque bolts to 55-60 lb-ft (75-81 Nm). 4. Install the two straps (4) and four new bolts (3) securing the bearing crosses to the axle. Torque bolts to 55-60 lb-ft (75-81 Nm). 5. Repeat the above procedure on the rear drive shaft. 6. Properly connect the battery. 7. Close and secure the engine cover. 8. Unblock the wheels. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
G10-55A, G12-55A
5-9
Axles, Drive Shafts, Wheels and Tires
5.5
WHEELS AND TIRES
5
WARNING Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, It is recommended that replacement tires have the following characteristics: • Equal or greater ply/load rating and size of original. • Tire tread contact width equal or greater than original. • Wheel diameter, width and offset dimensions equal to the original. • Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load). The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability. Foam filled tires have a positive effect on the weight, stability and handling characteristics of the machine, especially under load. The use of hydrofill as a tire-fill substance is not recommended because of possible environmental impact. Large-bore valve stems are used to help expedite tire inflation and deflation. An inner tube may be used if a tire does not provide an airtight seal. Check tire inflation pressures when the tires are cold. When mounting a tire on the wheel, the tire must be mounted on the wheel respective of the directional tread pattern of the tire; this produces a left or right tire and wheel assembly.
5-10
MY4190
The wheel and tire assemblies must be installed with the directional tread pattern “arrows” (5) facing in the direction of forward travel.
5.5.1
Removing Wheel and Tire Assembly from Machine
1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place an Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed. 4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly. 5. Lower the machine onto the support. 6. Remove lug nuts and lug washers in an alternating pattern. 7. Remove the wheel and tire assembly from the machine.
G10-55A, G12-55A
Axles, Drive Shafts, Wheels and Tires 5.5.2
Installing Wheel and Tire Assembly onto Machine
Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.
Tread “arrows” must point forward
6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
5.6
BRAKES
Check the brake disks for wear every 1,000 hours of operation or yearly. For more information on brake disk inspection, refer to the Axle Repair Manual (P/N 31200240).
5.7
TOWING A DISABLED MACHINE
Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power, before using the emergency towing procedures outlined below. Note: Block the wheels of the machine BEFORE attempting to release the park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable.
5.7.1
Install tires onto wheels to rotate in proper direction
Manually Releasing the Park Brake 5
5
5
5
MAH0460
1. Position wheel onto studs on wheel end of axle. 2. Install wheel lug washers. 3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 1
MZ1020
8
6
1. Loosen the nuts of the screws (5) for the manual release of the braking units. Draw the nuts back approximately 6 mm.
3
2. Tighten the screws until they are gently seated on the driving plate 9
10
4
5
7
2
MY4200
4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 350-400 lb-ft (475-542 Nm). 5. Remove machine from supports. G10-55A, G12-55A
3. Carefully tighten each release screw a 1/4 turn at a time in sequence until all have been turned on full turn 360°. 4. Repeat steps 1 thru 3 for the other side of the differential. Note: After the machine has been towed to a secure location, reactivate the parking brake. Carefully follow the procedures from start to finish. Contact the local distributor if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation. 5-11
Axles, Drive Shafts, Wheels and Tires 5.7.2
Manually Resetting the Park Brake
Note: Block the wheels of the machine BEFORE attempting to reset the machine’s park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable. 5
5
5
5 MZ1020
1. Loosen each release screw (5), only 1/4 turn at a time, in sequence, until each screw has lost contact with the guide pin. 2. Remove the screws along with the nuts and seals. Replace the seals, lubricate the screws with a silicone-based grease and re-install the screws along with the nuts. 3. Adjust the nut of the screw heads in relation to the arm by 1.18 in (30 mm). 4. Repeat steps 1 thru 3 for the other side of the differential. 5. After repairs to the machine have been made, start the machine and check the park brake and service brakes for proper function. Refer to Section 8.7.4, “Service Brake Bleeding,” Section 8.7.5, “Service Brake Test,” and Section 8.7.6, “Park Brake Test.”
5-12
G10-55A, G12-55A
Section 6 Transmission
Contents PARAGRAPH 6.1 6.2 6.3 6.4
6.5
6.6
G10-55A, G12-55A
TITLE
Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.4.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5.1 Torque Convertor Diaphragm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5.2 Torque Convertor Diaphragm Installation . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 6-2 6-3 6-3 6-3 6-3 6-4 6-5 6-5 6-6 6-6 6-6 6-7
6-1
Transmission
6.1
TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.
TRANSMISSION FILTER TORQUE CONVERTER
OIL DRAIN PLUG
OIL FILLER PLUG TRANSFER CASE BREATHER
OIL FILL TUBE AND DIPSTICK
SHIFT SOLENOIDS
SHIFT SOLENOIDS
OIL DRAIN PLUG MY0970
6-2
G10-55A, G12-55A
Transmission
WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual.
6.2
TRANSMISSION SERIAL NUMBER
6.4.1
Transmission Removal
WARNING NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling with a minimum lifting capacity of 1000 lb (454 kg). 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool.
MY0990
1
The transmission serial number plate (1) is located on the front of the transmission case behind the oil dipstick. Information on the serial number plate is required in correspondence regarding the transmission.
6.3
TRANSMISSION SPECIFICATIONS AND MAINTENANCE INFORMATION
4. Remove engine cover to allow easier access to the transmission. 5. Drain the hydraulic oil reservoir. Refer to Section 8.5.1, “Hydraulic Oil Reservoir Draining.” 6. Properly disconnect the battery. 7. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding.
For transmission, oil specifications and maintenance information, refer to Section 2, “General Information and Specifications.” Detailed transmission service instructions are provided in the following publications: • Service Manual (P/N 31200241) • Parts Manual (P/N 31200257)
6.4
TRANSMISSION REPLACEMENT
Note: Contact the local distributor if internal transmission repair is required during the warranty period. Note: Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components.
G10-55A, G12-55A
2
3
MY0980
8. Place a suitable receptacle under the transmission drain plug (2). Remove the transmission drain plug, and allow the transmission oil to drain into the receptacle. Repeat drain procedure with the drop box (3).
6-3
Transmission 9. Transfer the used transmission oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug.
26. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings.
10. Remove the transmission-to-axle drive shafts. Refer to Section 5.4.3, “Drive Shaft Removal.”
4
11. Remove air cleaner unit and intake tubes. 12. Remove the hydraulic pump. Refer to Section 8.6.1, “Implement Pump Replacement.” 13. Label and disconnect the transmission temperature switch connector and shift solenoid wiring harness connectors. 14. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission. 15. Remove the access plug from side of the engine bell housing. This will allow access to remove the four bolts holding the torque convertor diaphragm to the engine flywheel. 16. Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts to be accessed. Remove them one at a time. 17. Wipe up any spilled hydraulic and transmission oil. 18. Connect a lifting strap or chain to the lifting eye at the top of the transmission, and to a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain, but DO NOT raise the transmission at this time. 19. Place blocks under rear of engine for support BEFORE transmission mounts are removed.
MY0990
27. Remove the transmission oil filter (4) and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount. 28. If transmission oil is suspect to contamination or torque converter is damaged, remove the converter and flex plate from the transmission. 29. Remove the bolt and washers holding the converter to the flex plate.
6.4.2
Transmission Inspection and Internal Repair
If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are included with a new transmission.
20. Place blocks under the transmission to help support it during removal. 21. Remove both rear transmission mount bolts and lockwashers securing the transmission mount to the frame. 22. Remove the bolts and washers holding the transmission to the engine. 23. Remove the capscrews and lockwashers securing each rear transmission mount to the transmission. 24. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts. 25. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it will not move or fall.
6-4
G10-55A, G12-55A
Transmission 6.4.3
Transmission Installation
WARNING NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling. 1. Install both rear transmission mounts on the transmission. Torque capscrews to 125-140 lb-ft (170-190 Nm). 2. Install two guide studs near the top of the bell housing holes. 3. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis. 4. Align the torque converter, align the transmission bolt holes with the two studs in the bell housing. Install the eight bolts and washers and torque to 53 lb-ft (72 Nm). Remove the two alignment studs and install and torque the last two transmission mounting bolts. 5. Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers. Apply Loctite® 242 to the transmission mount bolts and torque to 125-140 lb-ft (169-190 Nm) 6. Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts through the access plug in the bell housing. Install them one at a time. DO NOT fully tighten until all of the capscrews and locknuts are in place. Torque to 26-39 lb-ft (35-59 Nm). Replace access plug. 7. Remove the hoist or overhead crane and sling. 8. Connect the transmission temperature switch connector and shift solenoid wiring harness connectors. 9. Secure the wiring harness to the transmission housing. 10. Connect the transmission oil cooler inlet and outlet hoses at the transmission. 11. Install the hydraulic pump. Refer to Section 8.6.1, “Implement Pump Replacement.” 12. Install the transmission-to-axle drive shafts. Refer to Section 5.4.5, “Drive Shaft Installation.” 13. Install the air cleaner and tubing. 14. Clean the transmission oil filter mounting surface.
5
6 MY0990
16. Transmission oil may be added through the dipstick tube (5). Remove the dipstick and add hydraulic oil. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished. 17. Transmission transfer case fluid may be added through the fill plug (6). Remove the fill plug and add approximately 1.5 quarts (1,4 liters) of hydraulic oil. Install fill plug and tighten. 18. Properly connect the battery. 19. Install the engine cover. 20. Close and secure the engine cover. 21. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6.4.4
After Transmission Service or Replacement
In general: 1. Check the transmission oil level and add oil as required. 2. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning. 3. Drain and flush the entire transmission cooling system. 4. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements. 5. Reassemble all components and fill the transmission with clean, fresh hydraulic oil through the dipstick tube opening (5). Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.
15. Apply a thin film of clean hydraulic oil to the new transmission filter gasket. Install the new filter and torque to 20-25 lb-ft (27-34 Nm). G10-55A, G12-55A
6-5
Transmission 6. Transmission transfer case fluid may be added through the fill plug (6). Remove the fill plug and add approximately 1.5 quarts (1,4 liters) of hydraulic oil. Install fill plug and tighten. 7. Run the engine for two minutes at idle to help prime the torque converter and the transmission oil lines. 8. Recheck the level of the fluid in the transmission with the engine running at idle. 9. Add hydraulic oil as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 180-200° F (83-94° C). 10. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.
6.5 6.5.1
TORQUE CONVERTOR DIAPHRAGM Torque Convertor Diaphragm Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. Note: In order to remove the engine drive plates, the engine and transmission must be separated. 2. Refer to Section 6.4.1, “Transmission Removal,” or Section 7.9.1, “Engine Removal.” 8
9
7
3. Remove the four bolts holding the diaphragms to the flywheel. 4. With the drive plates and torque converter removed, loosen and remove the four bolts (7) and eight lock washers holding the two diaphragms (8) to the torque converter (9). 5. Replace both diaphragms if damaged.
6.5.2
Torque Convertor Diaphragm Installation
1. Install the two new diaphragms on the torque converter and install the four bolts with lock washers. 2. Mount the diaphragm/converter assembly to the transmission. 3. Refer to Section 6.4.3, “Transmission Installation,” or Section 7.9.2, “Engine Installation,” for the remainder of the installation.
6-6
G10-55A, G12-55A
Transmission
6.6
TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the local distributor if internal transmission repair is required during the warranty period.
Problem 1. Transmission will not engage or will not shift properly.
G10-55A, G12-55A
The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features
Cause
Remedy
1. Oil level too high or low.
1. Fill transmission to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Transmission control lever not functioning properly and/or a fault in the wiring harness.Transmission control lever not functioning properly and/or a fault in the wiring harness.
2. Refer to Section 9.5, “Electrical System Schematics.”
3. Transmission valve body solenoids not functioning properly.
3. Refer to Section 9.5, “Electrical System Schematics.”
4. Pilot-operated shift valves not operating properly.
4. Clean the valve spool and housing. Replace return spring as needed.
5. Pump output pressure low.
5. Refer to Section Note:, “Contact the local distributor if internal transmission repair is required during the warranty period.,” Problem 2. “Low or no pump flow or pressure.”
6. Clutch piston o-rings damaged.
6. Replace o-rings.
7. Clutch discs worn or damaged.
7. Replace clutch discs.
8. Coupling shafts or gear teeth damaged.
8. Replace couplings.
6-7
Transmission
Problem 2. Low or no pump flow or pressure.
3. Low clutch pressure.
4. Lack of power.
6-8
Cause
Remedy
1. Low oil level.
1. Fill transmission to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Transmission filled with incorrect oil, or oil contaminated.
2. Drain transmission and fill to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
3. Pump suction pipe screen clogged.
3. Clean, repair and/or replace suction pipe.
4. Central shaft damaged.
4. Replace central shaft.
5. Pump worn or damaged.
5. Repair or replace pump assembly.
1. Incorrect oil level.
1. Fill transmission to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Main pressure valve stuck open.
2. Clean the valve spool and housing.
3. Broken or worn coupling shaft or piston o-rings.
3. Replace coupling and/or o-rings.
4. Pressure reducing valve stuck open.
4. Clean the valve spool and housing.
1. Park or service brake dragging.
1. Refer to Section 8.4, “Hydraulic Circuits.”
2. Low engine rpm causes converter stall.
2. Adjust the engine rpm to specifications. Refer to Engine Service Manual.
3. Pump output pressure is low.
3. Refer to Section Note:, “Contact the local distributor if internal transmission repair is required during the warranty period.,” Problem 2. “Low or no pump flow or pressure.”
4. Clutch discs worn or damaged.
4. Replace clutch discs.
5. Transmission overheating.
5. Refer to Section Note:, “Contact the local distributor if internal transmission repair is required during the warranty period.,” Problem 5. “Transmission overheating (oil above 248° F (120° C)).” G10-55A, G12-55A
Transmission
Problem 5. Transmission overheating (oil above 248° F (120° C)).
6. Grinding or “clunking” noise from transmission.
Cause
Remedy
1. Low oil level.
1. Fill transmission to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
2. Clogged radiator.
2. Remove debris from the radiator.
3. Transmission filled with incorrect oil, or oil contaminated.
3. Drain transmission and fill to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
4. Excessive “roading.”
4. Stop and idle the engine.
5. Restriction in oil cooler hoses.
5. Replace cooler hoses.
6. Pump worn or damaged.
6. Repair or replace pump assembly.
7. Engine thermostat stuck.
7. Replace engine thermostat. Refer to Section 7.4.2, “Thermostat Replacement.”
1. Oil level too low.
1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Repair or replace parts as needed.
G10-55A, G12-55A
2. Transmission filled with incorrect oil.
3. Drain transmission and fill to correct level with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.”
3. Incorrect clutch engagement.
4. Refer to Section 9.10.3, “Transmission Solenoid Valves.”
4. Internal damage.
5. Repair or replace parts as needed.
5. Broken diaphragm (torque convertor).
6. Replace diaphragm (torque convertor). Refer to Section 6.4.1, “Transmission Removal.”
6. Loose diaphragm (torque convertor) mounting capscrews.
7. Tighten capscrews.
6-9
Transmission
Problem 7. Oil leaking from transmission.
Cause 1. Oil leaking from vent (high oil level).
1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.” Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).
2. Drain plug loose and/or o-rings damaged or missing.
2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm).
3. Hose fittings loose.
3. Tighten fittings.
4. Oil leaking at valve bodies (possible valve body gaskets damaged or missing and/or mounting capscrews not tight).
4. Replace gaskets and/or tighten capscrews to 7 lb-ft (9,5 Nm).
5. Housing capscrews loose.
5. Tighten capscrews to 34 lb-ft (46 Nm).
6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight).
6. Replace o-rings and/or tighten capscrews to 85 lb-ft (115 Nm).
7. Oil leaking at converter bell (possible converter leak and/or input shaft seal damage).
7. Replace converter and/or input shaft seal.
8. Oil leaking at output shaft (output shaft seal damaged).
8. Replace output shaft seal.
9. Oil escaping from breather at shut down.
9. Transmission may be under full. Ensure transmission is at operating temperature, 185° F (85° C) and fill to upper mark on transmission dip stick.
10. Housing damaged.
6-10
Remedy
10. Replace housing as needed.
G10-55A, G12-55A
Section 7 Engine
Contents PARAGRAPH 7.1
7.2
7.3
7.4
7.5 7.6
7.7
7.8
7.9
7.10
G10-55A, G12-55A
TITLE
Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.1.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.2.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.3.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.3 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8.1 Air Cleaner Assembly Removal (John Deere & Perkins) . . . . . . . . . . . . . 7.8.2 Air Cleaner Assembly Installation (John Deere & Perkins) . . . . . . . . . . . . 7.8.3 Air Cleaner Assembly Removal (Cummins) . . . . . . . . . . . . . . . . . . . . . . . 7.8.4 Air Cleaner Assembly Installation (Cummins). . . . . . . . . . . . . . . . . . . . . . Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 7-2 7-2 7-2 7-2 7-3 7-4 7-4 7-4 7-4 7-5 7-6 7-6 7-6 7-6 7-7 7-8 7-8 7-8 7-9 7-10 7-10 7-10 7-10 7-12 7-12 7-12 7-13 7-13 7-13 7-13 7-13 7-14 7-14 7-14 7-15 7-17
7-1
Engine
7.1 7.1.1
INTRODUCTION - JOHN DEERE Disclaimer and Scope
These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis, repair and component replacement. A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140° F (60° C). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.
7-2
7.1.2
Engine Serial Number
The John Deere 4045HF275 serial number Is stamped on a plate which is secured to the engine block, near the fuel injector pump. Information contained in the serial number is required in correspondence with the engine manufacturer.
7.1.3
Specifications and Maintenance Information
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specifications.” Detailed John Deere engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate John Deere engine service manual. For engine electrical related issues, refer to the John Deere Engine Troubleshooting Manual (P/N 31200371).
G10-55A, G12-55A
Engine 7.1.4
Component Terminology
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
THERMOSTAT
TURBOCHARGER
FUEL INJECTOR PUMP
ENGINE CONTROL MODULE (ECM) MY1011
ALTERNATOR
STARTER
IN LINE FUEL FILTER
OIL FILTER
MY4500
G10-55A, G12-55A
7-3
Engine
7.2 7.2.1
INTRODUCTION - PERKINS Disclaimer and Scope
These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis, repair and component replacement. A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140° F (60° C). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.
7-4
7.2.2
Engine Serial Number
The Perkins 1104D serial number Is stamped on top of the engine. Information contained in the serial number is required in correspondence with the engine manufacturer.
7.2.3
Specifications and Maintenance Information
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specifications.” Detailed Perkins engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate Perkins engine service manual.
G10-55A, G12-55A
Engine 7.2.4
Component Terminology
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
THERMOSTAT
ENGINE CONTROL MODULE (ECM)
FUEL FILTER
FUEL INJECTOR PUMP
STARTER
OIL FILTER MAL0260
ALTERNATOR
TURBOCHARGER
MAL0270
G10-55A, G12-55A
7-5
Engine
7.3 7.3.1
INTRODUCTION - CUMMINS Disclaimer and Scope
These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis, repair and component replacement. A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140° F (60° C). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.
7-6
7.3.2
Engine Serial Number
The Cummins serial number Is stamped on top of the engine. Information contained in the serial number is required in correspondence with the engine manufacturer.
7.3.3
Specifications and Maintenance Information
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specifications.” Detailed Cummins engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate Cummins engine service manual.
G10-55A, G12-55A
Engine 7.3.4
Component Terminology
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
FUEL FILTER (SECONDARY)
FUEL INJECTOR PUMP OIL FILTER
ENGINE CONTROL MODULE (ECM)
FUEL FILTER (PRIMARY)
TURBOCHARGER THERMOSTAT ALTERNATOR
STARTER
MY5530
G10-55A, G12-55A
7-7
Engine
7.4
ENGINE COOLING SYSTEM
7.4.1
Radiator Pressure Cap
John Deere/Perkins: For a 210° F (99° C) system, use a 13 psi (90 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. Cummins: For a 210° F (99° C) system, use a 16 psi (110 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.
a. Thermostat Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
7.4.2
Thermostat Replacement
Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator. • If the engine seems to take a long time to warm up, the thermostat may be stuck in the open position and requires replacement. • If the engine runs hot, check the temperature of the upper radiator hose.
5. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap. 6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug and slowly remove to allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Replace the radiator drain plug. TYPICAL THERMOSTAT
• If the hose is not hot, the thermostat may be stuck in the closed position. • If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage. 1 2
2
MY4520
3
7. Disconnect the engine water temperature sender (1) if connected to the thermostat housing. 8. Remove the two capscrews (2) securing the thermostat housing (3) to the engine. 9. Remove the thermostat housing, old gasket and thermostat. Clean all gasket surfaces. DO NOT let any debris into the thermostat opening. Note: ALWAYS use the correct thermostat and install a new gasket. NEVER operate the engine without a thermostat, or engine damage will result.
7-8
G10-55A, G12-55A
Engine b. Thermostat Installation 1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews and torque as required. 2. Connect the engine water temperature sender if connected to the thermostat housing. 3. Properly connect the battery. 4. Open the radiator cap, and fill the radiator completely with coolant. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system. 5. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary.
5. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap. 6. Place a suitable container beneath the radiator drain. 7. Place a funnel at the base of the radiator to channel the drained coolant into a container. Loosen the drain cock and slowly remove to allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Tighten the radiator drain cock. 8. Label, disconnect and cap the hoses attached to the coolant recovery tank. Remove the coolant recovery tank. CUMMINS RADIATOR ASSSEMBLY
4
6
7
6. Close and secure the engine cover. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7.4.3
5
Radiator/Oil Cooler and Replacement
Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator. • If the engine runs hot, check the temperature of the upper radiator hose. • If the hose is not hot, the thermostat may be stuck in the closed position. • If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage. a. Radiator/Oil Cooler Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.
5 4
6 7 MY4530
9. Loosen the clamps on the hoses/tubes (4) attached to the intercooler. Work the hoses off the intercooler. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect the hoses, and replace if necessary. 10. Loosen the clamps on the hoses (5) attached to the radiator. Work the hoses off the radiator. Position the hoses out of the way to allow radiator removal, or remove the hoses/tubes from the engine. Inspect the hoses, and replace if necessary. 11. Loosen and remove the hoses (6) attached to the oil cooler. Plug and/or cap the hoses to prevent dirt and debris from entering the hydraulic system. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect the hoses, and replace if necessary.
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. G10-55A, G12-55A
7-9
Engine 12. Loosen and remove the hoses (7) attached to the transmission cooler. Plug and/or cap the hoses to prevent dirt and debris from entering the transmission system. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect the hoses, and replace if necessary.
7.5
ENGINE ELECTRICAL SYSTEM
The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9.5, “Electrical System Schematics.”
7.6
FUEL SYSTEM
13. Remove the radiator fan guard. 14. Remove the nuts and washers the radiator fan shroud and pull the shroud back over the fan.
7.6.1
Diesel Fuel
16. Carefully lift the radiator and oil cooler out of the engine compartment.
Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair.
Note: If more clearance is needed to remove the radiator, the engine fan may be removed for easier access.
Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance.
15. Remove the nuts and washers from the radiator and oil cooler mounts.
b. Radiator/Oil Cooler Installation 1. Install the isolator mounts to the bottom of the radiator and oil cooler. Place the radiator and oil cooler in the engine compartment at their original orientations. Secure with the previously used hardware. Note: Be sure there is adequate clearance between the radiator and the engine fan. 2. If necessary, install the engine fan. 3. Install the radiator fan shroud. 4. Uncap and connect the previously labeled hoses to the radiator, oil cooler and/or transmission cooler. 5. Connect both intercooler hoses. 6. Install the coolant recovery tank. Uncap and connect the previously removed hose. 7. Open the radiator cap and fill the radiator completely with coolant. Replace and tighten the radiator cap. Refer to Section 2.4, “Fluid and Lubricant Capacities,” for proper capacities. 8. Properly connect the battery. 9. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary. 10. Close and secure the engine cover. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7-10
Note: Due to the precise tolerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles. Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking. Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 32° F (0° C). When temperatures are below 32° F (0° C), a blend of #1 diesel and #2 diesel fuels (known as “winterized” #2 diesel) may be used. Note: #1 diesel fuel may be used, however, fuel economy will be reduced. Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10° below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistrokes to provide adequate fuel system lubrication.
7.6.2
Fuel Tank
Note: The fuel tank is a one piece unit. It is located on the rear of the cab. If it is determined that the fuel tank must be removed, the fuel must be drained before tank removal. Always dispose of fuel properly.
G10-55A, G12-55A
Engine a. Fuel Tank Removal
b. Disassembly
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF.
The fuel tank is a one-piece unit and cannot be disassembled. The fuel level indicator can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal.
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.
c. Cleaning and Drying
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. Note: If replacing the tank, remove all internal and external components from the old tank, and retain for use on the replacement tank. Note: Have a dry chemical (Class B) fire extinguisher near the work area. 6
If contaminated fuel or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the fuel tank, contact JLG Service Department. To clean the fuel tank: 1. Have a dry chemical (Class B) fire extinguisher near the work area. 2. Remove the fuel or oil tank drain plug, and safely drain any fuel into a suitable container. Dispose of fuel properly. 3. Clean the fuel tank with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly.
5
4. Add a diesel fuel emulsifying agent to the tank. Refer to the manufacturer’s instructions for the correct emulsifying agent-to-water mixture ratio. Refill the tank with water, and agitate the mixture for 10 minutes. Drain the tank completely. Dispose of contaminated water properly. 1 2
3
5. Refill the fuel tank with water until it overflows. Completely flush the tank with water. Empty the fuel tank, and allow it to dry completely.
4
d. Assembly MY4230
5. Remove fuel tank drain plug (1), and drain fuel into an approved and suitable container. Dispose of fuel properly.
The fuel level indicator can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal regulations.
6. Label, disconnect and cap the supply fuel line (2) from the bottom of the fuel tank.
e. Inspection
7. Label, disconnect and cap the return fuel line (3) from the bottom of the fuel tank.
Note: If a leak is suspected in the fuel tank, contact a JLG Service Department.
8. Disconnect the fuel gauge harness (4). 9. Remove screws securing fuel sender (5) to the tank. Remove fuel sender from tank. 10. Remove the bolts on the fuel tank hold down bar (13). 11. Lift the empty fuel tank from the rear of the cab. G10-55A, G12-55A
1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage. 2. With the fuel tank removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 1-1.5 psi (7-10 kPa) of air pressure through the elbow. Check the reservoir for leaks by applying a soap solution to 7-11
Engine the exterior and look for bubbles to appear at the cracked or damaged area. f.
Fuel Tank Installation
1. Set fuel tank in its original orientation at the rear of the cab. 2. Install the fuel tank hold down bar. 3. Install the fuel sender with new gasket into the fuel tank and secure with screws. DO NOT overtighten. 4. Connect the previously labeled fuel hoses to their appropriate locations. Secure with clamps. 5. Connect the fuel gauge harness. 6. Fill the fuel tank according to specifications.Refer to Section 2.4, “Fluid and Lubricant Capacities.”
7.7
ENGINE EXHAUST SYSTEM
7.7.1
Exhaust System Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids and the exhaust system to cool. 4. Properly disconnect the battery. 9
7. Check fuel tank for leaks. 8. Properly connect the battery. 9. Close and secure the engine cover.
8
10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7.6.3
7
After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
10
2. Vent air from the fuel system in accordance with the instructions found in the appropriate Operation & Safety Manual. 3. Fill the fuel tank with fresh, clean diesel fuel as required.
5
3 4
1 3
6 2
MY4240
5. Remove the muffler heat shield (1) 6. Remove the exhaust heat shield (2). 7. Loosen and remove both clamps (3) securing the muffler (4) to the frame mounted brackets. Remove the muffler. 8. Loosen and remove the clamp (5) securing the exhaust pipe (6) to the frame at the bottom rear corner of the engine pod. Remove the exhaust pipe. Note: Removal of the turbo charger heat shields may be required to access exhaust pipe bolts. 9. Disconnect and remove the three bolts (7) securing the exhaust pipe/flex pipe (8) to the turbo charger. Remove the exhaust pipe/flex pipe from under machine.
7-12
G10-55A, G12-55A
Engine 7.7.2
Exhaust System Installation
4. Properly disconnect the battery.
Note: Keep all clamps loosened until entire exhaust system is in place.
13
1. Install the exhaust pipe/flex pipe (8) with a new seal (9) to the turbo charger. 2. Install the exhaust pipe/flex pipe clamp (5) at the bottom rear corner of the engine pod. 3. Install the exhaust pipe (6) to the exhaust/flex pipe (8).
14 11
4. Install the muffler (4) to the exhaust pipe (6). 5. Install the tail pipe (10) to the muffler (4). 6. Install the clamps (3) securing the tail pipe/muffler/ exhaust pipe to the frame mounted brackets.
12
7. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps. 8. Install the exhaust heat shield (2). 9. Install the muffler heat shield (1). 10. Properly connect the battery. 11. Start engine and check for exhaust leaks at all exhaust connections. Adjust as needed. 12. Close and secure the engine cover. 13. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7.8
MY4250
5. Remove the clamp (11) securing the air intake elbow (12) to the air cleaner assembly (13). Pull the air intake elbow off the air cleaner. 6. Remove the capscrews and nuts securing the air cleaner mounting bracket (14) to the air cleaner mounting plate. Remove the air cleaner assembly.
7.8.2
AIR CLEANER ASSEMBLY
WARNING NEVER run the engine with only the inner safety element installed. Note: Refer to the appropriate Operation & Safety Manual for your machine for the correct element change procedure.
Air Cleaner Assembly Installation (John Deere & Perkins)
Note: Apply Loctite® 242 to the capscrew threads before installation. 1. Install the air cleaner assembly (13) to the cab mounting plate with the previously removed hardware (14). 2. Place the loosened clamp (11) over the air outlet elbow (12) and install elbow on the air cleaner assembly. 3. Adjust and tighten the clamp.
7.8.1
Air Cleaner Assembly Removal (John Deere & Perkins)
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. G10-55A, G12-55A
4. Properly connect the battery. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7.8.3
Air Cleaner Assembly Removal (Cummins)
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 7-13
Engine 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 15
16 17
7.9 7.9.1
ENGINE REPLACEMENT Engine Removal
Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section 7.4, “Engine Cooling System.” Several additional components must be removed before engine removal. They will be addressed in the following procedures. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF.
18
3. Open the engine cover. Allow the system fluids to cool.
MY5070
5. Loosen the clamp (15) securing the air intake elbow (16) engine. 6. Loosen the capscrews securing the air cleaner mounting bracket (17) to the engine fire wall. 7. Remove the air cleaner assembly (17 & 18). 8. Remove the air cleaner mounting bracket (17) from the air cleaner (18).
7.8.4
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.
Air Cleaner Assembly Installation (Cummins)
Note: Apply Loctite® 242 to the capscrew threads before installation. 1. Install the air cleaner (18) to the air cleaner mounting bracket (17). 2. Install the air cleaner assembly (17 & 18) to the engine fire wall. 3. Tighten the previously loosened capscrews. 4. Install the air intake elbow (16) onto the engine. 5. Adjust and tighten the clamp (15). 6. Properly connect the battery. 7. Close and secure the engine cover. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
4. Properly disconnect and remove the battery. Properly disconnect and remove the second battery if equipped. 5. Remove the engine cover. Mark the position of the cover to help with cover adjustment when being reinstalled. 6. Remove the oil pan cover underneath the engine compartment. 7. Drain and remove the radiator assembly. Refer to Section 7.4.3, “Radiator/Oil Cooler and Replacement.” 8. Remove the heater hoses attached to the engine (if equipped). Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at various places on the engine. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that the engine clears the harness during removal. 9. Label and disconnect all electrical wire connections on the engine. 10. Label and disconnect all electrical wire connections on the Power Distribution bracket. 11. Remove the Power Distribution bracket. 12. Disconnect and cap the fuel inlet line at the fuel filter head. 13. Disconnect and cap the fuel return line from the fuel filter head.
7-14
G10-55A, G12-55A
Engine 14. Remove the exhaust pipe from the exhaust manifold. Refer to Section 7.7.1, “Exhaust System Removal.” 15. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe. 16. Remove the air cleaner tube assembly. Refer to Section 7.8.1, “Air Cleaner Assembly Removal (John Deere & Perkins),” or Section 7.8.3, “Air Cleaner Assembly Removal (Cummins).”
7.9.2
Engine Installation
1. Secure the engine with a lifting strap or chain from the appropriate lifting points (1). Use a suitable hoist or overhead crane. Note: Apply Loctite® 242 to the engine mount bracket capscrew threads before installation. 2. Install two guide studs in the bell housing holes.
17. Remove the access plug from bottom of the engine bell housing. This will allow access to remove the bolts holding the torque convertor diaphragm to the engine flywheel.
3. Lift the engine and slowly push and lower into the engine bay. Have an assistant ensure that the engine clears the frame, hose and harness components during engine installation. Position engine brackets over the front frame mounts.
18. Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts to be accessed. Remove them one at a time.
4. Push the engine towards the transmission aligning the guide studs and the torque convertor shaft with the corresponding holes.
1
5. Push the engine against the transmission and install eight of the ten bolts and washers. Remove both guide studs and replace with the remaining two bolts and washers. Torque bolts to 53-58 lb-ft (72-79 Nm). 6. Remove the support from under the transmission and lower the engine the remainder of the way onto the frame. Align the motor mount holes and install the bolts. Apply Loctite® 242 to the motor mount bolts and torque to 125-140 lb-ft (169-190 Nm). 7. Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts through the access plug in the bell housing. Install them one at a time. DO NOT fully tighten until all of the capscrews and locknuts are in place. Torque to 26-39 lb-ft (35-59 Nm). Replace access plug.
1
MY4270
19. Secure the engine with a lifting strap or chain from the appropriate lifting points (1). Use a suitable hoist or overhead crane.
8. Install the exhaust pipe. Refer to Section 7.7.2, “Exhaust System Installation.” 9. Install the complete air cleaner assembly. Refer to Section 7.8.2, “Air Cleaner Assembly Installation (John Deere & Perkins),” or Section 7.8.4, “Air Cleaner Assembly Installation (Cummins).”
20. Place a support or jack under the transmission to hold the transmission in place while engine is being removed.
10. Connect the fuel inlet line to the fuel filter head.
21. Remove the bolts and washer securing the engine mounts.
12. Install the Power Distribution bracket.
22. Remove the ten bolts holding the transmission to the engine. Slightly lift and pull the engine out of the machine. Have an assistant ensure that the engine clears all frame components during removal. 23. Place engine on a flat, level surface.
11. Connect the fuel return line to the fuel filter head. 13. Connect all the previously labeled electrical wire connections on the Power Distribution bracket. 14. Connect all the previously labeled electrical wire connections on the engine. 15. Install both heater hoses to the engine and tighten clamps (if equipped). 16. Install the complete radiator assembly. Refer to Section 7.4.3, “Radiator/Oil Cooler and Replacement.”
G10-55A, G12-55A
7-15
Engine 17. Install the engine cover and adjust. 18. Install and properly connect the battery. Install and properly connect the second battery if equipped. 19. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and connected tightly. 20. From within the cab, lightly depress the throttle pedal to full-throttle position. As needed, adjust the limitstop screw until it touches the pedal bracket. Note: Have an assistant stand by with a Class B fire extinguisher. 21. Start the engine and run to normal operating temperature then shut off the engine. While the engine is cooling, check for leaks. 22. Allow the engine to cool. Check the radiator coolant level and add coolant if required. Replace the radiator cap. 23. Check for leaks from the engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill as required. Note: During the full throttle check: • DO NOT operate any hydraulic function. • DO NOT steer or apply any pressure to the steering wheel. • Keep the transmission in (N) NEUTRAL. 24. Obtain and connect an appropriate engine analyzer or tachometer. Check the engine rpm at full throttle. 25. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level. 26. Check for proper operation of all components. 27. Turn the engine OFF. 28. Install the oil pan cover underneath the engine compartment. 29. Close and secure the engine cover. 30. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7-16
G10-55A, G12-55A
Engine
7.10
TROUBLESHOOTING
Trouble
Possible Causes (see key, below)
Low Cranking Power
1, 2, 3, 4
Will Not Start
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure
4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking
9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration
13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure
4, 38, 41
Overheating
11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure
25, 31, 33, 34, 45, 55, 60
Poor Compression
11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops
10, 11, 12 Key to Possible Causes
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Battery charge low Bad electrical connection Faulty starter motor Incorrect grade of lubricating oil Low cranking speed Fuel tank empty Faulty stop control operation Fuel inlet restricted Faulty fuel lift pump Clogged fuel filter Restricted air cleaner Air in fuel system Faulty fuel injection pump Faulty fuel injectors or incorrect type Incorrect use of cold start equipment Faulty cold start equipment Broken fuel injection pump drive Incorrect fuel pump timing Incorrect valve timing Poor compression
G10-55A, G12-55A
21. Blocked fuel tank vent 22. Incorrect grade of fuel 23. Sticking throttle or restricted movement 24. Exhaust pipe restriction 25. Leaking cylinder head gasket 26. Overheating 27. Cold running 28. Incorrect tappet adjustment 29. Sticking valves 30. Incorrect high pressure pipes 31. Worn cylinder bores 32. Pitted valves and seats 33. Broken, worn or sticking piston ring(s) 34. Worn valve stems and guides 35. Restricted air cleaner 36. Worn or damaged bearings 37. Insufficient oil in sump 38. Inaccurate gauge 39. Oil pump worn 40. Pressure relief valve sticking open 41. Pressure relief valve sticking closed 42. Broken relief valve spring
43. 44. 45. 46. 47. 48. 49.
50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63.
Faulty suction pipe Restricted oil filter Piston seizure/pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors (if fitted) Coolant level too low Blocked sump strainer Broken valve spring Exhauster or vacuum pipe leak Turbo impeller damaged or dirty Turbo lubricating oil seal leak Induction system leaks 7-17
Engine
This Page Intentionally Left Blank
7-18
G10-55A, G12-55A
Section 8 Hydraulic System
Contents PARAGRAPH 8.1 8.2 8.3 8.4
8.5
8.6 8.7
8.8
G10-55A, G12-55A
TITLE
Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Tilt Circuit Port Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4 Service Brake Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.7 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.8 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.3 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.4 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.5 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 8-2 8-3 8-3 8-4 8-4 8-4 8-5 8-9 8-13 8-13 8-13 8-13 8-14 8-14 8-15 8-15 8-17 8-18 8-19 8-20 8-21 8-21 8-23 8-23 8-24
8-1
Hydraulic System
8.1
HYDRAULIC COMPONENT TERMINOLOGY
To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
EXTEND/RETRACT CYLINDER
HYDRAULIC FLUID RESERVOIR
LIFT/LOWER CYLINDER(S)
COMPENSATION CYLINDER
TILT CYLINDER
MAL0381
OUTRIGGER CYLINDER(S)
8-2
SWAY CYLINDER
STEERING CYLINDER(S)
MAIN CONTROL VALVE
STEERING CYLINDER(S)
STABILIZER CYLINDER
G10-55A, G12-55A
Hydraulic System
8.2
SAFETY INFORMATION
WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present. Hydraulic fluid has a flash point that ranges from 300-600° F (150-318° C) and an auto-ignition temperature of 500-750° F (262-402° C). Accordingly, periodically inspect all hydraulic system components, hoses, tubes, lines, fittings, etc. Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard. If in doubt, replace the component.
Some hydraulic functions are actuated by interfacing with electrical system components (switches, solenoids and sensors). When the hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also. Refer to Section 9.5, “Electrical System Schematics,” in this manual.
8.3
HYDRAULIC PRESSURE DIAGNOSIS
JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting: the JLG Pressure Test Kit. The kit is contained in a durable polyethylene carrying case for demanding field service conditions. Hydraulic Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system. The kit includes: • Gauges for testing high and low pressure circuits • Fittings, couplers and hoses
Operate the hydraulic controls after the engine has stopped to relieve trapped pressure. Note: Residual pressure may remain in hydraulic cylinders, hoses, valve bodies, components, etc. If the hydraulic lines going to or coming from a component are taut, slowly and cautiously relieve (“bleed off”) pressure. Whenever you disconnect a hydraulic line, coupler, fitting or other component, slowly and cautiously loosen the part involved. A hissing sound or slow seepage of hydraulic fluid may occur in most cases. After the hissing sound has ceased, continue removing the part. Any escaping oil should be directed into an appropriate container. Cap or otherwise block off the part to prevent further fluid seepage. Hydraulic system maintenance will, at times, require that the engine be operated. Always follow safety precautions. A major cause of hydraulic component failure is contamination. Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs. Sand, grit and other contaminants can damage the finely machined surfaces within hydraulic components. If operating in an exceptionally dirty environment, change filters and inspect the fluid more often. When servicing the system, cap or plug hydraulic fittings, hoses and tube assemblies. Plug all cylinder ports, valves and the hydraulic reservoir, and pump openings until installation occurs. Protect threads from contamination and damage.
G10-55A, G12-55A
MZ1460
Contact JLG Parts Department Toll Free at 1-877-554-5438 or 717-485-6472 for ordering information. Part Number
Description
Approximate Weight
Price and Availability
70000652
Dial Hydraulic Pressure Test Kit
10 lbs.
Consult Factory
70000101
Digital Hydraulic Pressure Test Kit
7 lbs.
Consult Factory
70027911
Digital Hydraulic Pressure Test Kit
7 lbs.
Consult Factory
8-3
Hydraulic System 8.3.1
Pressure Checks and Adjustments
When diagnosing trouble in the hydraulic system, use the hydraulic testing information in Section 8.4.1, “ Hydraulic Pressures.” In general, follow the steps below whenever conducting pressure checks and performing adjustments: 1. Park the machine on a firm, level surface. Engage the park brake, place the travel select lever in (N) NEUTRAL, level the boom and turn the engine OFF. 2. The test port is located at the top right corner of the main control valve. Install a pressure gauge capable of measuring at least 10% more pressure than that which the circuit being checked operates under. 3. Start the engine. Operate machine functions several times to allow hydraulic oil to reach operating temperature. The hydraulic oil temperature should be between 100-120°F (38-49° C). If a temperature gauge or thermometer is unavailable, the hydraulic oil reservoir should be warm to the touch. 4. Refer to Section 8.4.1, “ Hydraulic Pressures.” for testing procedures. 5. Fully depress the accelerator pedal if required. Place and hold the joystick in the position needed to operate the particular machine function being checked. Continue holding the joystick in position until pressure readings are taken. 6. Check the pressure gauge reading. It should read as specified in the Pressure Readings column of the charts found in Section 8.4.1, “ Hydraulic Pressures.” If the reading is not as specified, turn the engine OFF and check other components in the system. Verify that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly. 7. Adjust the relief valve by turning the adjustment screw Turning clockwise will increase the pressure; turning the screw counterclockwise will decrease the pressure. 8. Start the engine and check the pressure again. Turn the engine OFF. If there is pressure reading in the gauge, bleed it off then disconnect or remove the pressure gauge from the machine.
8.4
HYDRAULIC CIRCUITS
This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those pressures and a hydraulic schematic. Electrical and hydraulic functions are often related. Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit. Always check the following before beginning to troubleshoot a circuit that is not functioning correctly. 1. Check the hydraulic oil level in the reservoir. Oil level should be to the middle of the sight glass with all cylinders retracted. 2. Check hoses, tubes, fittings and other hydraulic components for leaks, bends, kinks, interference, etc. 3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder operation are signs of air in the hydraulic system. If air in the hydraulic system is suspected, you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid. Loose fittings, faulty o-rings or seals, trapped oil, leaks, system opened for service, etc., can cause air in the system. Determine what is causing air to enter the system and correct it. Bleed air from the system.
8.4.1
Hydraulic Pressures
a. Checking Pressure 1. Start the machine and warm the hydraulic system to operating temperature. 2. Shut off the machine and install a digital or a 5000 psi (345 bar) gauge to the appropriate test port on the hydraulic manifold. 3. Start the machine, run the engine at high idle and bottom the appropriate hydraulic function. Refer to Section 8.4.1, “ Hydraulic Pressures.” for the correct pressure rating. b. Adjusting Hydraulic Pressure 1. Shut the machine off. Remove the cap on the relief (if necessary). 2. Start the machine and loosen the jam nut on the relief. Turn the relief clockwise to increase pressure or counter-clockwise to decrease pressure. Set to the correct pressure.
8-4
G10-55A, G12-55A
Hydraulic System
3. Tighten the jam nut and recheck the pressure at full throttle. If the reading is within specification, shut the machine off, install the safety cap and remove the gauge from the test port.
10. Monitor the gauge and slowly raise the boom. The gauge should read 4100 psi (282 bar). 11. If pressure is correct, proceed to step 14. A
4. If the proper pressure cannot be set, use the accompanying hydraulic schematic and/or the electrical schematic to help troubleshoot and correct the problem.
8.4.2
A
Tilt Circuit Port Relief Adjustment
The following procedure is specific to the tilt circuit only and should be performed and verified if the main and/or load sense circuits pressures are in question. 1. Remove any attachment from the quick coupler assembly. Refer to Section 3.9, “Quick Switch Assembly.” 2. Raise the boom for access to the compensation cylinder.
1
2
HUSCO
REXROTH MY4490
FRONT OF MACHINE
12. If the pressure requires adjustment and if the machine is equipped with a Rexroth main control valve, adjust the relief on the (A) port and repeat steps 9 and 10. If the machine is equipped with a Husco main control valve, the relief on the (A) port is non-adjustable and must be replaced. Replace and repeat steps 9 and 10. 13. Verify pressure is correct. 14. Shut engine OFF. 15. Remove the digital or the 5000 psi (345 bar) gauge from the retract (1) port tee fitting on the compensation cylinder and cap the open port.
MY5520
3. Slowly loosen and remove the retract (1) hose from the compensation cylinder. 4. Install a tee fitting to the retract (1) port of the compensation cylinder. Reconnect the previously removed retract (1) hose to the tee fitting. 5. Slowly loosen and remove the extend (2) hose from the compensation cylinder. 6. Install a tee fitting to the extend (2) port of the compensation cylinder. Reconnect the previously removed extend (2) hose to the tee fitting and cap the open port.
16. Remove the cap and install a digital or a 5000 psi (345 bar) gauge to the extend (2) port tee fitting on the compensation cylinder. 17. Start the machine and if needed, warm the hydraulic system to operating temperature. 18. Tilt the forks up to allow the tilt cylinder to fully extend. 19. Monitor the gauge and slowly lower the boom. The gauge should read 4100 psi (282 bar). 20. If pressure is correct, proceed to step 23.
7. Install a digital or a 5000 psi (345 bar) gauge to the retract (1) port tee fitting on the compensation cylinder. 8. Start the machine and warm the hydraulic system to operating temperature. 9. Tilt the forks down to allow the tilt cylinder to fully retract.
G10-55A, G12-55A
8-5
Hydraulic System
B
HUSCO
B
REXROTH MY4490
FRONT OF MACHINE
21. If the pressure requires adjustment and if the machine is equipped with a Rexroth main control valve, adjust the relief on the (B) port and repeat steps 17 and 18. If the machine is equipped with a Husco main control valve, the relief on the (B) port is non-adjustable and must be replaced. Replace and repeat steps 17 and 18. 22. Verify pressure is correct. 23. Shut engine OFF. 24. Slowly remove the gauge, line and tee fitting from the compensation cylinder (1 & 2). Reinstall each hose and torque as required. 25. Install any previously removed attachment.
8-6
G10-55A, G12-55A
Hydraulic System a. Pressure Specifications Before S/N 0160037877 Hydraulic Circuit
Test Port
Function Used to Test
Adjustment Location
Main
P1 (A)
Bottom Tilt Down
1
3600-3650 psi (248-252 Bar)
Pilot
JS1 (B)
No Function
2
500-550 psi (34-38 Bar)
Standby
P1 (A)
No Function
3
750-775 psi (52-53 Bar)
Service Brake Supply
BV1 (C)
Bottom Steering, Any Mode
4
1000-1100 psi (69-76 Bar)
Steering
GLS (D)
Bottom Steering, Any Mode
5
2400-2500 psi (165-172 Bar)
Lift
LS2 (E)
Bottom Lift Down
6
3500-3525 psi (241-243 Bar)
Boom Retract
LS2 (E)
Bottom Boom Retract
7
3050-3075 psi (210-212 Bar)
E
HYDRAULIC MANIFOLD
E
HYDRAULIC MANIFOLD
3 1
Pressure Range
3 1
4
4
2
2
A
A
D
C
B
MY1141
D
G10-55A - Before S/N 0160031864 G12-55A - Before S/N 0160030644
C
B
MY1831
G10-55A - S/N 0160031864 & After G12-55A - S/N 0160030644 & After
MAIN CONTROL VALVE
MY1301
7
G10-55A, G12-55A
6
5
8-7
Hydraulic System b. Pressure Specifications S/N 0160037877 & After Hydraulic Circuit
Test Port
Function Used to Test
Adjustment Location
Main
P1 (A)
Bottom Tilt Down
1
3625-3700 psi (250-255 Bar)
Pilot
JS1 (B)
No Function
2
500-550 psi (34-38 Bar)
Standby
P1 (A)
No Function
3
750-775 psi (52-53 Bar)
Service Brake Supply
BV1 (C)
Bottom Steering, Any Mode
4
1050-1150 psi (72-79 Bar)
Steering
GLS (D)
Bottom Steering, Any Mode
5
2450-2550 psi (169-176 Bar)
Load Sense
LS2 (E)
Bottom Tilt Down
6
3350-3450 psi (231-238 Bar)
Boom Extend
LS2 (E)
Bottom Boom Extend
7
3300-3400 psi (227-234 Bar)
Boom Retract
LS2 (E)
Bottom Boom Retract
8
3300-3400 psi (227-234 Bar)
Lift
LS2 (E)
Bottom Lift Down
9
3300-3400 psi (227-234 Bar)
Auxiliary Hydraulic
LS2 (E)
Bottom Auxiliary Function
No Adjustment
3175-3325 psi (219-229 Bar)
E
HYDRAULIC MANIFOLD
Pressure Range
MAIN CONTROL VALVE
3
8
1 4 2
5
6
A
D
C
B
MY1831
7
9
MY4360
8-8
G10-55A, G12-55A
G10-55A, G12-55A
GP
MY1170H
3.66 CID
S
P
L,L1
1100 PSI
BV
BV1
STEERING ORBITROL
500 PSI
JS
LS2
LS
JS1
PR
SL
CYLINDER FRONT STEERING PB
T ST
SR
GLS
SLS
PLS
BLS
T
T STEER SELECT VALVE
A2
P
B2
B1 A1
70 PSI
RETURN FILTER B 8 = 75
CYLINDER REAR STEERING 10 MICRON BREATHER
HYDRAULIC OIL COOLER
STABILIZER CYLINDER W/O LOCK
.030
TANK BT
.030
LOAD SENSE BLS
OUTLET FSB
INLET BV
OUTLET RSB
SERVICE BRAKE VALVE
PARK BRAKES
FRONT SERVICE BRAKES
REAR SERVICE BRAKES
T2
T
SLS
LS
JS
P
PR
TO MAIN CONTROL VALVE
8.4.3
25 PSI
PT
Hydraulic System
Hydraulic Schematic
3625PSI
261PSI
8-9
T2
T
SLS
LS
JS
P
PR
TO PUMP
T
LS
PLS
P
RTT
T LUP
1 2 CIN
PR
2600 PSI
P
3650 PSI
LDN
3
JOYSTICK
b
COUT
LIFT
4
a
5000 PSI
B
A
CROWD
3150 PSI (-0/+25)
LOD
P
T
b a
1
B
2 LOU
A
1 ROD
LEFT OUTRIGGER
2
b a
B
A
B
A
P
T
SRT
1
SWAY
2
b a B
SLT
SWAY OUTRIGGER P T
.050
SWAY CYLINDER
.040
b a
RIGHT OUTRIGGER
5000 PSI
5000 PSI
ROU
RIGHT OUTRIGGER CYLINDER
LEFT AND RIGHT OUTRIGGER JOYSTICK
4100 PSI
5000 PSI
4100 PSI
LEFT OUTRIGGER CYLINDER
4100 PSI
CROWD CYLINDER
4100 PSI
LIFT CYLINDER
A
B
COMPENSATING CYLINDER
TILT
5000 PSI
TILT CYLINDER
4100 PSI
8-10 A
4100 PSI
LIFT CYLINDER
X
1
2
T
P
SV2
LS
P2
T2
SV1
L
SV4
SV3
R
COMBINATION VALVE
SV5
Hydraulic System
8.4.3 Hydraulic Schematic (Continued)
Before S/N 0160037877
MY1180H
G10-55A, G12-55A
G10-55A, G12-55A
T2
T
SLS
LS
JS
P
PR
T
INLET GAGE
GAGE
P
SLS
LS
3400psi
2600psi
PR
HPCO
PRIORITY FLOW INLET
TO PUMP (SEE SHEET 1)
RTT
PPA
LUP
T
P 1
LIFT
CIN
2
A
LDN
3
JOYSTICK
5000 PSI
LIFT CYLINDER
B
4
3300psi
COUT
PPA
5000 PSI
A
CROWD
3300psi
LIFT CYLINDER
B 3300psi
LOD
P
T
5000 PSI
LEFT OUTRIGGER CYLINDER
PPA
2 LOU
2
A
LEFT O/R
4100psi
1 ROD
B
ROU
LEFT AND RIGHT OUTRIGGER JOYSTICK
1
CROWD CYLINDER
4100psi
RIGHT O/R
PPA
5000 PSI
A
B
P
T
1 2
SWAY AUX
RIGHT OUTRIGGER CYLINDER
1
SWAY
PPA
2
.040
A
B
.050
SWAY CYLINDER
PPA
AUX
3000psi
A
B 3000psi
TILT
4100psi
DECOMPRESSION VALVE
"QD'S"
A
B
OUTLET
4100psi
PILOT
COMPENSATING CYLINDER
5000 PSI
TILT CYLINDER
SUMP
Hydraulic System
8.4.3 Hydraulic Schematic (Continued)
S/N 0160037877 & After
MAL0710-C
8-11
Hydraulic System 8.4.3 Hydraulic Schematic (Continued)
SWAY CYLINDER
.050
.040
SWAY/AUX JOYSTICKS T P
1
2
1
2
AUXILIARY HYDRAULICS PORTS
b
B
A
a
b
B
A
a
DECOMPRESSION VALVE
SWAY
AUX
AUXILIARY HYDRAULICS OPTION
8-12
MY1190H
G10-55A, G12-55A
Hydraulic System
8.5
HYDRAULIC RESERVOIR
8.5.2
Hydraulic Oil Reservoir Filling
1. Be sure the reservoir is clean and free of all debris.
JOHN DEERE/PERKINS
1
2. Install a new hydraulic oil filter. 3. Fill the reservoir with hydraulic oil. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 4. Properly connect the battery. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. MY1150
CUMMINS
8.5.3
Hydraulic Oil Reservoir Removal/ Installation
If it is determined that the hydraulic oil reservoir must be removed, the hydraulic oil must be drained before the reservoir is removed. Always dispose of hydraulic oil properly.
1
a. Reservoir Removal
MY5300
The hydraulic reservoir (1) is located on the frame between the engine compartment and the cab.
8.5.1
Hydraulic Oil Reservoir Draining
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Open the filler cap on the hydraulic oil reservoir. Remove the drain plug on the side of the hydraulic oil reservoir. 6. Transfer the used hydraulic oil into a suitable covered container, and label as "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
G10-55A, G12-55A
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Drain the hydraulic oil reservoir. Refer to Section 8.5.1, “Hydraulic Oil Reservoir Draining.” 6. Label, disconnect and cap all hydraulic hoses attached to the hydraulic oil reservoir. Cap all fittings and openings to keep dirt & debris from entering the hydraulic system. 7. Remove the bolts securing the hydraulic oil reservoir to the frame. 8. Remove the hydraulic oil reservoir. b. Disassembly The hydraulic oil reservoir is a one-piece unit and cannot be disassembled. The hydraulic oil level sight- glass and hydraulic oil filler cap can be removed and reused on the new replacement reservoir. Dispose of the old reservoir according to local regulations concerning hazardous materials disposal.
8-13
Hydraulic System c. Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the hydraulic oil reservoir, contact your local distributor. To clean the hydraulic oil reservoir: 1. Have a dry chemical (Class B) fire extinguisher near the work area. 2. Remove the hydraulic oil reservoir drain plug, and safely drain any hydraulic oil into a suitable container. Dispose of hydraulic oil properly. 3. Clean the hydraulic oil reservoir with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly. d. Inspection
8.6
IMPLEMENT PUMP
For internal service instructions contact your local distributor.
8.6.1
Implement Pump Replacement
a. Pump Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
1. Inspect the hydraulic oil reservoir thoroughly for any cracks, slices, leaks or other damage.
5. Drain the hydraulic reservoir. Refer to Section 8.5.1, “Hydraulic Oil Reservoir Draining.”
2. With the hydraulic oil reservoir removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 1-1.5 psi (7-10 kPa) of air pressure through the elbow. Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area.
6. Thoroughly clean the pump and surrounding area, including all hoses and fittings before proceeding. Note: Cap all hoses as you remove them to prevent unnecessary fluid spillage. 7. Label, disconnect and cap the hydraulic hoses attached to the pump.
e. Reservoir Installation 1. Place the hydraulic oil reservoir into its original orientation. 2. Secure the hydraulic oil reservoir to the frame with the previous mounting hardware.
2
3. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations.
2
4. Install the hydraulic fluid level sight-glass using special designed and drilled capscrews and gaskets. 5. Install hydraulic filter bracket and hydraulic filter. 6. Fill the hydraulic oil reservoir according to specifications. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 7. Check the hydraulic oil reservoir for leaks. 8. Properly connect the battery. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
8-14
MAL0720
8. Remove the four bolts and lockwashers (2) securing the pump to the transmission (top bolts shown only). Remove the o-ring located between the transmission and the pump. Wipe up any hydraulic oil spillage. G10-55A, G12-55A
Hydraulic System Note: DO NOT disassemble the operating pump. The pump is pre-set from the manufacturer. Any adjustments or repairs performed by anyone other than an authorized dealer could void the warranty. b. Pump Installation 1. Place the pump and a new, oiled o-ring into position on the transmission. Align the pump shaft with the internal transmission gear, so that the machined teeth mesh together. 2. Align the bolt holes with the pump mount holes. 3. Apply Loctite® 242 to the previously removed bolts. 4. Secure the pump to the transmission with the four bolts and washers. Torque as required. 5. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 6. Fill the hydraulic reservoir. Refer to Section 8.5.2, “Hydraulic Oil Reservoir Filling.” 7. Prime the pump by filling the case drain port with fresh, filtered hydraulic oil from a clean container before installing the case drain connector and hose. 8. Check all routing of hoses and tubing for sharp bends or interference with any rotating members. All tube and hose clamps must be tight. 9. Remove the 10 amp fuse from location F3 in power distribution unit located in the engine compartment. This will allow the engine to crank, but not start while air is worked out of the new pump. 10. Connect a hose to the “P1” port on the pump. Direct the open end of the hose into a fluid drip pan. 11. Properly connect the battery. 12. Turn the machine ignition switch to START and back OFF in 3 to 5 second intervals. Monitor the open end of the drain hose for a constant flow of fluid (no air) while engine is cranking. 13. Once a constant flow is achieved at the open end of the drain hose, disconnect the hose and reinstall the 10 amp fuse to location F3 in the power distribution unit.
8.7 8.7.1
CONTROL VALVES Main Control Valve
The main control valve is mounted at the top of the chassis in front of the mast supports. The main control valve assembly consists of individual working sections with their own valve assemblies, each providing a specific hydraulic function. a. Main Control Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Close the engine cover. 6. Remove the main valve cover. 7. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding. 8. Drain the hydraulic fluid reservoir. Refer to Section 8.5.1, “Hydraulic Oil Reservoir Draining.” 9. Place a suitable container to catch hydraulic fluid drainage beneath the frame. Note: Slowly remove the hydraulic hoses attached to the main control valve to relieve any possible trapped pressure in the hydraulic line. 10. Label, disconnect and cap all the hydraulic hoses, tubes and wires at the main control valve. 11. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
14. Inspect for leaks and check all fluid levels. The hydraulic reservoir oil level must be to the middle of the sight gauge. 15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. c. Pump Test Refer to Section 8.3.1, “Pressure Checks and Adjustments.” G10-55A, G12-55A
8-15
Hydraulic System 3. Carefully separate each remaining sections, being careful not to lose the load sense shuttle ball. 4. Remove both end caps from each end of the valve sections then remove each control spool.
1
5. Remove any check valves, compensator valves, anti-cavitation valves or shock valves from individual valve section if equipped.
1
6. Keep all parts being removed from individual valve sections tagged and kept together. c. Main Control Valve Parts Cleaning
1
Clean all components with a suitable cleaner, such as triclorethylene, before continuing. Blow dry. 1
d. Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear, damage, etc. If inner surfaces of any component DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals, damage to the polished surfaces within the component, and wear of and/or harm to other parts.
MAL0730
12. Remove the four bolts, washers and nuts (1) securing the main control valve to the frame. b. Main Control Valve Disassembly
2
8.7.2
Main Control Valve Assembly
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Assemble each Valve Section
MY1200
1. To disassemble the individual sections of the main control valve, remove the nuts from one end of the tie rods (2). Pull the tie rods out through the sections. 2. Disassemble each section assembly as required. Some sections include a pre-adjusted relief valve that regulates pressure in a specific circuit. Note: DO NOT adjust any of the relief valve assemblies! Tampering with a relief valve will irrevocably alter pressure in the affected circuit, requiring recalibration or a new relief valve. Disassemble each Valve Section 1. Carefully separate the load sense outlet section from the lift/lower section.
1. Reassemble any check valves, compensator valves, anti-cavitation valves or shock valves from each individual valve sections if equipped. 2. Install the control spool being careful not to nick or scratch the valve section bore or the control spool. 3. Install the end caps on each end of the valve section. Assemble the Main Control Valve. 1. Place all three tie rods (2) with the washers and nuts through the end main control valve section. 2. Stand the end main control valve section on end. 3. Install the proper o-rings and load sense shuttle on the inner face of the end main control valve section. Align the tilt control valve section over the three tie rods and slide onto the end main control valve section.
2. Remove the o-rings from between the two sections. 8-16
G10-55A, G12-55A
Hydraulic System 4. Using the proper o-rings and load sense shuttle, repeat step three for the remaining valve sections and lastly the inlet end valve section. 5. Install the three washers and nuts on the tie rods. Torque to 30 lb-ft (41 Nm). e. Main Control Valve Installation 1. Install the main control valve onto the frame, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts. 2. Prime the main control valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses. 3. Use new oiled o-rings as required. Uncap and connect all previously labeled hoses, clamps, etc. to the main control valve. 4. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps.
8.7.3
Service Brake Valve
a. Service Brake Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Label, disconnect and cap all hose attached to the service brake valve. 6. Remove the service brake pedal. Refer to Section 4.3.2, “Service Brake Pedal.” 4
5. Fill the hydraulic fluid reservoir. Refer to Section 8.5.2, “Hydraulic Oil Reservoir Filling.”
3 3
6. Properly connect the battery. 7. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions.
5
8. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 10. Install the main control valve cover. 11. Close and secure the engine cover. 12. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. f.
MAL0740
7. Remove the four capscrews, four nuts and four lockwashers (3) mounting the service brake valve (4) to the service brake bracket (5). Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective.
Main Control Valve Test
Conduct a pressure check of the hydraulic system in its entirety. Adjust pressure(s) as required. Refer to Section 8.3.1, “Pressure Checks and Adjustments.”
G10-55A, G12-55A
8-17
Hydraulic System b. Service Brake Valve Installation 1. Install the service brake valve (4) with the four capscrews, four lockwashers and four nuts (3) onto the service brake bracket (5).
6
2. Install the service brake pedal. Refer to Section 4.3.2, “Service Brake Pedal.” Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 3. Use new oiled o-rings as required. Uncap and connect the previously labeled hoses to the service brake valve. 4. Check the routing of all hoses, and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 5. Properly connect the battery. 6. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic functions. 7. Inspect the service brake valve and connections for leaks, and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
8.7.4
Service Brake Bleeding
6 MAL0750
2. Remove the plastic cap from one service brake bleeder (6). Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil. The end of the tubing must be below the oil level in the container. 3. Have the assistant depress the brake pedal. DO NOT open the service brake bleeder without holding the tubing firmly on the bleeder. There is pressure at the brakes. Carefully open the bleeder with a 12 mm. wrench. Close the service brake bleeder when air bubbles no longer appear in the oil. Release the brake pedal. Remove the tubing from the service brake bleeder. 4. Repeat Steps 2 and 3 for the remaining service brake bleeders. 5. Check hydraulic oil level and add if necessary. 6. Conduct a pressure and function check of the service brake. Refer to Section 8.4.1, “ Hydraulic Pressures.”
Carefully bleed the brake lines as soon as the brake valve is installed in the machine. Air in the system will not allow the brakes to apply properly. There are four brake bleeder located on the front axle (two inner service brake bleeders and two outer park brake bleeders) and two service brake bleeders on the rear axle). Work with an assistant to perform this procedure. 1. Place the travel select lever in (N) NEUTRAL, engage the park brake, and start the engine.
8-18
G10-55A, G12-55A
Hydraulic System 8.7.5
Service Brake Test
This procedure is used in order to determine if the service brake is functional. This procedure is not intended to measure the maximum brake performance. the brake holding torque that is required to sustain an engine torque at a specific engine rpm varies depending on the machine configuration. The variations are the differences in the engine settings, power train efficiency and in the brake holding ability, etc. Conduct the following service brake test on a dry level surface, clear of any personnel and/or obstacles. 1. Place the travel select lever in (N) NEUTRAL, engage the park brake, and start the engine. 2. Raise the boom to a travel position. 3. Depress the service brake, disengage the parking brake and place the travel select lever in third gear forward.
4. Smoothly and controllably release the service brake. 5. Smoothly and controllably depress the throttle pedal. Note: Do Not hold the accelerator pedal in the fully depressed position for more than ten seconds. Damage to the power train could occur. 6. Smoothly and controllably fully release the throttle pedal. 7. The machine should remain stationary during the test. 8. If the machine does not remain stationary during this test, contact the local distributor for proper service. 9. Engage the park brake, place the travel select lever in (N) NEUTRAL, lower the boom and shut engine OFF.
8.7.7
Steering Orbitrol Valve
4. Smoothly and controllably depress the throttle pedal. Note: Do Not hold the accelerator pedal in the fully depressed position for more than ten seconds. Damage to the power train could occur. 5. Smoothly and controllably fully release the throttle pedal. 6. The machine should remain stationary during the test. 7. If the machine does not remain stationary during this test, contact the local distributor for proper service. 8. Engage the park brake, place the travel select lever in (N) NEUTRAL, lower the boom and shut engine OFF.
8.7.6
Park Brake Test
This procedure is used in order to determine if the parking brake is functional. This procedure is not intended to measure the maximum brake performance. the brake holding torque that is required to sustain an engine torque at a specific engine rpm varies depending on the machine configuration. The variations are the differences in the engine settings, power train efficiency and in the brake holding ability, etc. Conduct the following parking brake test on a dry level surface, clear of any personnel and/or obstacles.
MY4280
7
The steering orbitrol valve (7) is located at the base of the steering wheel shaft, concealed by the lower dash cover. The valve is not serviceable and must be replaced in its entirety if defective. For detailed information refer to Section 4.3.1, “Steering Column and Orbitrol Valve.”
1. Place the travel select lever in (N) NEUTRAL, engage the park brake, and start the engine. 2. Raise the boom to a travel position. 3. Depress the service brake, disengage and place the travel select lever in first gear forward. G10-55A, G12-55A
8-19
Hydraulic System 8.7.8
Steer Select Valve
b. Steer Select Manifold and Valve Disassembly, Cleaning, Inspection and Assembly 1. Place the steer select assembly on a suitable work surface. 2. Separate the steer select valve from the manifold by removing the four socket head capscrews. Discard the four o-rings.
8
3. Remove the solenoid valves and cartridges from the steer select housing. 4. Clean all components with a suitable cleaner before inspection. MY4290
The machine can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve (8) controls the direction of hydraulic fluid flow to the steering cylinder mounted on each axle. The steer select valve is attached to a mounting plate under the frame near the left front corner of the cab. Verify the correct operation of the steer select valve solenoids before considering replacement of the valve. Refer to Section 9.5, “Electrical System Schematics,” and Section 9.11, “Display Monitor and Gauges.” The housing of the steer select valve is not serviceable and must be replaced if defective. a. Steer Select Manifold and Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Label, disconnect and cap the hydraulic hoses and the electrical plugs connected to the steering select valve. 6. Remove the bolts holding the steer select valve to the mounting plate on the frame. 7. Remove the steer select manifold with the attached steer select valve from the machine. Wipe up any hydraulic fluid spillage in, on, near and around the machine.
8-20
5. Inspect the solenoid cartridges for proper operation. Check by shifting the spool to ensure that it is functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination. 6. Inspect internal passageways of the steer select manifold and valve for wear, damage, etc. If inner surfaces of the manifold DO NOT display an ultrasmooth, polished finish, or components are damaged in any way, replace the manifold or appropriate part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 7. Install the solenoid valves and cartridges in the steer select housing. 8. Attach the steer select valve to the manifold using four new, oiled o-rings and the four socket head capscrews. c. Steer Select Valve and Manifold Installation 1. Install the steer select valve to the mounting plate under the left front side of the frame using the two bolts. 2. Connect all the hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the steer select valve 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 4. Properly connect the battery. 5. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions.
G10-55A, G12-55A
Hydraulic System 6. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.
a. General Cylinder Disassembly 1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder. 2. Clamp the barrel end of the cylinder in a soft-jawed vise or other acceptable holding equipment if possible.
8. Close and secure the engine cover. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. d. Steering Test
WARNING Significant pressure may be trapped inside the cylinder. Exercise caution when removing a counterbalance valve or a pilot-operated check valve from a cylinder.
Refer to Section 8.4.1, “ Hydraulic Pressures.” 1. Conduct a pressure check of the steering hydraulic circuit. 2. Check each steering mode for proper function.
8.8 8.8.1
Note: Avoid using excessive force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely. Excessive force can damage the cylinder tube. 1
HYDRAULIC CYLINDERS General Cylinder Removal Instructions
1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retract the boom. Allow sufficient work space around the hydraulic cylinder being removed. Support the boom if the lift/lower cylinder is being removed. Place the travel select lever in (N) NEUTRAL, engage the park brake, shut the engine OFF and chock wheels.
6
2
5
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Label, disconnect and cap or plug hydraulic hoses in relation to the cylinder. 6. Attach a suitable sling to an appropriate lifting device and to the cylinder. Make sure the device used can actually support the cylinder. 7. Remove the lock bolt and/or any retaining clips securing the cylinder pins. Remove the cylinder pins. 8. Remove the cylinder. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.
G10-55A, G12-55A
4 3 MY4300
3. If applicable, remove the counterbalance valve (1) from the side of the cylinder barrel (2). Note: DO NOT tamper with or attempt to adjust the counterbalance valve cartridge. If adjustment or replacement is necessary, replace the counterbalance valve with a new part. 4. Extend the rod (3) as required to allow access to the base of the cylinder.
8-21
Hydraulic System Note: Protect the finish of the rod at all times. Damage to the surface of the rod can cause seal failure. 5. Using a pin spanner wrench, unscrew the head gland (4) from the tube (2). A considerable amount of force will be needed to remove the head gland. 6. Carefully slide the head gland down along the rod toward the rod eye, away from the cylinder barrel. Note: When sliding the rod and piston assembly out of the barrel, prevent the threaded end of the barrel from damaging the piston. Keep the rod centered within the barrel to help prevent binding. 7. Carefully pull the rod assembly (3) along with the head gland (4) out of the cylinder barrel. 8. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. 9. Remove the set screw from the piston head (5). 10. If equipped, remove the piston head (5) mounting nut (6). Note: It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed. Some cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these parts, remove any accessible seals from the area of the bonded parts. Wipe off any hydraulic oil, then heat the part(s) uniformly to break the bond. A temperature of 300-400° F (149-204° C) will destroy the bond. Avoid overheating, or the parts may become distorted or damaged. Apply sufficient torque for removal while the parts are still hot. The sealant often leaves a white, powdery residue on threads and other parts, which must be removed by brushing with a soft brass wire brush prior to reassembly. 11. Remove the piston head (5) from the rod (3) and carefully slide the head gland (4) off the end of the rod. 12. Remove all seals, back-up rings and o-rings from the piston head and all seals, back-up rings and o-rings from the head gland. Note: The head gland bearing will need to be inspected to determine if replacement is necessary. DO NOT attempt to salvage cylinder seals, sealing rings or o-rings. ALWAYS use a new, complete seal kit when rebuilding hydraulic components. Consult the parts catalog for ordering information.
8-22
b. Cylinder Cleaning Instructions 1. Discard all seals, back-up rings and o-rings. Replace with new items from seal kit to ensure proper cylinder function. 2. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, grooves, threads, etc. Note: If a white powdery residue is present on threads or parts, it can be removed by using a soft brass wire brush. Wipe clean with Loctite® Cleaner prior to reassembly.
8.8.2
Cylinder Inspection
1. Inspect internal surfaces and all parts for wear, damage, etc. If the inner surface of the cylinder barrel does not display a smooth finish, or is scored or damaged in any way, replace the barrel. 2. Remove light scratches on the piston, head gland, rod or inner surface of the cylinder barrel with a 400600 grit emery cloth. Use the emery cloth in a rotary motion to polish out and blend the scratch(es) into the surrounding surface. 3. Check the piston rod assembly for run-out. If the rod is bent, it must be replaced. c. General Cylinder Assembly Instructions 1. Use the proper tools for specific installation tasks. Clean tools are required for installation. 2. Install new seals, back-up rings and o-rings on the piston and new seals, back-up rings, o-rings and bearing on the head gland. Note: The extend/retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head. 3. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. Note: Protect the finish on the cylinder rod at all times. Damage to the surface of the rod can cause seal failure. 4. Lubricate and slide the head gland over the cylinder rod. Install the piston head on to the end of the cylinder rod. Loctite® and install the set screw in the piston head. Refer to Section 8.8.5, “Cylinder Torque Specifications” for torque specifications for the piston head and the set screw.
G10-55A, G12-55A
Hydraulic System Note: Avoid using excess force when clamping the cylinder barrel in a vise. Apply only enough force to hold the cylinder barrel securely. Excessive force can damage the cylinder barrel. 5. Place the cylinder barrel in a soft-jawed vise or other acceptable holding devise. Note: When sliding the rod and piston assembly into the cylinder barrel, prevent the threaded end of the cylinder barrel from damaging the piston head. Keep the cylinder rod centered within the barrel to prevent binding. 6. Carefully insert the cylinder rod assembly into the cylinder barrel. 7. Screw the head gland into the cylinder barrel and tighten with a spanner wrench. Refer to Section 8.8.5, “Cylinder Torque Specifications” for torque specifications for the head gland.
8.8.3
Cylinder Pressure Checking
Attach a 5000 psi (345 bar) gauge to the test port on the P1 port on the hydraulic manifold to check the system pressure. For more information, refer to Section 8.4.1, “ Hydraulic Pressures.” Note: If a hydraulic cylinder pressure is greater than the main control valve pressure, increase the main control valve pressure by adjusting the main relief. Generally, one half turn clockwise will be adequate to check an individual circuit. Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn. Re-check the main relief setting and adjust if necessary.
8.8.4
Steering Cylinders STEERING CYLINDER
8. If applicable, install new counter balance valve into block on the cylinder barrel. d. General Cylinder Installation 1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the cylinder into it’s mounting position. 2. Align cylinder bushing and install pin, lock bolt or retaining clip. 3. Connect the hydraulic hoses in relation to the labels or markings made during removal. 4. Before starting the machine, check fluid level of the hydraulic fluid reservoir and if necessary fill to full mark with hydraulic oil. 5. Properly connect the battery.
AXLE CENTER SECTION
MY4310
The steer cylinder is attached to each axle center housing.The steer cylinder assembly can be found in Section 5.3, “Axle Assemblies.” The steer cylinder is covered in the appropriate manufacturer’s axle literature.
6. Start the machine and run at low idle for about one minute. Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil. 7. Inspect for leaks and check level of hydraulic fluid in reservoir. Add hydraulic fluid if needed. Shut the engine OFF. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
G10-55A, G12-55A
8-23
Hydraulic System 8.8.5
Cylinder Torque Specifications
a. Lift/Lower Cylinder
G10-55A - Before S/N 0160033659 excluding 0160033452
Head
Nut
CB Valve
CB Cap Screw
550-600 lb-ft (745-813 Nm)
2125-2175 lb-ft (2881-2949 Nm)
45-50 lb-ft (54-61 Nm)
28-30 lb-ft (38-41 Nm)
1600-2000 lb-ft (2169-2711 Nm)
30-35 lb-ft (40-47 Nm)
24-27 lb-ft (32-36 Nm)
G10-55A - S/N 0160033659 thru 0160035822 including 0160033452 G10-55A - S/N 0160035822 & After
755-923 lb-ft (1024-1251 Nm)
1600-2000 lb-ft (2169-2711 Nm)
30-35 lb-ft (40-47 Nm)
24-27 lb-ft (32-36 Nm)
G12-55A - Before S/N 0160033659 excluding 0160033452
550-600 lb-ft (745-813 Nm)
2850-2900 lb-ft (3864-3932 Nm)
45-50 lb-ft (54-61 Nm)
28-30 lb-ft (38-41 Nm)
1600-2000 lb-ft (2169-2711 Nm)
45-50 lb-ft (54-61 Nm)
24-27 lb-ft (32-36 Nm)
755-923 lb-ft (1024-1251 Nm)
1600-2000 lb-ft (2169-2711 Nm)
45-50 lb-ft (54-61 Nm)
24-27 lb-ft (32-36 Nm)
Head
Nut
CB Valve (Large)
CB Valve (Small)
500-550 lb-ft (678-745 Nm)
1325-1375 lb-ft (1796-1864 Nm)
110 lb-ft (149 Nm)
35 lb-ft (47 Nm)
G10-55A - S/N 0160033661 thru 0160035822
1400-1700 lb-ft (1796-1864 Nm)
110 lb-ft (149 Nm)
33 lb-ft (44 Nm)
G10-55A - S/N 0160035822 & After
1400-1700 lb-ft (1796-1864 Nm)
110 lb-ft (149 Nm)
33 lb-ft (44 Nm)
1325-1375 lb-ft (1796-1864 Nm)
110 lb-ft (149 Nm)
35 lb-ft (47 Nm)
G12-55A - S/N 0160033659 thru 0160035879 including 0160033452
1400-1700 lb-ft (1796-1864 Nm)
110 lb-ft (149 Nm)
33 lb-ft (44 Nm)
G12-55A - S/N 0160035879 & After
1400-1700 lb-ft (1796-1864 Nm)
110 lb-ft (149 Nm)
33 lb-ft (44 Nm)
G12-55A - S/N 0160033659 thru 0160035879 including 0160033452 G12-55A - S/N 0160035879 & After b. Extend/Retract Cylinder
G10-55A - Before S/N 0160033661
G12-55A - Before S/N 0160033659 excluding 0160033452
8-24
500-550 lb-ft (678-745 Nm)
G10-55A, G12-55A
Hydraulic System c. Tilt Cylinder Head
Nut
CB Valve
550-600 lb-ft (745-813 Nm)
2050-2100 lb-ft (2779-2847 Nm)
44 lb-ft (60 Nm)
G10-55A - S/N 0160033661 thru 0160035822
2200-2400 lb-ft (2982-3254 Nm)
44 lb-ft (60 Nm)
G10-55A - S/N 0160035822 thru 0160037689
2200-2400 lb-ft (2982-3254 Nm)
44 lb-ft (60 Nm)
G10-55A - Before S/N 0160033661
G10-55A - S/N 0160037689 & After
500-600 lb-ft (678-813 Nm)
2200-2500 lb-ft (2982-3389 Nm)
40-45 lb-ft (54-61 Nm)
G12-55A - Before S/N 0160033659 excluding 0160033452
550-600 lb-ft (745-813 Nm)
2250-2300 lb-ft (3050-3118 Nm)
44 lb-ft (60 Nm)
G12-55A - S/N 0160033659 thru 0160035879 including 0160033452
2400-2600 lb-ft (3254-3525 Nm)
44 lb-ft (60 Nm)
G12-55A - S/N 0160035879 thru 0160037689
2400-2600 lb-ft (3254-3525 Nm)
44 lb-ft (60 Nm)
2200-2500 lb-ft (2982-3389 Nm)
40-45 lb-ft (54-61 Nm)
G12-55A - S/N 0160037689 & After
500-600 lb-ft (678-813 Nm)
d. Compensation Cylinder
G10-55A - Before S/N 0160033659 excluding 0160033452
Head
Nut
550-600 lb-ft (745-813 Nm)
2050-2100 lb-ft (2779-2847 Nm)
G10-55A - S/N 0160033659 thru 0160037689 including 0160033452
2200-2400 lb-ft (2982-3254 Nm)
G10-55A - S/N 0160037689 & After
2200-2400 lb-ft (2982-3254 Nm)
G12-55A - Before S/N 0160033659 excluding 0160033452
600 lb-ft (813 Nm)
2250-2300 lb-ft (3050-3118 Nm)
G12-55A - S/N 0160033659 thru 0160037689 including 0160033452
1600-2000 lb-ft (2169-2712 Nm)
G12-55A - S/N 0160037689 & After
1600-2000 lb-ft (2169-2712 Nm)
G10-55A, G12-55A
8-25
Hydraulic System e. Sway Cylinder Head
Nut
Check Valve
300-325 lb-ft (407-441 Nm)
750-800 lb-ft (1016-1085 Nm)
15 lb-ft (20 Nm)
G10-55A - S/N 0160033661 thru 0160037690
1125-1375 lb-ft (1525-1864 Nm)
33 lb-ft (45 Nm)
G10-55A - S/N 0160037690 & After
1125-1375 lb-ft (1525-1864 Nm)
33 lb-ft (45 Nm)
750-800 lb-ft (1016-1085 Nm)
15 lb-ft (20 Nm)
G12-55A - S/N 0160033659 thru 0160035879 including 0160033452
1125-1375 lb-ft (1525-1864 Nm)
33 lb-ft (45 Nm)
G12-55A - S/N 0160035879 & After
1125-1375 lb-ft (1525-1864 Nm)
33 lb-ft (45 Nm)
G10-55A - Before S/N 0160033661
G12-55A - Before S/N 0160033659 excluding 0160033452
f.
300-325 lb-ft (407-441 Nm)
Stabilizer Cylinder
G10-55A - Before S/N 0160033661
Head
Nut
Cartridge
Cartridge Nut
300-325 lb-ft (407-441 Nm)
775-825 lb-ft (1050-1119 Nm)
22 lb-ft (30 Nm)
2.5 lb-ft (3,3 Nm)
800-1000 lb-ft (1085-1356 Nm)
22 lb-ft (30 Nm)
2.5 lb-ft (3,3 Nm)
775-825 lb-ft (1050-1119 Nm)
22 lb-ft (30 Nm)
2.5 lb-ft (3,3 Nm)
800-1000 lb-ft (1085-1356 Nm)
22 lb-ft (30 Nm)
2.5 lb-ft (3,3 Nm)
G10-55A - S/N 0160033661 & After
G12-55A - Before S/N 0160033659 excluding 0160033452
300-325 lb-ft (407-441 Nm)
G12-55A - S/N 0160033659 & After including 0160033452 g. Outrigger Cylinder
8-26
Head
Nut
Valve Mount
100-400 lb-ft (136-542 Nm)
1300-1350 lb-ft (1762-1830 Nm)
30-35 lb-ft (41-47 Nm)
100-400 lb-ft (136-542 Nm)
1100 lb-ft (1491 Nm)
30-35 lb-ft (41-47 Nm)
G10-55A, G12-55A
Section 9 Electrical System
Contents PARAGRAPH 9.1
9.2 9.3 9.4
9.5
9.6
9.7
G10-55A, G12-55A
TITLE
PAGE
Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.1.1 General Overview - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.1.2 General Overview - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.1.3 General Overview - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.4.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.4.3 Power Distribution Unit (VEC) - John Deere/Perkins . . . . . . . . . . . . . . . . 9-7 9.4.4 Power Distribution Unit (VEC) - Cummins . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.4.5 Optional Power Distribution Unit (VEC) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.5.1 Cab Schematic - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.5.2 Cab Schematic - Perkins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 9.5.3 Cab Schematic - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 9.5.4 Options Schematic - John Deere/Perkins . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 9.5.5 Options - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 9.5.6 Chassis Schematic - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 9.5.7 Chassis Schematic - Perkins Before S/N 0160037186. . . . . . . . . . . . . . . 9-16 9.5.8 Chassis Schematic - Perkins S/N 0160037186 Thru 0160039397 Excluding 0160039394 & 0160039397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17 9.5.9 Chassis Schematic - Cummins S/N 0160039451 and After Including 0160039394 & 0160039397. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 9.5.10 Power Unit Schematic - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 9.5.11 Power Unit Schematic - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20 9.5.12 Power Unit Schematic - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22 9.6.1 Constant Power Circuit from Battery - John Deere & Perkins. . . . . . . . . . 9-22 9.6.2 Constant Power Circuit from Battery - Cummins . . . . . . . . . . . . . . . . . . . 9-23 9.6.3 Start & Charge Circuit - John Deere & Perkins . . . . . . . . . . . . . . . . . . . . . 9-24 9.6.4 Start & Charge Circuit - Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 9.7.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27 9.7.3 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9-1
Electrical System 9.8 9.9 9.10
9.11 9.12
9.13
9.14 9.15
9-2
Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1 Fuel Shut-off Solenoid - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.2 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.3 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.4 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.5 Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.6 Air Manifold Temperature Sensor - John Deere . . . . . . . . . . . . . . . . . . . . 9.10.7 Engine Oil Pressure Sender/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.8 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.9 Inclinometer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.10 Front and Rear Axle Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting - John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.1 Engine Fault Codes Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.2 Engine Fault Codes Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . .
9-28 9-29 9-30 9-30 9-30 9-30 9-31 9-32 9-32 9-32 9-34 9-34 9-35 9-36 9-37 9-37 9-37 9-38 9-38 9-39 9-40 9-40 9-40 9-42 9-43
G10-55A, G12-55A
Electrical System
9.1
ELECTRICAL COMPONENT TERMINOLOGY
To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
9.1.1
General Overview - John Deere
4 IN 1 GAUGE
DASH SWITCHES
OPTIONAL POWER DISTRIBUTION UNIT (behind dash panel)
OPTIONAL HEATER/AC CONTROLS MY5540
IGNITION SWITCH
ALTERNATOR OIL PRESSURE SWITCH
POWER DISTRIBUTION UNIT (in engine compartment)
COOLANT TEMPERATURE SENDER OIL PRESSURE SENDER
FUEL SHUT-OFF SOLENOID
STARTER RELAY
MY1030
MY1281
ENGINE CONTROL MODULE (ECM)
G10-55A, G12-55A
9-3
Electrical System 9.1.2
General Overview - Perkins
3 IN 1 GAUGE
DASH SWITCHES
OPTIONAL POWER DISTRIBUTION UNIT (behind dash panel)
OPTIONAL HEATER/AC CONTROLS MY4350
IGNITION SWITCH
POWER DISTRIBUTION UNIT (in engine compartment) COOLANT TEMPERATURE SENDER (Below Alternator)
ALTERNATOR
ENGINE CONTROL MODULE (ECM)
OIL PRESSURE SWITCH
OIL PRESSURE SENDER
STARTER RELAY
MAL0320 MY1850
9-4
G10-55A, G12-55A
Electrical System 9.1.3
General Overview - Cummins
3 IN 1 GAUGE
DASH SWITCHES
OPTIONAL POWER DISTRIBUTION UNIT (behind dash panel)
OPTIONAL HEATER/AC CONTROLS MY4350
IGNITION SWITCH
POWER DISTRIBUTION UNIT (in engine compartment)
FUSE HOLDER
COOLANT TEMPERATURE SENDER
MY4550
ALTERNATOR
OIL PRESSURE SENDER
STARTER RELAY
RELAY
ENGINE CONTROL MODULE (ECM) MY4540
G10-55A, G12-55A
9-5
Electrical System
9.2
SPECIFICATIONS
9.4.2
Cab
Electrical system specifications are listed in Section 2, “General Information and Specifications.”
9.3
3
SAFETY INFORMATION TILT SPEED CONTROL
WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual.
9.4 9.4.1
FUSES AND RELAYS Engine Compartment MY0410
PERKINS
JOHN DEERE
2
2
The optional power distribution unit is located in the cab. For access, remove the screws securing the load chart panel (3) to the dash.
1
1
MY1800
CUMMINS
2
1
MY4550
The starter relay (1) and power distribution unit (2) is located on the power distribution unit bracket in the engine compartment.
9-6
G10-55A, G12-55A
Electrical System 9.4.3
Power Distribution Unit (VEC) - John Deere/Perkins
F8
F3
CB3
F4
CB4
CB2
F9
F7
F10 F11
IGN1 CB1
F1 IGN3
ACCY1
F12
F5 F6
F2 ACCY2
MY1250
Connector Legend No.
Function
Amp Rating
CB1
Options Power 3
20
CB2
Options Power 4
20
CB3
Options Power 1
20
CB4
Options Power 2
20
F1
Trans/Park Brake Power
15
F2
Alternator Excite
5
F3
Engine ECU Ignition Power
10
F4
Gauge Power
10
F5
Spare Accessory Power
15
F6
Auxiliary Electric Power
10
F7
Horn Power
15
F8
Spare Battery Power
25
F9
Engine ECU Battery Power
25
F10
Steer/Sway Power
10
F11
Rear Axle Stabilizer/Tilt Power
10
F12
Key Battery Power
15
IGN1
Ignition 1
IGN 2
Ignition 2
ACCY1
Accessory 1
ACCY2
Accessory 2
G10-55A, G12-55A
9-7
Electrical System 9.4.4
Power Distribution Unit (VEC) - Cummins
F8
F3
F15
F4
F16
F14
F9
F7
F10 F11
IGN1 F13
F1 IGN3
ACCY1
F12
F5 F6
F2 ACCY2
MY4610
Connector Legend No.
Function
Amp Rating
F1
Trans/Park Brake Power
15
F2
Alternator Excite
5
F3
Engine ECU Ignition Power
10
F4
Gauge Power
10
F5
Spare Accessory Power
15
F6
Auxiliary Electric Power
10
F7
Horn Power
15
F8
Spare Battery Power
25
F9
Engine ECU Battery Power
25
F10
Steer/Sway Power
10
F11
Rear Axle Stabilizer/Tilt Power
10
F12
Key Battery Power
15
F13
Options Power 3
20
F14
Options Power 4
20
F15
Options Power 1
20
F16
Options Power 2
20
IGN1
Ignition 1
IGN 2
Ignition 2
ACCY1
Accessory 1
ACCY2
Accessory 2
9-8
G10-55A, G12-55A
Electrical System 9.4.5
Optional Power Distribution Unit (VEC)
F1
R1
F2 F3
R2
F4 F5
R3
F6 F7
R4
F8
R5 R6 R7 R8
MY1260
Connector Legend No.
Function
Amp Rating
F1
Wiper
20
F2
Option (Roof Wiper)
5
F3
Option
15
F4
Option
25
F5
Heater
20
F6
Lights
20
F7
Beacon
10
F8
Dash Fan
10
R1
Wiper
R2
Heater Blower
R3
Aux Elec 1
R4
Aux Elec 2
R5
Option
15
R6
Option
25
R7
Lights
R8
Beacon/Fan
G10-55A, G12-55A
9-9
G10-55A, G12-55A MY1060
KEY BAT PWR
B
S I
A
G
ON
DASH PANEL HARNESS HD34-24-31ST
3
2
OFF
ON
OFF
SHTDN OVR
3
2
HORN
(BLK, 18 GA GXL)
CHECK ENG (RED, 18 GA GXL)
TRANS TMP WRN (RED, 18 GA GXL)
LEFT DASH PANEL
TRAN/BRK PWR
4
5
6
2
3 ON
OFF
1 7
PK BRK SOL
6
3
7
PARK BRAKE
5
CRAB
ALL WHL
4
2
-
1
STEER MODE
+
DASH GND
ST RLY PK BRK SOL SHIFT PWR 1
HR MTR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
3
1 2 3 4 5 6 7 8
4 B+
(D BLU, 18 GA GXL) (D BLU, 18 GA GXL) (BLK, 18 GA GXL) (D BLU, 18 GA GXL) (RED, 18 GA GXL) (ORG, 18 GA GXL) (D BLU, 18 GA GXL) (ORG, 18 GA GXL)
2
FUL LVL OIL PSI DASH GND CLT TMP GAGE PWR FAULT LT/473 TRANS TMP SW HR MTR
1
KEY ACC KEY START
HORN PWR HORN OVR SUP/911 OVR SGN/918
STR CRB STEER/SWAY PWR STR AW
OVR SGN/918 FAULT LT/473 TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED
BEEDE GAUGE
KEY/IGN
KEY IGN
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL HR MTR OIL PSI CLT TMP OVR SUP/911
9-10 DASH GND
Y6 (ONLY IF PARK BRAKE OFF)
Y6 (ONLY IF PARK BRAKE OFF)
Y6 (ONLY IF PARK BRAKE OFF)
N2
N3
N4
TO CHASSIS ASSEMBLY
Y2, Y6
Y6 (ONLY IF PARK BRAKE OFF)
Y2, Y3, Y6
R3
N1
Y2, Y3, Y5, Y6
R2
R4
Y1, Y6
Y2, Y3, Y4, Y6
Y1, Y3, Y6
F4
Y1, Y3, Y5, Y6
F3
R1
Y1, Y3, Y4, Y6
SW4
SW2
F2
1
4 R
F
ACTIVATED TRANS SOLENOIDS
2
3
1 2 3 4 5 6 7 8
3
2
N
F1
1
4
N
HOBBS
TRANSMISSION LEGEND
R
F
GEAR SW3
SW1
12 TURNS PER FOOT TWIST
A B C D E F
WILLIAMS (SUSPENDED) 86
5
87
4
87a 30
1
SHIFTER HARNESS HD34-24-31PT
85
2
86
5
87
4
87a 30
1
WARN LIGHT TEST RELAY
RED YEL
TILT SPEED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
3
85
2
3
REVERSE RELAY
STD JOY PWR
THROTTLE
PLUGGED TRAN/BRK PWR REVERSE TRANS SOL Y2 SHIFTER GND
PLUGGED SHIFTER GND TRANS TMP SW KEY START SHIFTER GND
STAB/TILT PWR
TRANSMISSION SHIFTER
TRANS SOL Y1 TRANS SOL Y3 TRANS SOL Y5 TRANS SOL Y4 SHIFT PWR 1 KEY START TRANS SOL Y2 PK BRK SOL
THR SGN/915 THR RTN/914 OVR SUP/911 PLUGGED PLUGGED PLUGGED
TRANS SOL Y1 TRANS SOL Y2 TRANS SOL Y3 TRANS SOL Y4 TRANS SOL Y5 PLUGGED KEY START SHIFT PWR 1 PK BRK SOL REVERSE TRAN/BRK PWR SHIFTER GND OVR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR PLUGGED PLUGGED PLUGGED
1 2 3 4
SP-1 SP-2 SP-3 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 AC CLUTCH
TILT DOWN
1 2 3 4 5 6
TILT UP
RED BLK GRY BLU
STANDARD JOYSTICK
SHIFTER HARNESS DT06-4S TO TILT ON JOYSTICK ROLLER OPTION
STAB/TILT PWR SHIFTER GND TILT UP TILT DN
TILT UP STD JOY PWR STD JOY PWR TILT DN PLUGGED PLUGGED
PLUG PLUG
SEE SHEET 2
9.5.1
9.5
Cab Schematic - John Deere
ELECTRICAL SYSTEM SCHEMATICS Electrical System
G10-55A, G12-55A
9-11 120 OHM
CAN TERMINATOR
MAL0160
A B C
B S I A
KEY/IGN
ON
OFF
HORN
DASH PANEL HARNESS HD34-24-31ST
3
2
ENG STOP
(BLK, 18 GA GXL)
(RED, 18 GA GXL)
(RED, 18 GA GXL) ENG WARN
TRAN/BRK PWR
4
5
6
2
3 ON
OFF
1 7
7
PARK BRAKE
6
3
CRAB
ALL WHL
5
2
-
PK BRK SOL
4
1
STEER MODE
+
DASH GND
ST RLY SHIFT PWR 1 PK BRK SOL
HR MTR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
3
1 2 3 4 5 6 7 8 9 10 11 12
4 G
B+
WAIT TO START
TRANS TMP WRN (RED, 18 GA GXL)
LEFT DASH PANEL
(RED, 18 GA GXL)
(D BLU, 18 GA GXL) (D BLU, 18 GA GXL) (BLK, 18 GA GXL) (D BLU, 18 GA GXL) (RED, 18 GA GXL) (ORG, 18 GA GXL) (D BLU, 18 GA GXL) (ORG, 18 GA GXL) (ORG, 18 GA GXL) (WHT, 18 GA GXL) PLUGGED PLUGGED
2
FUL LVL OIL PSI DASH GND CLT TMP GAGE PWR ENG STOP LT TRANS TMP SW HR MTR ENG WARN LT WAIT TO START LT
1
KEY ACC KEY START
HORN PWR HORN
STR CRB STEER/SWAY PWR STR AW
BEEDE GAUGE
SHIELDED CABLE
KEY IGN
(CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020)
KEY BAT PWR
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL HR MTR OIL PSI CLT TMP WAIT TO START LT ENG WARN LT ENG STOP LT TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED CAN H CAN L SHIELD
DASH GND
Y6 (ONLY IF PARK BRAKE OFF)
Y6 (ONLY IF PARK BRAKE OFF)
N3
N4
TO CHASSIS ASSEMBLY
Y6 (ONLY IF PARK BRAKE OFF)
N2
Y2, Y6
SW4
12 TURNS PER FOOT TWIST
A B C D E F
WILLIAMS (SUSPENDED) 87
4
87a 30
1
3
SHIFTER HARNESS HD34-24-31PT
87
4
87a 30
1
3
RED YEL
TILT SPEED
1 2 3 4
86
5
86
5
WARN LIGHT TEST RELAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
85
2
85
2
REVERSE RELAY
PLUGGED TRAN/BRK PWR REVERSE TRANS SOL Y2 SHIFTER GND
PLUGGED SHIFTER GND TRANS TMP SW KEY START SHIFTER GND
STD JOY PWR
THROTTLE
THR SGN/915 THR RTN/914 THR SUP/911 IVS PLUGGED PLUGGED
SW2
Y6 (ONLY IF PARK BRAKE OFF)
Y2, Y3, Y6
R4
R
F
N1
Y2, Y3, Y5, Y6
R3
Y1, Y6
F4
R2
Y1, Y3, Y6
F3
Y2, Y3, Y4, Y6
Y1, Y3, Y5, Y6
R1
Y1, Y3, Y4, Y6
1
4
F2
2
2
1 2 3 4 5 6 7 8
3
3 N
ACTIVATED TRANS SOLENOIDS
1
4
N
TRANSMISSION LEGEND
R
F
F1
GEAR
SW3
SW1
TRANS SOL Y1 TRANS SOL Y3 TRANS SOL Y5 TRANS SOL Y4 SHIFT PWR 1 KEY START TRANS SOL Y2 PK BRK SOL
HOBBS
TRANS SOL Y1 TRANS SOL Y2 TRANS SOL Y3 TRANS SOL Y4 TRANS SOL Y5 PLUGGED KEY START SHIFT PWR 1 PK BRK SOL REVERSE TRAN/BRK PWR SHIFTER GND THR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR IVS PLUGGED PLUGGED STAB/TILT PWR
SHIFTER HARNESS DT06-4S TO TILT ON JOYSTICK ROLLER OPTION
SP-1 SP-2 SP-3 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 AC CLUTCH
TILT DOWN
SEE OPTIONS SCHEMATIC
1 2 3 4 5 6
TILT UP
STANDARD JOYSTICK
RED BLK GRY BLU PLUG PLUG
TRANSMISSION SHIFTER
STAB/TILT PWR SHIFTER GND TILT UP TILT DN
TILT UP STD JOY PWR STD JOY PWR TILT DN PLUGGED PLUGGED
9.5.2
Cab Schematic - Perkins Electrical System
CAN TERMINATOR
120 OHM
(CAN H/904, YELLOW) (CAN L/905,GREEN) (SHIELD/020)
A B C
A B C
A B C
6 7 8
3 4 5
2
1
1
3 2
B
S
I
A
KEY/IGN
YEL (CAN H/904) GRN (CAN L/905) BRN/BLK (SHIELD/020)
SHIELDED CABLE
3
2
ON
OFF
HORN
ENG STOP (RED, 18 GA GXL)
ENG WARN (RED, 18 GA GXL)
6
3
7 4 5
1 2
ON
OFF
PARK BRAKE
PK BRK SOL
5 6
2 3
7 4
1
ALL WHL
CRAB
STEER MODE DASH GND
STR CRB STEER/SWAY PWR STR AW TRAN/BRK PWR
DASH PANEL HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
R
F
1
4
N
1 2 3 4 5 6 7 8
3
2
3
2 1
4
N
R
F
SW4
SW2
Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF)
N3 N4
TO CHASSIS ASSEMBLY
Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF)
N2
Y2, Y6
R4 N1
Y2, Y3, Y6
R3
Y1, Y6
Y2, Y3, Y5, Y6
F4 Y2, Y3, Y4, Y6
Y1, Y3, Y6
F3
R2
Y1, Y3, Y5, Y6
F2
R1
Y1, Y3, Y4, Y6
ACTIVATED TRANS SOLENOIDS
F1
GEAR
TRANSMISSION LEGEND ZF
SW3
SW1
HOBBS
A B C D E F
WILLIAMS (SUSPENDED)
12 TURNS PER FOOT TWIST
REVERSE RELAY
87a 30 1
THROTTLE 87 4
TRANSMISSION SHIFTER ZF
WARN LIGHT TEST RELAY
87a 30 1
WAIT TO START
TRANS TMP WRN (RED, 18 GA GXL) 86 5
3
5 4 87 4
3
6 86 5
MAIN DASH PANEL
THR SGN/915 THR RTN/914 THR SUP/911 IVS ON-IDLE IVR
85 2
PLUGGED TRAN/BRK PWR REVERSE REVERSE SOL SHIFTER GND
85 2
PLUGGED SHIFTER GND TRANS TMP SW KEY START SHIFTER GND
SHIFTER HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
TRANS SOL Y1 REVERSE SOL TRANS SOL Y3 TRANS SOL TRANS SOL Y5 TRANS SOL Y6 KEY START SHIFT PWR 1 SHIFT PWR 2 REVERSE TRAN/BRK PWR SHIFTER GND THR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR IVS ON-IDLE IVR
(CAN L/905, GREEN) (CAN H/904, YELLOW)
KEY IGN
1
2
TILT SPEED
RED
(SHIELD/020)
KEY BAT PWR
(BLK, 18 GA GXL)
FUL LVL
(D BLU, 18 GA GXL)
DASH GND
(ORG, 18 GA GXL) (WHT, 18 GA GXL) PLUGGED
GAGE PWR ENG STOP LT TRANS TMP SW
(RED, 18 GA GXL) (ORG, 18 GA GXL) (D BLU, 18 GA GXL) ENG WARN LT WAIT TO START LT KEY ACC KEY START
YEL
STD JOY PWR
STAB/TILT PWR
(RED, 18 GA GXL)
HORN PWR HORN
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL
ST RLY SHIFT PWR 1 PK BRK SOL
WAIT TO START LT ENG WARN LT ENG STOP LT TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED YEL (CAN H) GRN (CAN L) BRN/BLK (CAN SHIELD)
TRANS SOL Y1 TRANS SOL Y3 TRANS SOL Y5 TRANS SOL SHIFT PWR 1 KEY START REVERSE SOL SHIFT PWR 2
STAB/TILT PWR SHIFTER GND TILT UP TILT DN
SHIFTER HARNESS DT06-4S TO TILT ON JOYSTICK ROLLER OPTION
1 2 3 4
TILT UP TILT DOWN
STANDARD JOYSTICK
1 2 3 4 5 6
RED BLK GRY BLU PLUG PLUG
9-12 SP-1 SP-2 SP-3 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 AC CLUTCH
TILT UP STD JOY PWR STD JOY PWR TILT DN PLUGGED PLUGGED
R
F
1
4
N
1
4
N
F
R
SW4
SW2
1 2 3 4 5 6 7 8 9 10 11 12
3
2
3
2
HOBBS
E4, E3 NO SOLENOIDS INGAUGED
R3 N
E4, E2
E4, E1
E6, E3
R2
R1
F4
E5, E1
E5, E3
E5, E2
F1 F2 F3
ACTIVATED TRANS SOLENOIDS
GEAR
TRANSMISSION LEGEND TURNER
SEE SHEET 2
SW3
SW1
TRANSMISSION SHIFTER TURNER
9.5.3 TRANS SOL Y1 TRANS SOL TRANS SOL Y3 TRANS SOL Y6 SHIFT PWR 2 REVERSE SOL PLUGGED TRANS SOL Y5 KEY START SHIFT PWR 1 PLUGGED PLUGGED
STONERIDGE GAUGE
Electrical System Cab Schematic - Cummins
MY4570A
G10-55A, G12-55A
DASH GND
2
3
5
6
2
3
AUX ELECTRIC OPTION
EXTRA
1
4
1
SIDESHIFT
MAST
6
5
4
7
1 2 3 4 5 6 7 8 9
10 11 12
F1 F2 F3 F4 F5 F6 F7 F8
20A 15A 15A 25A 20A 20A 10A 10A
WIPER PWR 15A OPTION 1 PWR 15A OPTION 2 PWR 25A OPTION PWR HEATER/BLOWER PWR LIGHT PWR BEACON PWR DASH FAN PWR
OPTIONS FUSE LEGEND
87a 30
86
87
LIGHTS
85
OPTION (15A)
BCN/FAN
87a 30
OPTION (25A)
87a 30
AUX ELEC1
F6 20
F8 10
AUX ELEC2
GRAY-2 H G F E D C B A
BLACK-1 H G F E D C B A
87a 30
86
87
87
87
87a 30
87a 30
86
86
86
AUX ELEC
GREEN-4 A B C D E F G H
TO CHASSIS ASSEMBLY
OPTIONS HARNESS HD36-24-19PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A B OPTION 25 A
A OPTION 2 B 15 A
A OPTION 1 B 15 A
85
86
AC SW 25A OPT GND 25A OPT
SW1 86 HEATER GND CAB LT GND DOME/BCN GND AUX RLYS PWR SW1 87A SW2 86 SW2 87A
SEE SHEET 1
25A OPT 25A OPT GND
15A OPT 2 15A OPT 2 GND
15A OPT 1 15A OPT 1 GND
BLUE-3
85
85
85
WIPER PWR HEATER PWR KEY ACC BCN PWR D FAN PWR DOME LT CAB LT PWR S/W LT PWR
RLY 87
30
87a 87
DOME/BCN GND
S/W LT PWR
STOP LT
A/C RELAY
THERMOSTATIC SWITCH A/C
A B
A
DOME LT
F7 10
87
87
87
F4
25
1 2 3 4 5 6 7 8
M 17A
PRS SW
M
WORKLIGHT/ BEACON OPTION
A B
A B
CAB LTS CAB LT GND
F5 20
86
7
87a 30
SWING
87
86
F3
15
CAB LTS CAB LT GND
AUX ELEC
SWING EXTRA SW2 87A SW2 86 MAST SW1 87A SIDESHIFT SW1 86 AUX SW GND PLUGGED PLUGGED PLUGGED
SWING EXTRA SW2 87A SW2 86 MAST SW1 87A SIDESHIFT SW1 86 AUX SW GND PLUGGED PLUGGED PLUGGED
86
A B C D E F G H
BLOWER MOTOR
M
A B C D
DASH FAN
M
A B
M
HEATER HI
CONDENSER FANS (ON ROOF)
PRESSURE SWITCH
WASHER
F1 20
M
1 2 3 4 5 6 7 8 9 10
HEATER VALVE
A B C D E F
A B
M
RLY 87 25A OPT GND
ENCLOSED CAB OPTION
RESISTOR LOCATED APPROX 10" BEHIND HEATER TEMP SWITCH CONNECTION IN ENCLOSED CAB OPTIONS HARNESS
WIPER LO WIPER HI WIPER PARK EMPTY EMPTY
ON
6
5
4
A
B
C
8K OHM
HTR TEMP
AC SW
ON
OFF
BEACON
L C
M H B
BLOWER
3
2
RIGHT DASH PANEL
HEATER HI HEATER MED HEATER LOW
3
2
1
OFF
WORKLIGHTS
BCN PWR BCN LT
WORK LT S/W LT PWR
WIPER MOTOR
24 KOHM,1W
HEATER/BLOWER
D FAN PWR D FAN GND
WINDSHIELD WASHER MOTOR
HEATER MED HEATER LOW HEATER GND
CAB LIGHTS BEACON LEFT RIGHT
D FAN PWR HEATER PWR WIPER PWR HEATER GND D FAN GND PLUGGED
85
85
F2
15
87a 30 85
25A OPT 15A OPT 2 OPT PWR 1 AUX SW GND 15A OPT 1 OPT PWR 2 OPT PWR 3 OPT PWR 4
85
PLUGGED PLUGGED 25A OPT GND 15A OPT 2 GND 15A OPT 1 GND OPT GND 1 OPT GND 2 D FAN GND
KEY ACC AUX RLYS PWR STOP LT WORK LT PLUGGED PLUGGED MAST OPT PWR 1 SIDESHIFT OPT PWR 2 SWING OPT PWR 3 EXTRA OPT PWR 4 PLUGGED OPT GND 1 PLUGGED OPT GND 2 PLUGGED
BCN LT DOME/BCN GND
STOP LT S/W LT PWR BCN PWR DOME LT DOME/BCN GND CAB LT PWR CAB LT GND WORK LT STOP LT S/W LT PWR BCN PWR DOME LT DOME/BCN GND CAB LT PWR CAB LT GND WORK LT
EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY HEATER GND HTR CNTRL B EMPTY HEATER PWR D FAN PWR HEATER PWR WIPER PWR HEATER GND D FAN GND PLUGGED
DOME LIGHT
HEATER GND HTR CNTRL A HEATER PWR
STOPLIGHT SWITCH
(RED)
WIPER
AC CLUTCH
FAN SW C (RED/WHITE)
OPTIONS VEC
HEATER PWR
G10-55A, G12-55A P
H
WIPER HI WIPER LO
(BLACK)
A/C SWITCH
B
WIPER
L W
WIPER PARK WASHER
9.5.4
25A OPT GND
AUX HYD PANEL
Electrical System
Options Schematic - John Deere/Perkins
MY1070
9-13
WIPER PWR
CAB LT PWR CAB LTS
AUX ELECTRIC OPTION
6
3
1 2 3 4 5 6 7 8 9 10 11 12
F1 F2 F3 F4 F5 F6 F7 F8
WIPER PWR 15A OPTION 1 PWR 15A OPTION 2 PWR 25A OPTION PWR HEATER/BLOWER PWR LIGHT PWR BEACON PWR DASH FAN PWR
OPTIONS FUSE LEGEND
20A 15A 15A 25A 20A 20A 10A 10A
86
87
LIGHTS
87a 30
85
OPTION (15A)
87a 30
87a 30
BCN/FAN
87
85
OPTION (25A)
87
F7 10
AUX ELEC1
F6 20
F8 10
AUX ELEC2
25A OPT 25A OPT GND
TO CHASSIS ASSEMBLY
A B OPTION 25 A
A OPTION 2 B 15 A
SEE SHEET 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
OPTIONS HARNESS HD36-24-19PE
SW1 87A SW2 86 SW2 87A
AC SW
86
25A OPT GND 25A OPT
SW1 86 HEATER GND CAB LT GND DOME/BCN GND AUX RLYS PWR
WIPER PWR HEATER PWR KEY ACC BCN PWR D FAN PWR DOME LT CAB LT PWR S/W LT PWR
5A ROOF WIPER PWR 5A ROOF WIPER GND
A B C D E F G H
A B C D E F G H
15A OPT 2 15A OPT 2 GND
GRAY-2 H G F E D C B A
BLACK-1 H G F E D C B A
87
87
87
86 86 86
F1 20
87
85 85
F5 20
85
87a 30 87a 30
GREEN-4 BLUE-3
HEATER/BLOWER
85
87a
RLY 87
30
87
DOME/BCN GND
S/W LT PWR
STOP LT
A/C RELAY
THERMOSTATIC SWITCH A/C
A B
A
1 2 3 4 5 6 7 8
PRS SW
M 17A
M
CONDENSER FANS (ON ROOF)
PRESSURE SWITCH
WORKLIGHT/ BEACON OPTION
A B
A B
M
WASHER
WIPER
DOME LT
5
86
86
86
F4
25
CAB LTS CAB LT GND
2
86
85
85
F3
15
87a 30 85
87a 30
F2
5
CAB LTS CAB LT GND
CAB LIGHTS BEACON LEFT RIGHT
A B C D
M
M
A B
BLOWER MOTOR
DASH FAN
D FAN PWR D FAN GND
DOME LIGHT
M
1 2 3 4 5 6 7 8 9 10
HEATER VALVE
A B C D E F
A B
M
WIPER MOTOR
WIPER LO WIPER HI WIPER PARK EMPTY EMPTY
RLY 87 25A OPT GND
ENCLOSED CAB OPTION
RESISTOR LOCATED APPROX 10" BEHIND HEATER TEMP SWITCH CONNECTION IN ENCLOSED CAB OPTIONS HARNESS
M
1 2
ON
4 5 6
A
B
8K OHM
C
HTR TEMP
HEATER HI HEATER MED HEATER LOW
3
OFF
WORKLIGHTS
24 KOHM,1W
OPTIONS VEC
HEATER HI HEATER MED HEATER LOW HEATER GND
7
D FAN PWR HEATER PWR WIPER PWR HEATER GND D FAN GND PLUGGED
4
QC GND QC GND PWR PLUGGED QC PWR PWR QC PWR PLUGGED GND PLUGGED PLUGGED PLUGGED
QC GND QC GND SW2 87A SW2 86 QC PWR SW1 87A QC PWR SW1 86 AUX SW GND PLUGGED PLUGGED PLUGGED
87
25A OPT 15A OPT 2 OPT PWR 1 AUX SW GND 5A ROOF WIPER PWR OPT PWR 2 OPT PWR 3 OPT PWR 4
87a 30
PLUGGED PLUGGED 25A OPT GND 15A OPT 2 GND 5A ROOF WIPER GND OPT GND 1 OPT GND 2 D FAN GND
KEY ACC AUX RLYS PWR STOP LT WORK LT PLUGGED PLUGGED QC PWR OPT PWR 1 QC PWR OPT PWR 2 QC GND OPT PWR 3 QC GND OPT PWR 4 PLUGGED OPT GND 1 PLUGGED OPT GND 2 PLUGGED
BCN LT DOME/BCN GND
STOP LT S/W LT PWR BCN PWR DOME LT DOME/BCN GND CAB LT PWR CAB LT GND WORK LT STOP LT S/W LT PWR BCN PWR DOME LT DOME/BCN GND CAB LT PWR CAB LT GND WORK LT
EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY HEATER GND HTR CNTRL B EMPTY HEATER PWR D FAN PWR HEATER PWR WIPER PWR HEATER GND D FAN GND PLUGGED
1
AC SW
3
2
L
M
C
H B
BLOWER
ON
OFF
BEACON
RIGHT DASH PANEL
WORK LT S/W LT PWR
ROOF WIPER MOTOR
BCN PWR BCN LT
WINDSHIELD WASHER MOTOR
HEATER GND HTR CNTRL A HEATER PWR
8
AC CLUTCH
FAN SW C (RED) (RED/WHITE)
STOPLIGHT SWITCH
HEATER PWR
9-14 P
B
WIPER H LW
WIPER HI WIPER LO
(BLACK)
A/C SWITCH
WIPER PARK WASHER
9.5.5
25A OPT GND
AUX HYD PANEL
Electrical System Options - Cummins
MY4580A
G10-55A, G12-55A
WIPER PWR
CAB LT PWR CAB LTS
87
IGNITION-1
87
ACCY-2
85
1 2
1 2
IGNITION-2
C
BAT GND
BLACK-6
A
BAT GND
ALL WHEEL STEER MODE VALVE CRAB
87a 30
ACCY-1
A
C
5
F1 15
F6 10
GRAY-2 H G F E D C B A
A B C D
(-)
A B C D E F G H A B C D E F G H
A B
SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND
DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2
POWER DIST VEC
STR CRB STR/SWAY GND
STR AW STR/SWAY GND
F5 15
F2
GRAY-5
BAT POS
BLACK-1 H G F E D C B A
87a 30
87
87
GRN RED BLK REVERSE STOP LT WORK LT LT GND
A B
GREEN-4 BLUE-3
BAT POS
85
85
86
86
87a 30
87a 30
F9
85
CB4
20
F8
25
F3
10
CB3 F4
20 10
86
86
WORK LT LT GND
SHIFTER GND OPT PWR 2 KEY IGN SP BAT PWR ECU IGN/012 OPT PWR 1 GAGE PWR ECU BAT/022
10
CB1 F7
20 15
F10
10
CB2
20 10
F11
15
F12
ENG GND OPT PWR 3 HORN PWR STEER/SWAY PWR OPT PWR 4 STAB/TILT PWR KEY BAT PWR ECU GND/050
REVERSE LT GND
A B C D
SWAY PROXIMITY SWITCH
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
LT
SV2
1 2
SWAY LT STR/SWAY GND
OPTIONS POWER 3 OPTIONS POWER 4 OPTIONS POWER 1 OPTIONS POWER 2 TRANS/PARK BRK PWR ALTERNATOR EXCITE ENGINE ECU IGN PWR GAGE (INST PANEL) PWR SPARE ACCESSORY PWR AUX ELECTRIC PWR HORN PWR SPARE BATTERY PWR ENGINE ECU BAT PWR STEER/SWAY PWR R. AXLE STAB/TILT PWR KEY BATTERY PWR
BLU
SV1
1 2
SWAY LOCK STR/SWAY GND
POWER DISTRIBUTION
WHT
6A
SV5
1 2
6A
SV3
1 2
SWAY PILOT RT VALVE
SV4
1 2
SWAY LOCK STR/SWAY GND
FUSE/BREAKER LEGEND
20A 20A 20A 20A 15A 5A 10A 10A 15A 10A 15A 25A 10A 10A 10A 15A
BLK
SWAY LOCK STR/SWAY GND
CB1 CB2 CB3 CB4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
RED
SWAY RT STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(-)15 DEG RLY
85 2
STEER/SWAY PWR STEER/SWAY PWR SWAY ENABLE STR/SWAY GND ORG
TO SHIFTER HARNESS HD36-24-31ST CHASSIS HARNESS
(+)15 DEG RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
TO OPTIONS HARNESS 8-SHT3-REV BLK AND BOM HD34-24-19SE CHASSIS HARNESS
CAB SIDE (+)15 DEG LAT TILT SWITCH
1 2 3 4
ENGINE SIDE (-)15 DEG LAT TILT SWITCH
1 2 3 4
SWAY ENABLE MINUS 15 PLUG STR/SWAY GND RED YELLOW GREEN BLACK
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL HR MTR OIL PSI CLT TMP OVR SUP/911 OVR SGN/918 FAULT LT/473 TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED +
TO CAB ASSEMBLY
SWAY ENABLE PLUG PLUS 15 STR/SWAY GND
TO DASH PANEL HARNESS HD36-24-31PT CHASSIS HARNESS
85 2
A B
STABILIZER VALVE
A B
STAB VLV FUL/STAB GND
HORN
86 5 87 4
STAB VLV FUL/STAB GND
REVERSE ALARM
A B C D
12 TURNS PER FOOT TWIST
M
(OPT)
A/C COMPRESSOR
STABILIZER PROXIMITY SWITCH
BLU
STOP TAIL
+
HORN
(OPT) TAIL LIGHT
WHT
A B A B
TILT-ON JOYSTICK VALVE
TILT DN FUL/STAB GND TILT UP FUL/STAB GND
BU
STR/SWAY GND MINUS 15 SWAY RT STEER/SWAY PWR 86 5 87 4 1
30
3 87a
ORG
TRANS SOL Y1 TRANS SOL Y2 TRANS SOL Y3 TRANS SOL Y4 TRANS SOL Y5 PLUGGED KEY START SHIFT PWR 1 PK BRK SOL REVERSE TRAN/BRK PWR SHIFTER GND OVR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 2 SP CAB GND 1 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR PLUGGED PLUGGED PLUGGED STR/SWAY GND PLUS 15 SWAY LT STEER/SWAY PWR 1
30
3 87a
RED
KEY ACC AUX RLYS PWR STOP LT WORK LT PLUGGED PLUGGED MAST OPT PWR 1 SIDESHIFT OPT PWR 2 SWING OPT PWR 3 EXTRA OPT PWR 4 PLUGGED OPT GND 1 PLUGGED OPT GND 2 PLUGGED RED YELLOW GREEN BLACK
SP-3 SP-2 SP-1 SP BAT PWR SP ACCY PWR SP GND 1 SP GND 2 AC CLUTCH STAB/TILT PWR STAB/TILT PWR STAB VLV FUL/STAB GND BLK
RT TM
(OPT) AUXILIARY ELECTRIC A S LT
REMOVE DIODES FOR OPTIONAL ROLLER TILT ON JOYSTICK AND INSTALL "EMPTY" PLUG
ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND CLT TMP PK BRK SOL OVR SGN/918 FAULT LT/473 ALT EXC OVR SUP/911 THR SGN/915 THR RTN/914 ST RLY HR MTR OIL PSI GAGE PWR TRANS TMP SW PLUGGED TRANS SOL Y1 PLUGGED TRANS SOL Y2 TRANS SOL Y3 PLUGGED PLUGGED TRANS SOL Y4 TRANS SOL Y5 PLUGGED PLUGGED PLUGGED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
A B C D E F
A B
FUEL SNDR
FUL LVL FUL/STAB GND
EMPTY BLK RED YEL BLU ORG PLUGGED MAST SIDESHIFT AUX ELEC GND SWING EXTRA PLUGGED
G10-55A, G12-55A CHASSIS HARNESS HD34-24-29PE
+
-
NEGATIVE CABLE FLAG TO CHASSIS FRAME
POSITIVE CABLE TO STARTER AND ALTERNATOR NEGATIVE CABLE TO ENG BLOCK
12 VDC BATTERY
NEGATIVE CABLE TO CAB FIREWALL
9.5.6
TO POWER UNIT ASSEMBLY
(OPT) FRONT RIGHT WORKLIGHT
Electrical System
Chassis Schematic - John Deere
MY1080
9-15
POWER DISTRIBUTION
IGNITION-1
87a 30
ACCY-2
ALL WHEEL STEER MODE VALVE CRAB
A
BLACK-6
IGNITION-2
C
1 2
1 2
OPTIONS POWER 3 OPTIONS POWER 4 OPTIONS POWER 1 OPTIONS POWER 2 TRANS/PARK BRK PWR ALTERNATOR EXCITE ENGINE ECU IGN PWR GAGE (INST PANEL) PWR SPARE ACCESSORY PWR AUX ELECTRIC PWR HORN PWR SPARE BATTERY PWR ENGINE ECU BAT PWR STEER/SWAY PWR R. AXLE STAB/TILT PWR KEY BATTERY PWR
86
86
BAT GND
CB3
20A 20A 20A 20A 15A 5A 10A 10A 15A 10A 15A 25A 25A 10A 10A 15A
87
87
ACCY-1
87
GRAY-5
A
A B
5
F1 15
F6 10
F5 15
F2
C
GRAY-2 H G F E D C B A
A B C D E F G H
A B C D E F G H
(-)
A B C D
GRN RED BLK
A B
SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND
DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2
POWER DIST VEC
STR CRB STR/SWAY GND
STR AW STR/SWAY GND
BLACK-1 H G F E D C B A
87
85
85
86
86
WORK LT LT GND
FUSE/BREAKER LEGEND
F8
25
87a 30
F4
20 10
87a 30
F9
25
87a 30
CB4
20
F7
BAT GND
F3
10
85
85
BAT POS
CB2 20 F11 10
SHIFTER GND OPT PWR 2 KEY IGN SP BAT PWR ECU IGN/012 OPT PWR 1 GAGE PWR ECU BAT/022
GREEN-4
BLUE-3
BAT POS
CB1
20 15
F10
10
F12
15
ENG GND OPT PWR 3 HORN PWR STEER/SWAY PWR OPT PWR 4 STAB/TILT PWR KEY BAT PWR ECU GND/050
CB1 CB2 CB3 CB4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
A B C D
SWAY PROXIMITY SWITCH
WHT
LT
SV2
1 2
SWAY LT STR/SWAY GND
TO SHIFTER HARNESS HD36-24-31ST CHASSIS HARNESS
TO OPTIONS HARNESS HD34-24-19SE CHASSIS HARNESS
SV4
1 2
SV5
1 2
SWAY PILOT VALVE
SV1
1 2
6A
6A
RT
SV3
1 2
(-)15 DEG RLY
(+)15 DEG RLY
ENGINE SIDE (-)15 DEG LAT TILT SWITCH
CAB SIDE (+)15 DEG LAT TILT SWITCH
1 2 3 4
1 2 3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
BLK
SWAY LOCK STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
RED
SWAY LOCK STR/SWAY GND
REVERSE STOP LT WORK LT LT GND
TO DASH PANEL HARNESS HD36-24-31PT CHASSIS HARNESS
ORG
SWAY LOCK STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
BLU
STEER/SWAY PWR STEER/SWAY PWR SWAY ENABLE STR/SWAY GND +
SWAY RT STR/SWAY GND
TAIL
1
STOP
2 85
BU
SWAY ENABLE MINUS 15 PLUG STR/SWAY GND RED YELLOW GREEN BLACK
REVERSE LT GND
TO CAB ASSEMBLY
SWAY ENABLE PLUG PLUS 15 STR/SWAY GND
HORN
3
A B
STABILIZER VALVE
A B
STAB VLV FUL/STAB GND
REVERSE ALARM
5 86
STAB VLV FUL/STAB GND
HORN
(OPT) TAIL LIGHT
4 87
12 TURNS PER FOOT TWIST
M
A/C COMPRESSOR
(OPT)
A B C D
STABILIZER PROXIMITY SWITCH
BLK
A B A B
TILT-ON JOYSTICK VALVE
REMOVE DIODES FOR OPTIONAL ROLLER TILT ON JOYSTICK AND INSTALL "EMPTY" PLUG
A B C D E F
A B
FUEL SNDR
AUXILIARY ELECTRIC
A B C D E F
ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND CLT TMP PK BRK SOL ENG WARN LT ENG STOP LT ALT EXC THR SUP/911 THR SGN/915 THR RTN/914 ST RLY HR MTR OIL PSI GAGE PWR TRANS TMP SW IVS TRANS SOL Y1 WAIT TO START LT TRANS SOL Y2 TRANS SOL Y3 PLUGGED PLUGGED TRANS SOL Y4 TRANS SOL Y5 CAN H CAN L SHIELD
TILT DN FUL/STAB GND TILT UP FUL/STAB GND
(OPT) FRONT RIGHT WORKLIGHT
2
RED
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL HR MTR OIL PSI CLT TMP WAIT TO START ENG WARN LT ENG STOP LT TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED CAN H CAN L SHIELD
4 87
STR/SWAY GND MINUS 15 SWAY RT STEER/SWAY PWR
5 86
85 30 87a
STR/SWAY GND PLUS 15 SWAY LT STEER/SWAY PWR 1
WHT
TRANS SOL Y1 TRANS SOL Y2 TRANS SOL Y3 TRANS SOL Y4 TRANS SOL Y5 PLUGGED KEY START SHIFT PWR 1 PK BRK SOL REVERSE TRAN/BRK PWR SHIFTER GND THR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR IVS ENG GND PLUGGED 3 30 87a
ORG
KEY ACC AUX RLYS PWR STOP LT WORK LT PLUGGED PLUGGED QC PWR OPT PWR 1 QC PWR OPT PWR 2 QC GND OPT PWR 3 QC GND OPT PWR 4 PLUGGED OPT GND 1 PLUGGED OPT GND 2 PLUGGED RED YELLOW GREEN BLACK
SP-3 SP-2 SP-1 SP BAT PWR SP ACCY PWR SP GND 1 SP GND 2 AC CLUTCH BLU
STAB/TILT PWR STAB/TILT PWR STAB VLV FUL/STAB GND +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
FUL LVL FUL/STAB GND
BLK RED YEL BLU ORG PLUGGED QC PWR QC PWR AUX ELEC GND QC GND QC GND PLUGGED
9-16 CHASSIS HARNESS HD34-24-29PE
12 VDC BATTERY
NEGATIVE CABLE FLAG TO CHASSIS FRAME
POSITIVE CABLE TO STARTER AND ALTERNATOR NEGATIVE CABLE TO ENG BLOCK
+
-
QC DIVERTOR VALVE
NEGATIVE CABLE TO CAB FIREWALL
1 2
9.5.7
TO POWER UNIT ASSEMBLY
(OPT)
Electrical System Chassis Schematic - Perkins Before S/N 0160037186
MAL0180
G10-55A, G12-55A
86
86
CB4
87a 30
A
BLACK-6
IGNITION-2
C
1 2
1 2
ACCY-1
GRAY-5
A
A B
5
F1 15
F6 10
F5 15
F2
C
GRAY-2 H G F E D C B A
A B C D E F G H
A B C D E F G H
(-)
A B C D
GRN RED BLK
A B
SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND
DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2
POWER DIST VEC
STR CRB STR/SWAY GND
STR AW STR/SWAY GND
WORK LT LT GND
BLACK-1 H G F E D C B A
87a 30
IGNITION-1
87
ACCY-2
85
85
BAT GND
F4
ALL WHEEL STEER MODE VALVE CRAB
CB3
20 10
87
20
F7
OPTIONS POWER 3 OPTIONS POWER 4 OPTIONS POWER 1 OPTIONS POWER 2 TRANS/PARK BRK PWR ALTERNATOR EXCITE ENGINE ECU IGN PWR GAGE (INST PANEL) PWR SPARE ACCESSORY PWR AUX ELECTRIC PWR HORN PWR SPARE BATTERY PWR ENGINE ECU BAT PWR STEER/SWAY PWR R. AXLE STAB/TILT PWR KEY BATTERY PWR
F8
25
87
87
BAT POS
CB1
BAT GND
F3
10
86
86
85
85
87a 30
87a 30
F9
25
GREEN-4
BLUE-3
BAT POS
CB2 20 F11 10
SHIFTER GND OPT PWR 2 KEY IGN SP BAT PWR ECU IGN/012 OPT PWR 1 GAGE PWR ECU BAT/022
20 15
F10
10
F12
15
ENG GND OPT PWR 3 HORN PWR STEER/SWAY PWR OPT PWR 4 STAB/TILT PWR KEY BAT PWR ECU GND/050
REVERSE LT GND
POWER DISTRIBUTION
CABLE
A B C D 1 2
SWAY LT STR/SWAY GND
20A 20A 20A 20A 15A 5A 10A 10A 15A 10A 15A 25A 25A 10A 10A 15A
1 2
SWAY LOCK STR/SWAY GND
FUSE/BREAKER LEGEND
6A
1 2
1 2
SWAY LOCK STR/SWAY GND
CB1 CB2 CB3 CB4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
SWAY LOCK STR/SWAY GND
REVERSE STOP LT WORK LT LT GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
6A
1 2
(-)15 DEG RLY
(+)15 DEG RLY
TO OPTIONS HARNESS HD34-24-19SE CHASSIS HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4
SWAY ENABLE MINUS 15 PLUG STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
SWAY RT STR/SWAY GND
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL PLUGGED PLUGGED PLUGGED WAIT TO START ENG WARN LT ENG STOP LT TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED YEL (CAN H) GRN (CAN L) BRN/BLK (CAN SHIELD) STEER/SWAY PWR STEER/SWAY PWR SWAY ENABLE STR/SWAY GND
TO SHIFTER HARNESS HD36-24-31ST CHASSIS HARNESS
1 2 3 4
SWAY ENABLE PLUG PLUS 15 STR/SWAY GND
TO DASH PANEL HARNESS HD36-24-31PT CHASSIS HARNESS
A B
STABILIZER VALVE
A B
12 TURNS PER FOOT TWIST
STAB VLV FUL/STAB GND
TAIL
2
KEY ACC AUX RLYS PWR STOP LT WORK LT PLUGGED PLUGGED QC PWR OPT PWR 1 QC PWR OPT PWR 2 QC GND OPT PWR 3 QC GND OPT PWR 4 PLUGGED OPT GND 1 PLUGGED OPT GND 2 PLUGGED STAB VLV FUL/STAB GND
STOP
5
HORN
CABLE
M
A/C COMPRESSOR
(OPT)
A B C D
STABILIZER PROXIMITY SWITCH
BLK
BU
4 85
BLU
A B A B
TILT-ON JOYSTICK VALVE
REMOVE DIODES FOR OPTIONAL ROLLER TILT ON JOYSTICK AND INSTALL "EMPTY" PLUG
A B C D E F
A B
FUEL SNDR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
A B C D E F
ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND PLUGGED PK BRK SOL ENG WARN LT ENG STOP LT ALT EXC THR SUP/911 THR SGN/915 THR RTN/914 ST RLY YEL (CAN H) GRN (CAN L) BRN/BLK (CAN SHIELD) TRANS TMP SW IVS TRANS SOL Y1 WAIT TO START LT TRANS SOL Y2 TRANS SOL Y3 PLUGGED PLUGGED TRANS SOL Y4 TRANS SOL Y5 PLUGGED PLUGGED PLUGGED
TILT DN FUL/STAB GND TILT UP FUL/STAB GND
TO CAB ASSEMBLY
1 86
RED
HORN
3 87
WHT
BLK RED YEL BLU ORG PLUGGED QC PWR 1 QC PWR 2 AUX ELEC GND QC GND 5 QC GND 7 PLUGGED
REVERSE ALARM
5 86
STR/SWAY GND MINUS 15 SWAY RT STEER/SWAY PWR
2 85
30 87a
STR/SWAY GND PLUS 15 SWAY LT STEER/SWAY PWR 1
4 87
SP-3 SP-2 SP-1 SP BAT PWR SP ACCY PWR SP GND 1 SP GND 2 AC CLUTCH STAB/TILT PWR STAB/TILT PWR STAB VLV FUL/STAB GND ORG
TRANS SOL Y1 TRANS SOL Y2 TRANS SOL Y3 TRANS SOL Y4 TRANS SOL Y5 PLUGGED KEY START SHIFT PWR 1 PK BRK SOL REVERSE TRAN/BRK PWR SHIFTER GND THR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR IVS ENG GND PLUGGED 3 30 87a
+
FUL LVL FUL/STAB GND CHASSIS HARNESS HD34-24-29PE
(OPT) TAIL LIGHT
12 VDC BATTERY
NEGATIVE CABLE FLAG TO CHASSIS FRAME
NEGATIVE CABLE TO ENG BLOCK
POSITIVE CABLE TO STARTER AND ALTERNATOR
+
-
QC DIVERTOR VALVE
NEGATIVE CABLE TO CAB FIREWALL
1 2
TO POWER UNIT ASSEMBLY
G10-55A, G12-55A A S LT
RT TM
(OPT) AUXILIARY ELECTRIC
AUXILIARY ELECTRIC
(OPT)
A B C D E F
BLK RED YEL BLU ORG PLUGGED
9.5.8 MAST SIDESHIFT AUX ELEC GND SWING EXTRA PLUGGED
(OPT) FRONT RIGHT WORKLIGHT
Electrical System
Chassis Schematic - Perkins S/N 0160037186 Thru 0160039397 Excluding 0160039394 & 0160039397
MY4730F
9-17
CB1 CB2 CB3 CB4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
87
87
CB4
A
IGNITION-2
C
1 2
1 2
ACCY-1
GRAY-5
A
5
F1 15
F6 10
F5 15
F2
C
GRAY-2 H G F E D C B A
A B C D E F G H
A B C D E F G H
A B
SP CAB GND 1 SP CAB GND 2 SP GND 1 SP GND 2 AUX ELEC GND LT GND STR/SWAY GND FUL/STAB GND
DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2
POWER DIST VEC
STR CRB STR/SWAY GND
STR AW STR/SWAY GND
(-)
A B C D
GRN RED BLK
REVERSE STOP LT WORK LT LT GND
A B
WORK LT LT GND
BLACK-1 H G F E D C B A
87a 30
IGNITION-1
87a 30
ACCY-2
85
85
BAT GND
BLACK-6
CB3
ALL WHEEL STEER MODE VALVE CRAB
F8
25
87a 30
F4
20 10
87a 30
F9
25
86
86
20
F7
BAT GND
F3
10
87
87
85
85
86
86
BAT POS
CB2 20 F11 10
SHIFTER GND OPT PWR 2 KEY IGN SP BAT PWR ECU IGN/012 OPT PWR 1 GAGE PWR ECU BAT/022
GREEN-4
BLUE-3
BAT POS
CB1
20 15
F10
10
F12
ENG GND OPT PWR 3 HORN PWR STEER/SWAY PWR OPT PWR 4 STAB/TILT PWR KEY BAT PWR ECU GND/050
15
OPTIONS POWER 3 OPTIONS POWER 4 OPTIONS POWER 1 OPTIONS POWER 2 TRANS/PARK BRK PWR ALTERNATOR EXCITE ENGINE ECU IGN PWR GAGE (INST PANEL) PWR SPARE ACCESSORY PWR AUX ELECTRIC PWR HORN PWR SPARE BATTERY PWR ENGINE ECU BAT PWR STEER/SWAY PWR R. AXLE STAB/TILT PWR KEY BATTERY PWR CABLE
A B C D 1 2
SWAY LT STR/SWAY GND
20A 20A 20A 20A 15A 5A 10A 10A 15A 10A 15A 25A 25A 10A 10A 15A
1 2
SWAY LOCK STR/SWAY GND
FUSE/BREAKER LEGEND
6A
1 2
1 2
SWAY LOCK STR/SWAY GND
POWER DISTRIBUTION
SWAY LOCK STR/SWAY GND
REVERSE LT GND
TO SHIFTER HARNESS HD36-24-31ST CHASSIS HARNESS
6A
1 2
SWAY RT STR/SWAY GND
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL PLUGGED PLUGGED PLUGGED WAIT TO START ENG WARN LT ENG STOP LT TRAN/BRK PWR PLUGGED PLUGGED PLUGGED PLUGGED PLUGGED YEL (CAN H) GRN (CAN L) BRN/BLK (CAN SHIELD) STEER/SWAY PWR STEER/SWAY PWR SWAY ENABLE STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(-)15 DEG RLY
(+)15 DEG RLY
TO OPTIONS HARNESS HD34-24-19SE CHASSIS HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4
SWAY ENABLE MINUS 15 PLUG STR/SWAY GND
TO DASH PANEL HARNESS HD36-24-31PT CHASSIS HARNESS
1 2 3 4
SWAY ENABLE PLUG PLUS 15 STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
A B
STABILIZER VALVE
A B
12 TURNS PER FOOT TWIST
STAB VLV FUL/STAB GND
TAIL
2
KEY ACC AUX RLYS PWR STOP LT WORK LT PLUGGED PLUGGED QC PWR OPT PWR 1 QC PWR OPT PWR 2 QC GND OPT PWR 3 QC GND OPT PWR 4 PLUGGED OPT GND 1 PLUGGED OPT GND 2 PLUGGED STAB VLV FUL/STAB GND
STOP
4
HORN
CABLE
M
A/C COMPRESSOR
(OPT)
A B C D
STABILIZER PROXIMITY SWITCH
BLK
A B A B
TILT-ON JOYSTICK VALVE
REMOVE DIODES FOR OPTIONAL ROLLER TILT ON JOYSTICK AND INSTALL "EMPTY" PLUG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
A B C D E F
A B
FUEL A B C D E F SNDR
ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND PLUGGED PK BRK SOL ENG WARN LT ENG STOP LT ALT EXC THR SUP/911 THR SGN/915 THR RTN/914 ST RLY YEL (CAN H) GRN (CAN L) BRN/BLK (CAN SHIELD) TRANS TMP SW IVS TRANS SOL Y1 WAIT TO START LT TRANS SOL Y2 TRANS SOL Y3 ON-IDLE IVR TRANS SOL Y4 TRANS SOL Y5 PLUGGED TRANS SOL Y6 PLUGGED
FUL/STAB GND
BU
1
BLU
TILT DN FUL/STAB GND TILT UP
TO CAB ASSEMBLY
5 86
85
RED
HORN
3 87
WHT
BLK RED YEL BLU ORG PLUGGED QC PWR 1 QC PWR 2 AUX ELEC GND QC GND 5 QC GND 7 PLUGGED
REVERSE ALARM
5 86
4 87
STR/SWAY GND MINUS 15 SWAY RT STEER/SWAY PWR
2 85
30 87a
STR/SWAY GND PLUS 15 SWAY LT STEER/SWAY PWR 1
SP-3 SP-2 SP-1 SP BAT PWR SP ACCY PWR SP GND 1 SP GND 2 AC CLUTCH STAB/TILT PWR STAB/TILT PWR STAB VLV FUL/STAB GND ORG
TRANS SOL Y1 TRANS SOL Y2 TRANS SOL Y3 TRANS SOL Y4 TRANS SOL Y5 TRANS SOL Y6 KEY START SHIFT PWR 1 PK BRK SOL REVERSE TRAN/BRK PWR SHIFTER GND THR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR IVS ON-IDLE IVR 3 30 87a
+
FUL LVL FUL/STAB GND CHASSIS HARNESS HD34-24-29PE
(OPT) TAIL LIGHT
12 VDC BATTERY
NEGATIVE CABLE FLAG TO CHASSIS FRAME
NEGATIVE CABLE TO ENG BLOCK
POSITIVE CABLE TO STARTER AND ALTERNATOR
+
-
QC DIVERTOR VALVE
NEGATIVE CABLE TO CAB FIREWALL
1 2
TO POWER UNIT ASSEMBLY
9-18 A S LT
RT TM
(OPT) AUXILIARY ELECTRIC
AUXILIARY ELECTRIC
(OPT)
A B C D E F
BLK RED YEL BLU ORG PLUGGED
9.5.9 MAST SIDESHIFT AUX ELEC GND SWING EXTRA PLUGGED
(OPT) FRONT RIGHT WORKLIGHT
Electrical System Chassis Schematic - Cummins S/N 0160039451 and After Including 0160039394 & 0160039397
MY4590A
G10-55A, G12-55A
TO CHASSIS ASSEMBLY
HD36-24-29SE POWER UNIT HARNESS
120 OHM
CAN TERMINATOR
120 OHM
CAN TERMINATOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
A B C
A B C
6A/400V
(CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020)
(CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020)
SHTDN/941
ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND CLT TMP PK BRK SOL OVR SGN/918 FAULT LT/473 ALT EXC OVR SUP/911 THR SGN/915 THR RTN/914 ST RLY HR MTR OIL PSI GAGE PWR TRANS TMP SW PLUGGED TRANS SOL Y1 PLUGGED TRANS SOL Y2 TRANS SOL Y3 PLUGGED PLUGGED TRANS SOL Y4 TRANS SOL Y5 PLUGGED PLUGGED PLUGGED
SHIELDED CABLE
SHIELDED CABLE
CRANK SENSOR
A B
A B
FUEL TMP/428 THR RTN/914
A B
CLT/461 THR RTN/914
A B
MAN TMP/463 THR RTN/914
DEERE ENGINE ECU
A B
A B C
390 OHM, 1W
12 TURNS PER FOOT TWIST
12 TURNS PER FOOT TWIST
INJECTOR PUMP
THR RTN/914 OVR SUP/911 OIL PRS/467
OIL PRESSURE SENSOR
INJ A/491 INJ B/493
DIAGNOSTIC CONNECTOR
A B C D E F G H J
SHIELDED CABLE
Y1, Y3, Y4, Y6 Y1, Y3, Y5, Y6 Y1, Y3, Y6 Y1, Y6 Y2, Y3, Y4, Y6 Y2, Y3, Y5, Y6 Y2, Y3, Y6 Y2, Y6 Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF)
F2 F3 F4 R1 R2 R3 R4 N1 N2 N3 N4
ACTIVATED TRANS SOLENOIDS
TRANSMISSION LEGEND
F1
GEAR
RESISTOR LOCATED AT SPLIT OF CRANK SENSOR WIRES A/447& B/448 IN ENGINE ECU HARNESS
ECU GND/050 ECU IGN/012 (CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020) PLUGGED PLUGGED PLUGGED PLUGGED
FUEL TEMP SENSOR
Y1
A B
TRANS SOL Y1 ENG GND
COOLANT TEMP SENSOR
Y2
A B
TRANS SOL Y2 ENG GND
CRANK A/447 CRANK B/448
SHTDN/941 ECU IGN/012 INJ B/493 CLT/461 CRANK A/447 OVR SGN/918 HI LO/947 PLUGGED FUEL TMP/428 MAN TMP/463 CRANK B/448 THR RTN/914 THR SGN/915 OVR SUP/911 PLUGGED CAN L/905 PLUGGED OIL PRS/467 CAN H/904 PLUGGED FAULT LT/473 PLUGGED PLUGGED PLUGGED PLUGGED ECU GND/050 PLUGGED ECU BAT/022 INJ A/491 PLUGGED A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
Y4
A B
TRANS SOL Y5 ENG GND
Y5
A B
Y6
A B
PK BRK SOL ENG GND
TRANSMISSION
Y3
A B
TRANS SOL Y3 ENG GND
G10-55A, G12-55A TRANS SOL Y4 ENG GND
TRANS TMP SW ENG GND 250 F
A B
PK BRK SOL ENG GND
GAGE PWR HR MTR
ALT EXC A
1 2
A B
A
G
PARK BRAKE VALVE
CLT TEMP SENDER OIL PRESS SENDER
ENGINE OIL PRESSURE SWITCH
ALTERNATOR
OIL PSI
5 PSI
D+ 6A/400V
B+
M
STARTER
CLT TMP
(4 AWG, RED)
ST RLY PWR (3/0 AWG, RED) (4 AWG, RED)
STRT SOL
(3/0 AWG, BLACK)
(3/0 AWG, RED)
85
86
87
30
STARTER RELAY
(3/0 AWG, RED)
POSITIVE CABLE TO BATTERY
ST RLY PWR STRT SOL ST RLY ENG GND
(3/0 AWG, BLACK)
NEGATIVE CABLE TO BATTERY
9.5.10
MANIFOLD AIR TEMP SENSOR
Electrical System
Power Unit Schematic - John Deere
MY1090
9-19
TO CHASSIS ASSEMBLY
HD36-24-29SE POWER UNIT HARNESS
120 OHM
CAN TERMINATOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
A B C
6A/400V
(CAN H/904, YELLOW) (CAN L/905, GREEN) (SHIELD/020)
ECU IGN/012 ECU BAT/022 ECU GND/050 ENG GND CLT TMP PK BRK SOL ENG WARN LT ENG STOP LT ALT EXC THR SUP/911 THR SGN/915 THR RTN/914 ST RLY HR MTR OIL PSI GAGE PWR TRANS TMP SW IVS TRANS SOL Y1 WAIT TO START TRANS SOL Y2 TRANS SOL Y3 PLUGGED PLUGGED TRANS SOL Y4 TRANS SOL Y5 CAN H/904 CAN L/905 SHIELD/020
SHIELDED CABLE
CAN H/904 CAN L/905 SHIELD/020 THR RTN/914 ECU IGN/012 THR SUP/911 IVS THR SGN/915 COLD START AID ENG WARN LT ENT STOP LT WAIT TO START LT
64 PIN
PERKINS ECM
NOTE: ONLY USED CONNECTIONS SHOWN
Y6 (ONLY IF PARK BRAKE OFF)
N4
Y1
Y3
A B
Y4
A B
TRANS SOL Y5 ENG GND
Y5
A B
Y6
A B
PK BRK SOL ENG GND
TRANSMISSION
Y2
A B
Y6 (ONLY IF PARK BRAKE OFF)
N3
A B
Y6 (ONLY IF PARK BRAKE OFF)
N2
Y2, Y6
R4 Y6 (ONLY IF PARK BRAKE OFF)
Y2, Y3, Y6
R3
TRANS SOL Y1 ENG GND
N1
Y2, Y3, Y5, Y6
Y1, Y6
F4 Y2, Y3, Y4, Y6
Y1, Y3, Y6
F3
R2
Y1, Y3, Y5, Y6
F2
R1
Y1, Y3, Y4, Y6
F1
ACTIVATED TRANS SOLENOIDS
TRANSMISSION LEGEND
TRANS SOL Y2 ENG GND
9-20 TRANS SOL Y3 ENG GND
MY1820 TRANS SOL Y4 ENG GND
TRANS TMP SW ENG GND 250 F
A B
PK BRK SOL ENG GND
B+
87
85
86
30
RELAY
PARK BRAKE VALVE
TO GLOW PLUGS
GLOW PLUG PWR
ECU IGN/012 COLD START AID
CSA RLY PWR
1 2
CLT TEMP SENDER
ENGINE OIL PRESSURE SWITCH
OIL PRESS SENDER
5 PSI
D+
G
OIL PSI
6A/400V
ALTERNATOR
M
STARTER
CLT TMP
A B
A
ALT PWR
GAGE PWR HR MTR
ALT EXC A
CSA RLY PWR
ST RLY PWR (3/0 AWG, RED) (4 AWG, RED)
STRT SOL
85
86
(3/0 AWG, BLACK)
(3/0 AWG, RED)
87
30
STARTER RELAY
(3/0 AWG, RED)
POSITIVE CABLE TO BATTERY
ST RLY PWR STRT SOL ST RLY ENG GND
(3/0 AWG, BLACK)
NEGATIVE CABLE TO BATTERY
9.5.11
ECU GND/050 ECU BAT/022 1 2 3 7 8 9 10 15 16 20 21 22 33 40 41 45 54 57 59 60 63
GEAR
Electrical System Power Unit Schematic - Perkins
G10-55A, G12-55A
9-21 1
1
VEH GND
BTTY - BLK 2/0AWG
TO VEH GND
NEG BATTERY CABLE
1
SPLICE 1 SPLICE 11
POSITIVE BATTERY CABLE
BTTY - BLK 2/0AWG 1 1 BTTY - BLK 2/0AWG
IVS VIO 18AWG
THR SGN/915 GRN 18AWG
ON-IDLE ORG 18AWG
SPLICE 2 SPLICE 3
THR SUP/911 BRN 18AWG THR RTN/914 YEL 18AWG
VEC PWR RED 8AWG VEC PWR RED 8AWG
IVR BLU 18AWG
VEC GND BLK 8AWG VEC GND BLK 8AWG
1
STRT PWR
TO STRT PWR, F7
1
ENG GND
30A TBD FUSE HOLDER, ATO
WAIT TO START WHT 18AWG
VEC POS A B
B
STARTER RELAY, 12V, 75 AMP
1 2 FC206
87
30
RL196-87 1
ECU BAT/022 RED 10AWG
G
ECU GND/050 BLK 4AWG ALT GND BLK 8AWG
RL196-30 1
ECU BAT/022 RED 10AWG SPLICE 5
RL196 2 1
ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG ECU GND/050 BLK 12AWG ECU GND/050 BLK 12AWG
85 86
4 3 2 1
VEC NEG A
CAN SHIELD/020 GRY 18AWG ECU IGN/012 RED 18AWG HTR SIG ORG 18AWG HTR RTN BLK 18AWG ENG STOP LT ORG 18AWG ENG WARN LT VIO 18AWG CAN H/904 YEL18AWG CAN L/905 GRN 18AWG
F
TO ENG GND STUD
BTTY - BLK 2/0AWG
BTTY + RED 2/0AWG
TO STRT GND, F7
STRT GND STRT GND
TO STRT GND, F7
ENG GND CABLE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
SPLICE 4
CONNECTS TO 60 PIN RECEPTICLE ON ENGINE ECM
VEH GND CABLE
BTTY - BLK 2/0AWG
TO VEH GND
VEH GND
BATTERY CABLES
CAN H/904 YEL 18AWG CAN L/905 GRN 18AWG CAN SHIELD/020 GRY 18AWG
ECU BAT/022 RED 18AWG ECU GND/050 BLK 18AWG
CAN H/90 YEL 18AWG CAN L/905 GRN 18AWG CAN SHIELD/020 GRY 18AWG
ECU IGN/012 RED 18AWG
ECU IGN/012 RED 18AWG ECU IGN/012 RED 18AWG
* MAIN BATTERY
E
A B C
DIAGNOSTIC
H J B A F G C D E
FC205
1 2 FC208
TRANS SOL Y6 BRN 16AWG
PK BRK SOL VIO 16AWG ENG WARN LT VIO 18AWG ENG STOP LT ORG 18AWG ALT EXC RED 18AWG THR SUP/911 BRN 18AWG THR SGN/915 GRN 18AWG THR RTN/914 YEL 18AWG ST RLY ORG 16AWG CAN H/904 YEL 18AWG CAN L/905 GRN 18AWG CAN SHIELD/020 GRY 18AWG TRANS TMP SW BLU 16AWG IVS VIO 18AWG TRANS SOL Y1 BRN 16AWG WAIT TO START WHT 18AWG TRANS SOL Y2 BRN 16AWG TRANS SOL Y3 BRN 16AWG ON-IDLE ORG 18AWG IVR BLU 18AWG TRANS SOL Y4 BRN 16AWG TRANS SOL Y5 BRN 16AWG
ENG GND BLK 12AWG
ECU IGN/012 RED 12AWG
ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG
STRT AID NEG CABLE
120 OHMS
CONNECTS TO 29 PIN CHASISS HARNESS 1 2
1 MAIN B-
A
1 MAIN B+
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1
1
B- TERM
5A TBD FUSE HOLDER, ATO
1
B- TERM
BTTY + RED 2/0AWG
B+ TERM
5A TBD FUSE HOLDER, ATO
STRT AID POS CABLE
BTTY + RED 2/0AWG
B+ TERM BTTY - BLK 2/0AWG
* EXTRA BATTERY
MY4720A
BTTY - BLK 2/0AWG
G10-55A, G12-55A SPLICE 6
SPLICE 7
STRT SOL ORG 10AWG
ST RLY PWR RED 10AWG
ENG GND BLK 16AWG ST RLY ORG 16AWG
MOLDED DIODE A B SOL1
1 2
TRANS SOL Y1 BRN 16AWG ENG GND BLK 16AWG
DIODE 4
H2
DIODE 5
ZF TRANSMISSION
PK BRK SOL VIO 16AWG
SPLICE 13 DIODE 7
TRANS SOL Y1 BRN 16AWG TRANS SOL Y2 BRN 16AWG TRANS SOL Y3 BRN 16AWG TRANS SOL Y4 BRN 16AWG
SPLICE 8
1 2
TRANS SOL Y2 BRN 16AWG ENG GND BLK 16AWG
1 2
TRANS SOL Y3 BRN 16AWG ENG GND BLK 16AWG
DIOCE 6
TRANS TMP SW BLU 16AWG ENG GND BLK 16AWG ENG GND BLK 16AWG
1 2
TRANS SOL Y4 BRN 16AWG ENG GND BLK 16AWG
H1
MOLDED DIODE A B SOL2
TRANS SOL Y1 BRN 16AWG TRANS SOL Y2 BRN 16AWG TRANS SOL Y3 BRN 16AWG TRANS SOL Y4 BRN 16AWG TRANS SOL Y5 BRN 16AWG
MOLDED DIODE A B SOL3
1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12
MOLDED DIODE A B SOL4
TRANS SOL Y5 BRN 16AWG TRANS SOL Y6 BRN 16AWG PRK BRK SOL VIO 16AWG TRANS TMP SW BLU 16AWG ENG GND BLK 16AWG ENG GND BLK 16AWG
MOLDED DIODE
PRK BRK SOL VIO 16AWG ENG GND BLK 16AWG
1 2
TRANS SOL Y5 BRN 16AWG ENG GND BLK 16AWG
DIODE 8
1 2
PK BRK SOL VIO 16AWG ENG GND BLK 16AWG
DIODE 9
FUSIBLE LINK
1 2
DIODE 3
1 2
1
A B C D
SIGNALS
BATT GROUND
ECU GND/050 BLK 4AWG
BATT POSITIVE
ALTERNATOR
TURNER TRANSMISSION
H3
K3
K2
K1 1 1 PWR STUD 1 SOL STUD 1 GND STUD
M
GRID HTR PWR RED 2AWG
1 RL198-4
1 RL198-2
1 RL198-3
1 RL198-1 87
86
85
30
1 FC197-2
1 FC197-1
CONNECTS TO H1 WHEN TURNER TRANSMISSION IS USED
PRK BRK SOL VIO 16AWG ENG GND BLK 16AWG
ALT GND BLK 8AWG
ALT EXC RED 18AWG
ALT PWR - 12AWG FUSIBLE LINK STRT SOL ORG 10AWG
STRT PWR RED 2/0AWG
HTR RTN BLK 18AWG
HTR SIG ORG 18AWG
GRID HTR PWR RED 2AWG
HTR PWR A RED 2AWG
HTR PWR RED 2AWG
HTR PWR A RED 2AWG
VALVE, PARK BRAKE
SPLICE 10
DIODE 10
DIODE 11 MOLDED DIODE
DIODE 12
SPLICE 12
1 2
SPLICE 16
1 2
TRANS SOL Y1 BRN 16AWG ENG GND BLK 16AWG
1 2
TRANS SOL Y2 BRN 16AWG ENG GND BLK 16AWG
TRANS SOL E1 BRN 16AWG TRANS SOL E4 BRN 16AWG TRANS SOL E3 BRN 16AWG TRANS SOL E2 BRN 16AWG TRANS SOL E5 BRN 16AWG TRANS SOL E6 VIO 16AWG
1 2
TRANS SOL Y3 BRN 16AWG ENG GND BLK 16AWG
TRANS TMP SW BLU 16AWG ENG GND BLK 16AWG ENG GND BLK 16AWG
1 2
TRANS SOL Y4 BRN 16AWG ENG GND BLK 16AWG
DIODE 13
DIODE 14 MOLDED DIODE
DIODE 15
STARTER ENGINE
TBD
SLO-BLO 300A (LITTLEFUSE)
GRID HEATER FUSE
GRID HEATER RELAY TBD
1 EC202
TEM SW TRANS TMP SW BLU 16AWG 1
HTR PWR - 6AWG
MOLDED DIODE
ALT PWR - 12AWG ALT PWR RED 8AWG FUSIBLE LINK SPLICE 14 SPLICE 15
A B SOL5
MOLDED DIODE A B PKSOL
TRANS TMP SW BLU 16AWG A ENG GND BLK 16AWG B TEMPSW
MOLDED DIODE 1 2 SOL E1
MOLDED DIODE 1 2 SOL E2
1 2 SOL E3
1 2 3 4 5 6 7 8 9 10 11 12
MOLDED DIODE 1 2 SOL E4
MOLDED DIODE TRANS SOL Y5 BRN 16AWG ENG GND BLK 16AWG
1 2 SOL E5
1 2
TRANS SOL Y6 BRN 16AWG ENG GND BLK 16AWG
1 2 SOL E6
TEMP SWITCH COLD START
GRID HEATER ENGINE
9.5.12
Power Unit Schematic - Cummins Electrical System
Electrical System
CIRCUIT BREAKDOWNS Constant Power Circuit from Battery - John Deere & Perkins
BAT POS BAT POS
TRAN/BRK PWR
ST RLY
HORN PWR
STARTER
ST RLY PWR (3/0 AWG, RED) (4 AWG, RED)
(4 AWG, RED) ALT EXC A
6A/400V
TO SHIFTER HARNESS
ALTERNATOR
G
B+
A
D+ 6A/400V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
SP BAT PWR REVERSE RELAY
3
TRAN/BRK PWR
OPT PWR 1
KEY/IGN
B
M
STRT SOL
TRAN/BRK PWR
ST RLY
HORN PWR
KEY ACC
KEY BAT PWR
OPT PWR 4
OPT PWR 3
OPT PWR 4 OPT PWR 3 OPT PWR 2
OPT PWR 2
OPT PWR 1
KEY ACC
KEY BAT PWR
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 1
KEY ACC KEY ACC KEY ACC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
A B C D E F G H BLACK-1
GRAY-2
TO DASH PANEL HARNESS
(3/0 AWG, BLACK)
SP BAT PWR
GRAY-2 H G F E D C B A
86
SP BAT PWR
ST RLY
87 85
SP BAT PWR
A B C D E F G H
30
(3/0 AWG, RED)
TRAN/BRK PWR
TRAN/BRK PWR
ST RLY PWR STRT SOL ST RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
85
BLUE-3
F12
F7
CB2
15
20
20 15
CB1
85
87
KEY ACC
ECU BAT/022
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
(3/0 AWG, RED) STARTER RELAY
SP BAT PWR
TO OPTIONS HARNESS
POSITIVE CABLE TO BATTERY
ALT EXC
86
BLACK-1 H G F E D C B A
86
87a 30
CB3
F9 10
20
F8 25
20
NEGATIVE CABLE FLAG TO
ACCY-1
85
CB4
86
87
IGNITION-1
POSITIVE CABLE TO STARTER AND ALTERNATOR NEGATIVE CABLE TO ENG BLOCK
(3/0 AWG, BLACK)
2
-
A B C D E F G H
87
GREEN-4
85
87
86
87a 30
85
86
87
87a 30
5
F1 15
87a 30
12 VDC BATTERY
IGNITION-2
5
F2 ACCY-2
+
POWER DIST VEC
C GRAY-5
4
A
87a 30
C
BLACK-6
1
A
NEGATIVE CABLE TO BATTERY TO ENGINE ECU
ECU BAT/022
NEGATIVE CABLE TO CAB FIREWALL
SP BAT PWR
9.6.1
SP BAT PWR
9.6
A
S
SHIFTER HARNESS
I
LIGHTS
OFF
2 3
PARK BRAKE
OFF
7 1
4
2
5
3
87
86
85
87a 30
87
87a 30
86
85
ON
ST RLY
87a 30
87
85
86
87
87a 30
86
85
BCN/FAN
HORN
TRAN/BRK PWR
OPTION (15A)
HORN PWR
87a 30
87
86
85
87a 30
87
86
85
OPTION (25A)
GREEN-4
H G F E D C B A
BLUE-3
H G F E D C B A
6 ON
WIPER
HEATER/BLOWER
OPTIONS VEC LEFT DASH PANEL OPTIONS HARNESS
9-22
DASH PANEL HARNESS
MY1102
G10-55A, G12-55A
Electrical System
9.6.2
Constant Power Circuit from Battery - Cummins BAT POS BAT POS
POWER DIST VEC
OPTIONS VEC
87a 30
87
86
85
87a 30
5
F1 20 F5 20
F6 10
GREEN-4
GREEN-4
F5 15
85
86
87
87a 30
85
86
87
87a 30
IGNITION-2
87
HEATER/BLOWER
WIPER
F2 ACCY-2
85
B
GRAY-5
86
A BLACK-6
F7 10 F8 10 LIGHTS
F6 20
BCN/FAN
85
86
87
87a 30
85
86
87
85
86
87
87a 30 86
85
87
87a 30
GRAY-2
SP BAT PWR
CHASSIS HARNESS
HORN PWR
KEY BAT PWR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY/IGN B
A
ECU BAT/022
F2 5
BLACK-1 H G F E D C B A
BLUE-3
87
85
86
87a 30
87
86
85
87a 30
F4
F3
25
OPT PWR 2 OPT PWR 1
15
AUX ELEC2
OPT PWR 3
OPT PWR 3
OPTION (25A)
HORN PWR
OPT PWR 4
OPT PWR 1 OPT PWR 2
AUX ELEC1
OPTION (15A)
OPT PWR 4
BLUE-3
F12
CB2 20 F11 10
F10 10
15
F7
20 15
CB1
85
86
GRAY-2 H G F E D C B A
KEY BAT PWR
BLACK-1 H G F E D C B A
87
87a 30
F4
F9
20 10
25
CB3
F8
F3
25
20
10
85
86
87
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
ACCY-1
CB4
87a 30
IGNITION-1
87a 30
F1 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
HORN OFF
2
SHIFTER HARNESS
SP BAT PWR
ON
S I
DASH PANEL HARNESS
POSITIVE CABLE TO STARTER AND ALTERNATOR
+
12 VDC BATTERY
HTR PWR RED 2AWG 1 FC197-1
1 2 FC206
4 3 2 1
FUSIBLE LINK
30A FUSE HOLDER, ATO
ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG
HTR PWR A RED 2AWG
1 FC197-2 GRID HEATER FUSE SLO-BLO 300A (LITTLEFUSE) 30
HTR PWR A RED 2AWG
1 RL198-1
87
ECU BAT/022 RED 12AWG ECU BAT/022 RED 12AWG
1 2
86 FC205 85
H J B A F G C D E
ECU BAT/022 RED 18AWG
GRID HEATER RELAY
DIAGNOSTIC STRT PWR RED 2/0AWG
85 86 30
1 PWR STUD
M
ENGINE STARTER RL196-30 1 ST RLY PWR RED 10AWG
ALT PWR - 8AWG
1 K1 A B C D
87 STARTER RELAY, 12V, 75 AMP 5A FUSE HOLDER, ATO
BATT POSITIVE
1
SIGNALS BATT GROUND
ALTERNATOR ENGINE HARNESS
G10-55A, G12-55A
MY5040
9-23
Electrical System 9.6.3
Start & Charge Circuit - John Deere & Perkins
BAT POS BAT POS
A
F2
GREEN-4
85
86
87
87a 30
86
85
BLUE-3
F12
F7
CB2
15
20
CB1
85
TRAN/BRK PWR
A B C D E F G H
ST RLY
ST RLY
KEY START
KEY BAT PWR KEY IGN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
30 87 86 85
(3/0 AWG, RED) (3/0 AWG, BLACK) STARTER
M
STRT SOL
ST RLY PWR (3/0 AWG, RED) (4 AWG, RED)
(4 AWG, RED) ALT EXC A
6A/400V
A
ALTERNATOR
G
B+
D+ 6A/400V
TO SHIFTER HARNESS
KEY START
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
TRAN/BRK PWR
ST RLY
KEY START
ST RLY PWR STRT SOL ST RLY
TO DASH PANEL HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY BAT PWR KEY IGN
(3/0 AWG, RED) STARTER RELAY
ALT EXC
KEY BAT PWR
86
87
A B C D E F G H
POSITIVE CABLE TO BATTERY
GRAY-2 H G F E D C B A
KEY IGN
BLACK-1 H G F E D C B A
20 15
CB3 20
10
F8 25
F9
87a 30
ACCY-1
85
CB4
NEGATIVE CABLE FLAG TO
86
IGNITION-1
20
POSITIVE CABLE TO STARTER AND ALTERNATOR NEGATIVE CABLE TO ENG BLOCK
5
F1 15
87
12 VDC BATTERY
IGNITION-2
-
87a 30
+
87
87a 30
ACCY-2
POWER DIST VEC
C GRAY-5
(3/0 AWG, BLACK)
TRAN/BRK PWR
C
BLACK-6
KEY START
A
TRAN/BRK PWR
NEGATIVE CABLE TO CAB FIREWALL
NEGATIVE CABLE TO BATTERY
TRAN/BRK PWR REVERSE RELAY 3 1
TRANSMISSION SHIFTER HOBBS
SW1 KEY/IGN
B
F
F N
N
87a 30
4
87
5
86
2
85
SW2
R
R
A 4
4
SW3
S I
3
3
2
2
1
SW4
WARN LIGHT TEST RELAY 3 1
87a 30
4
87
5
86
2
85
1 2 3 4 5 6 7 8
PARK BRAKE
OFF
7 1
4
2
5
3
6
ST RLY
TRAN/BRK PWR
KEY START
1
SHIFTER HARNESS
ON
LEFT DASH PANEL DASH PANEL HARNESS
9-24
MY1111
G10-55A, G12-55A
Electrical System
REVERSE ALARM
F2
5
GREEN-4
F5 15 F6 10
F1 15
BLUE-3
F12
20 F11 10
15
ST RLY TRAN/BRK PWR
A B C D E F G H
ENG WARN LT VIO 18AWG
GRAY-2 H G F E D C B A
12 VDC BATTERY
1
6
BATT GROUND
K3 RL196 2 1
ST RLY ORG 16AWG ST RLY PWR RED 10AWG
RL196-30 1
RL196-87 STRT SOL ORG 10AWG 1
STRT PWR RED 2/0AWG 1 PWR STUD STRT SOL ORG 10AWG 1
30 87
M
SOL STUD 1 GND STUD
POWER UNIT
TRANS TEMP SW
REVERSE TRAN/BRK PWR
85 86
STARTER ENGINE
29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
KEY START SHIFT PWR 1
TRAN/BRK PWR REVERSE
ON
PARK BRAKE
3
R
TRAN/BRK PWR REVERSE
4
4
WARN LIGHT TEST RELAY
SW2
R
3
N
85
F N2
2
2 85
3
1
4
5
87
87a 30
(RED, 18 GA GXL)
ENG STOP (RED, 18 GA GXL)
F
5
SW1
ENG WARN (RED, 18 GA GXL)
4
TRANS TMP WRN (RED, 18 GA GXL)
1
SW3
SW4
3
2
1
WAIT TO START LT ENG WARN LT TRANS TMP SW ENG STOP LT GAGE PWR
3 2
(RED, 18 GA GXL)
1
WAIT TO START STONERIDGE GAUGE 5 4 6
30
TRANS TEMP SW KEY START
8 7 6 5 4 3 2 1
87
KEY/IGN
86
POSITIVE CABLE TO STARTER AND ALTERNATOR
5
3
I
7 4
2
SIGNALS
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
TRAN/BRK PWR
A S
ST RLY
-
KEY START SHIFT PWR 1
TRAN/BRK PWR
WAIT TO START ENGINE WARN LT
TRANS TEMP SW ST RLY SHIFT PWR 1
GAGE PWR
KEY START
KEY START
KEY BAT PWR KEY IGN
OFF
B
1
+
A B C D K2
KEY BAT PWR KEY BAT PWR KEY IGN
GAGE PWR
KEY IGN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
K1
ALT EXC RED 18AWG
POSITIVE CABLE TO STARTER AND ALTERNATOR
CHASSIS HARNESS
BATT POSITIVE
1
86
CB2
F10 10
F7
CB1
85
87
86
WAIT TO START ENG STOP LT ALT EXC
ALT EXC
REVERSE
BLACK-1 H G F E D C B A
20 15
F4
CB3
20 10
25
F3 10
F8 25
20
F9
87a 30
ACCY-1
85
86
87
CB4
87a 30
IGNITION-1
A B C D E F G H
ALTERNATOR ALT PWR - 12AWG FUSIBLE LINK
87a
85
87
86
87a 30
86
IGNITION-2 85
87
87a 30
ACCY-2
POWER DIST VEC
WAIT TO START WHT 18AWG ENG STOP LT ORG 18AWG ENG WARN LT VIO 18AWG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
D C B A
CONNECTS TO 60 PIN RECEPTICLE ON ENGINE ECM
C
GRAY-5
BLK RED GRN
BU
A BLACK-6
B A
(OPT) TAIL LIGHT STOP TAIL
BAT POS
BAT POS
Start & Charge Circuit - Cummins
(-)
9.6.4
REVERSE RELAY
1
1
2 HOBBS
3 4 5
(ORG, 18 GA GXL) (D BLU, 18 GA GXL)
DASH PANEL
6 7 8
(ORG, 18 GA GXL) (WHT, 18 GA GXL)
MAIN DASH PANEL
G10-55A, G12-55A
TRANSMISSION SHIFTER ZF
MY5050
9-25
Electrical System
9.7
ENGINE START CIRCUIT
9.7.1
Starter
1
2. If a “whirring” noise is heard but the engine does not turn over, the starter is spinning but not engaging the flywheel. The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective. Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine. 3. If the starter only “clicks” it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection. Check the battery state of charge and battery condition first, then check the cables and cable connections. 4. For additional information on the starting circuit, refer to Section 9.5, “Electrical System Schematics.” c. Starter Removal
MY4600
Remove the starter only if it fails. To remove the starter:
The starter (1) is located on the left side of the engine (the right side of the machine - John Deere).
1. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
The starter (1) is located on the right side of the engine (the right side of the machine - Perkins & Cummins).
2. Open the engine cover.
a. Testing the Starter on the Engine
4. Remove the wires from the solenoid stud. Remove the positive (+) battery cable from the starter. Label and disconnect the wire from the starter solenoid housing stud. Record how the wires are installed to ensure correct installation later.
If the starter does not engage when the ignition key switch is turned, check the following: 1. The main fuse may be blown, requiring replacement. Check for the cause of the blown fuse. 2. There may be a defect in the ignition key switch, ignition wiring or starter solenoid. 3. Check battery condition. Clean the battery posts and the connectors at each end of the battery cables. 4. Check for broken wiring and damaged insulation on the wiring. Replace all broken or damaged wiring. 5. Check all connections at the starter solenoid, key switch and wiring harness plugs. Clean and tighten all connections. 6. If the starter still does not operate after these checks have been performed, check the starting circuit. b. Starter Circuit Checks 1. Check wires and connections for looseness, corrosion, damage, etc.
3. Properly disconnect the battery.
5. Loosen, but DO NOT remove, the three fasteners securing the starter to the flywheel housing. Support the starter securely, as it is relatively heavy and will fall if not supported. 6. Support the starter and remove the fasteners securing the starter to the engine. Remove the negative (-) ground cable from its starter mounting bolt. 7. Remove the starter from the machine. d. Starter Installation 1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with the three fasteners. 2. Connect the positive (+) battery cable to the upper solenoid stud. Install the wires to the upper solenoid stud, and secure with lock washer and nut. 3. Connect the wire to the solenoid mounting stud. 4. Properly connect the battery. 5. Close and secure the engine cover.
9-26
G10-55A, G12-55A
Electrical System 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.7.2
4. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket. 5. While lifting the automatic belt tensioner away from the belt, remove the fan serpentine belt.
Charging Circuit 2
Note: Record how the alternator is installed to ensure correct installation later. 6. Label and disconnect the wire leads attached to the alternator. 7. Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine. 8. While supporting the alternator with one hand, remove the upper (longer) mounting hardware from the upper alternator mount. Remove the alternator from the machine. b. Alternator Installation
MY0370
Before using a battery charger, an attempt can be made to recharge the battery by jump-starting the machine (Refer to the appropriate Operation & Safety Manual). Allow the engine to run, which will enable the alternator (2) to charge the battery. If the engine alternator charging warning indicator illuminates, perform the following checks: 1. Check all battery cable connections at the battery, and verify that they are clean and tight. 2. Check the external alternator wiring and connections, and verify that they are in good condition. 3. Check the fan belt condition and tension. 4. Run the engine and check the alternator for noise. A loose drive pulley, loose mounting hardware, worn or dirty internal alternator bearings, a defective stator or defective diodes can cause noise. Replace a worn or defective alternator.
1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper (longer) mounting hardware through the alternator mount. Thread the longer capscrew into the alternator front mount. DO NOT tighten completely at this time. 2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounting capscrew. Tighten the lower capscrew and upper capscrew securely. 3. Place a drive ratchet into the square hole on the serpentine belt tensioner bracket. Apply pressure against the tensioner bracket and route the serpentine belt onto the alternator and engine pulleys. Release and check the tensioner pulley to verify that it is pivoting freely in order to provide the proper tension on the belt. Check for proper belt alignment. (Refer to the appropriate Operation & Safety Manual.) 4. Connect the previously labeled wire leads to the alternator. 5. Properly connect the battery. 6. Close and secure the engine cover.
9.7.3
Alternator
7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
a. Alternator Removal 1. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 2. Open the engine cover. Allow the system fluids to cool. 3. Properly disconnect the battery. G10-55A, G12-55A
9-27
Electrical System
9.8
WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR
b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective.
a. Removal Note: It may be necessary to remove several hydraulic hoses from behind the dash in order to remove and install the wiper motor housing. (Refer to Section 4.3.1, “Steering Column and Orbitrol Valve.”) 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
c. Inspection and Replacement Inspect the motor terminals for continuity. Replace motor if continuity is not found. d. Installation and Testing 1. Install all required hardware to the motor assembly. 2. Align motor with the mounting holes and bolt the motor to the mounting bracket. 3. Connect the wiper linkage to the wiper motor shaft. Note: Align the wiper linkage arm with the flat on the motor shaft to ensure wiper stroke covers window area, and it does not swipe past the glass area. 4. Connect the cab harness connectors to windshield wiper motor connectors. 5. Replace the main dash panel to its original orientation. Secure with the previously used screws. 6. Properly connect the battery. 7. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved. 8. If previously removed, install hydraulic hoses under the dash. (Refer to Section 4.3.1, “Steering Column and Orbitrol Valve.”) 9. Close and secure the engine cover.
3
10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
MY0440
5. Remove the screws that secure the main dash panel. Pull out the dash panel to gain access to the wiper motor (3). 6. Disconnect the cab harness connectors from the wiper motor. 7. Remove the linkage attached to the wiper motor. 8. Loosen and remove the four bolts holding the wiper motor to the mounting bracket. Note: Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing. 9. Remove the motor from the inside of the cab. 9-28
G10-55A, G12-55A
Electrical System 9.8.1
Windshield/Rear Window Washer Reservoir
2. Connect the cab wiring harness connectors to the reservoir connectors. 3. Install the reservoir tank onto the mounting bracket. 4. Install the lock washers and nuts and secure.
4
5. Fill the washer fluid reservoir with washer fluid. 6. Properly connect the battery. 7. Turn the ignition key switch to the RUN position and press the washer switch. Verify that fluid is sprayed on both the windshield and rear glass. 8. Close and secure the engine cover.
MY1220
9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
The windshield washer motor and reservoir (4) is located in the cab behind the seat. It is labeled as a unit and cannot be serviced separately. a. Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the nuts and the lock washers from the washer mounting bolts. 6. Pull the washer reservoir out and away from the mounting bracket. 7. Rotate the washer reservoir, label and remove the cab harness connectors from the washer reservoir connectors. 8. Remove the windshield washer hoses from the reservoir. b. Disassembly DO NOT disassemble the pump. The pump is not serviceable. Replace pump if found to be defective. c. Installation and Testing 1. Connect the windshield washer hoses to the reservoir.
G10-55A, G12-55A
9-29
Electrical System
9.9 9.9.1
CAB HEATER AND FAN
c. Installation and Testing 1. Check that the variable speed fan control is in the OFF position.
Cab Heater Controls
Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. a. Cab Heater Controls Removal
2. Install the heater controls to the dash panel with the previously used hardware. 3. Connect the cab electrical harness connector to the controls. 4. Install the control knobs.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
5. Install the screws securing the dash panel to the cab. 6. Properly connect the battery. 7. Turn the ignition key to the ON position and check the fan speeds. If further repair is needed, refer to Section 9.5, “Electrical System Schematics.”
3. Open the engine cover. Allow the system fluids to cool.
8. Start the machine and allow engine to warm to operating temperature. Check heat control at different levels.
4. Properly disconnect the battery.
9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5
9.10
9.10.1
SOLENOIDS, SENSORS AND SENDERS Fuel Shut-off Solenoid - John Deere
a. Fuel Shut-off Solenoid Removal
MY1230
5. Remove the screws securing the right cab dash panel (5). 6. Pull out the panel to gain access to the heater control electrical connections. Disconnect the harnesses. 7. Remove the heater control knobs. 8. Remove the necessary hardware securing the heater control from the dash panel. Remove the control from the panel.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
b. Disassembly DO NOT disassemble the cab heater and fan controls. The controls are not serviceable. Replace controls if found to be defective.
9-30
G10-55A, G12-55A
Electrical System 9.10.2
Park Brake Solenoid Valve
a. Park Brake Solenoid Valve Removal
6
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. MY1030
5. Disconnect the wiring connector at the fuel shut-off solenoid (6) lead. 6. Remove the fuel shut-off solenoid from the fuel injector pump.
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Disconnect the wiring connector at the park brake solenoid lead. 7
b. Fuel Shut-off Solenoid Disassembly DO NOT disassemble a fuel shut-off solenoid. Replace a defective fuel shut-off solenoid with a new part. c. Fuel Shut-off Solenoid Inspection and Replacement Use a 12-volt DC source and ground to test the solenoid. Energize the solenoid, and watch for the plunger to retract. If the plunger does not retract, replace the fuel shut-off solenoid with a new part.
8
d. Fuel Shut-off Solenoid Installation 1. Clean the exterior of the fuel injector pump. 2. Install the fuel shut-off solenoid on the fuel injection pump. Do Not Over Tighten. 3. Connect the wiring connector at the fuel shut-off solenoid lead. 4. Properly connect the battery.
MY1140
6. Remove the nut on the end of the park brake coil (7). 7. Remove the park brake coil. 8. Remove the park brake solenoid (8). (Remove only if the electrical coil is found to not be faulty.)
5. Start the engine. If the engine starts, the fuel shutoff solenoid is functioning. If the engine fails to start, the fuel shut-off run solenoid may have a poor ground connection. Visually check the wiring at the fuel shutoff solenoid leads and/or check for continuity with a voltmeter as required.
b. Disassembly
6. Check for fuel and/or oil leakage around the solenoid.
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.
7. Close and secure the engine cover. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
G10-55A, G12-55A
DO NOT disassemble the solenoid. The solenoid is not serviceable. Replace solenoid if found to be defective. c. Park Brake Solenoid Valve Installation
1. If necessary, install the park brake solenoid in its original orientation.
9-31
Electrical System 2. Slide the park brake coil over the solenoid. Tighten the nut to secure the solenoid. DO NOT overtighten. 3. Connect the wiring connector to the park brake coil lead. 4. Properly connect the battery. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.10.3
Transmission Solenoid Valves
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the transmission temperature sender connector from the wiring harness connector. 6. The sender is threaded into the transmission housing. Remove the sender.
9 (Y2) 9 (Y4) 10
9 (Y5)
9 (Y1)
MY4330
Note: If the transmission is not shifting properly, the transmission shift control switch (travel select lever), wiring harness or transmission shift solenoids (9) should be checked in order to determine which component is defective. Specific information to determine which travel position and corresponding component is not responding can be found in the detailed transmission service instructions (covering repair, disassembly, reassembly and adjustment information) are provided in the ZF Powershift Transmission 4WG-92/98 TSC Repair Manual, (JLG P/N 31200241) and can be obtained by calling your local JLG dealer or ZF Service Center.
b. Transmission Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part. c. Transmission Temperature Sender Installation and Testing 1. Thread the transmission temperature sender into the transmission housing snugly, then connect the sender connector to the wiring harness connector. 2. Properly connect the battery. 3. Check for proper fluid level. 4. Start the engine, allow it to reach operating temperature and observe the operator’s display cluster for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, damaged transmission, improper or low fluid, etc. 5. Close and secure the engine cover.
The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.
9.10.5
Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.
a. Engine Coolant Temperature Sender Removal
9.10.4
Transmission Temperature Sender
a. Transmission Temperature Sender Removal The transmission temperature sender (10) is located at the bottom left side of the transmission housing. 9-32
6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
Engine Coolant Temperature Sender
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
G10-55A, G12-55A
Electrical System 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. CUMMINS ENGINE SHOWN
4. Start the engine, allow it to reach operating temperature and observe the operator’s instrument cluster for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, improper or low coolant, obstructed or faulty radiator, coolant pump, loose fan belt, defective instrument display, etc. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
1 2
MY4620
5. Unplug the engine coolant temperature sender connector (1) from the wiring harness connector. 6. The engine coolant temperature sender (2) is located near the upper radiator hose thermostat housing and threaded into the engine block. Remove the sender. b. Engine Coolant Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part. c. Engine Coolant Temperature Sender Installation and Testing 1. Thread the engine coolant temperature sender into the engine block snugly, then connect the sender connector to the wiring harness connector. 2. Properly connect the battery. 3. Check for proper coolant level.
G10-55A, G12-55A
9-33
Electrical System 9.10.6
Air Manifold Temperature Sensor John Deere
a. Air Manifold Temperature Sensor Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the engine coolant temperature sender/ switch connector from the wiring harness connector. 6. Unplug the air manifold temperature sensor connector from the wiring harness connector.
4. Start the engine, allow it to reach operating temperature and observe the operator’s instrument cluster for warning indication. If the sensor is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, improper or low coolant, obstructed or faulty radiator, coolant pump, loose fan belt, defective instrument display, etc. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.10.7
Engine Oil Pressure Sender/Switch
a. Engine Oil Pressure Sender/Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
3
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the engine oil pressure sender connector from the wiring harness connector. MY1270
7. The air manifold temperature sensor (3) is threaded into the engine block. Remove the sender. b. Air Manifold Temperature Sensor Inspection and Replacement Inspect the sensor and the wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new part. c. Air Manifold Temperature Sensor Installation and Testing 1. Thread the air manifold temperature sensor into the air manifold snugly, then connect the sensor connector to the wiring harness connector. 2. Properly connect the battery. 3. Check for proper coolant level.
9-34
G10-55A, G12-55A
Electrical System
PERKINS
c. Engine Oil Pressure Sender Installation and Testing
JOHN DEERE
1. Thread the engine oil pressure sender into the fitting or engine block snugly, then connect the sender connector to the wiring harness connector.
5
2. Properly connect the battery. 3. Check for proper oil level. 4
4 MY1810
CUMMINS
4. Start the engine, and observe the operator’s display for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, low oil, obstructed or faulty oil pump, defective instrument display. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.10.8
Fuel Level Sender
a. Fuel Level Indicator Testing
4
The fuel level sender wiring harness leads can be accessed from the top of the fuel tank. 7
6
MY4640
6. Unplug the wiring harness connector from the engine oil pressure sender (4) or switch (5). 7. John Deere/Perkins - The engine oil pressure sender/switch is threaded into a fitting on the bracket weldment. Remove the sender/switch. Cummins - The engine oil pressure sender is threaded into the engine block directly above the oil filter. Remove the sender. b. Engine Oil Pressure Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part.
G10-55A, G12-55A
8 MY4340
1. Loosen and remove he four screws securing the fuel sender cover (6). 2. Disconnect the fuel level sender wiring harness leads (7) from the fuel sender (8). With the help of an assistant, touch both harness leads together. 3. From the operator’s cab, have the assistant turn the ignition key switch to the RUN position. DO NOT start the engine. Observe the fuel level indicator needle on the operator’s instrument cluster. The reading must be at the FULL mark. 4. Turn the ignition key switch to the OFF position. The fuel level indicator needle should return to the EMPTY position.
9-35
Electrical System b. Fuel Level Circuit Tests 9
If the fuel level sender (8) is suspected of giving a false reading, perform the following checks:
10
1. If the fuel level indicator needle does not move, check the fuel tank for fuel. 2. Check for loose or defective wiring, faulty ground connections, and corrosion on the fuel tank sender and wiring lead. 3. If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN position, use a test lamp to determine whether current is flowing from the ignition switch to the fuel level sender. 4. If the fuel level indicator does not move and a faulty or defective fuel level sender in the fuel tank has been ruled out, and in addition, wiring and connectors have been checked and ruled out, the fuel level indicator is defective and must be replaced. 5. Check that the ignition terminal has current and that the fuse in the fuse panel is not blown. 6. Check for broken, shorted, frayed, disconnected or damaged wiring between the fuel level indicator wiring at the cab, fuse and relay panel, ignition key switch, and from the fuel level sender on the fuel tank through the wiring in the cab. 7. Check the fuel level sender. A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving. Refer to Section 9.5, “Electrical System Schematics,” for further information.
9.10.9
Inclinometer Switch
G10-55A Before S/N 0160038543 G12-55A Before S/N 0160038542
10
MY1311
6. Unplug and label the inclinometer switch connector (9) from the wiring harness connector. 7. Remove the hardware securing the inclinometer switch (10) to the machine frame. b. Inclinometer Switch Installation 1. Install the inclinometer switch to the machine frame with the previously used hardware. 2. Connect the previously labeled wires to the inclinometer switch. 3. Install the inclinometer switch protective cover. 4. Properly connect the battery. 5. Close and secure the engine cover. 6. Start the engine. Fully retract and level the boom and level the frame. 7. Locate a 12” curb and drive the left front and left rear tires onto the curb. Sway the machine to the right. When the frame is out of level by 15°, the machine will automatically sway back to 14.7°. 8. Repeat step 7 for the right side of the machine. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
a. Inclinometer Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise and support the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the inclinometer switch protective cover. 9-36
G10-55A, G12-55A
Electrical System 9.10.10
Front and Rear Axle Proximity Sensors
The sensors used on each axle allow the steering to be changed to one of three different settings. The sensors will not allow the change to be completed unless both axles are in the central location. Each sensor is mounted in the center of each steer cylinder.
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. JOHN DEERE
12
11
a. Removal 1. Open engine cover. Allow system fluids to cool. 2. Properly disconnect the battery. 3. Unplug the axle proximity sensor from the wiring harness. 4. Remove the bolts holding the sensor to the steering cylinder barrel.
PERKINS BEFORE S/N 0160037186
12
11
b. Disassembly 1. Inspect the sensor and the wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new sensor. c. Installation and Testing 1. Install the bolts holding the sensor to the steering cylinder barrel.
MY1840
PERKINS S/N 0160037186 THRU 0160039451 EXCLUDUING 0160039394 & 0160039397
2. Connect the axle proximity sensor to the wiring harness. 3. Properly connect the battery. 4. Close and secure engine cover.
12
11
5. Start the machine, select a steering mode, turn the steering wheel until the display unit shows the steering has been "locked" into the selected mode.
9.11 9.11.1
DISPLAY MONITOR AND GAUGES Analog Gauges
a. Gauge Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
CUMMINS S/N 0160039451 & AFTER INCLUDING 0160039394 & 0160039397 MY5060
5. Remove the screws (11) securing the dash panel. 6. Label and disconnect the wires from the gauge, remove the gauge bracket. 7. Pull the gauge (12) out from the dash.
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
G10-55A, G12-55A
9-37
Electrical System b. Disassembly
b. Disassembly
DO NOT disassemble the gauge. The gauge is not serviceable. Replace the gauge if found to be defective.
DO NOT disassemble the ignition switch. Replace a defective switch with a new part.
c. Gauge Installation and Testing
c. Inspection and Replacement
3. Install the dash panel with the previously used hardware (11).
T BA
2. Connect the previously labeled wires to the gauge.
To determine the proper operation of the ignition key switch, test the terminals on the back of the switch for continuity with an ohmmeter. 13
AC C
1. Install the gauge (12) in the dash. Install the gauge bracket.
7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
ST
6. Close and secure the engine cover.
BAT
5. Turn the ignition to the ON position to check the gauge values.
ACC
4. Properly connect the battery.
IG
N
IG
N MY0830
9.12 9.12.1
DASH SWITCHES Ignition Key Switch
Note: For information on the front windshield wiper, rear window wiper and washer systems, refer to Section 9.8, “Window Wiper/Washer Windshield Wiper Motor.”
Test the ignition key switch for continuity, by checking from the BAT terminal (13) to each of the remaining terminals in their corresponding switch position. If all terminals do not show proper continuity, replace the ignition switch. d. Ignition Switch Installation
a. Ignition Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
1. Connect the ignition key switch to the previously labeled wires. 2. Align the ignition switch in the dash so that when it is in the OFF position, the key slot is positioned vertically (straight up and down). Install the hex nut securing the ignition switch to the dash. DO NOT overtighten.
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
3. Install the dash panel with the previously used hardware.
3. Open the engine cover. Allow the system fluids to cool.
5. Close and secure the engine cover.
4. Properly disconnect the battery. 5. Remove the screws securing the dash panel. 6. Remove the hex nut securing the ignition key switch to the dash.
4. Properly connect the battery. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. Note: If further information is needed, refer to Section 9.5, “Electrical System Schematics.”
7. Label and disconnect the ignition switch wires and remove the switch from the machine.
9-38
G10-55A, G12-55A
Electrical System 9.12.2
Dash Switches
a. Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. There are three frames with three switches in each frame. 6. Pull the frame out of the dash, disconnect the harness connector to the switch in question and push the switch out of the frame. b. Disassembly DO NOT disassemble the dash switch. Replace a defective switch with a new part. c. Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions. Replace a defective or faulty switch with a new switch. d. Switch Installation 1. Connect the switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel and snap into position. 3. Properly connect the battery. 4. Start the machine and check the replaced switch for proper function. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
G10-55A, G12-55A
9-39
Electrical System
9.13
TROUBLESHOOTING - JOHN DEERE
9.13.1
Engine Fault Codes Retrieval
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL and engage the park brake.
Note: When the engine sensor inputs exceed normal operating ranges, the ECU will derate the amount of fuel that is delivered to the engine. A fault code will always accompany a fuel derate. If the engine is running at a much lower rate, check the fault codes first to see if the engine is experiencing an internal problem.
2. Turn the ignition switch to “ON”. 3. Push down and hold the Reset button on the dash for 3-5 seconds. The fault lamp will begin to flash a code number. The light will flash the first digit then pause for a short time and then flash the second digit. If there are “active” codes, the system will first flash code 32. If there are no “active” codes, the system will flash code 88. The system will then flash code 33 if there are any “stored” fault codes. If there are no “stored” codes, the system will flash code 88. 4. Once the code is retrieved, turn the ignition OFF.
9.13.2
Engine Fault Codes Chart
Fault Codes
SPN Codes
FMI Codes
Definition
11
N/A
N/A
Analog Throttle (A) Input High
12
N/A
N/A
Analog Throttle (B) Input High
18
110
3
Engine Coolant Temperature Input Voltage High
19
110
4
Engine Coolant Temperature Input Voltage Low
21
620
3
Sensor Supply Voltage High
1079
3
Sensor Supply Voltage High
620
4
Sensor Supply Voltage Low
1079
4
Sensor Supply Voltage Low
23
100
3
Engine Oil Pressure Input Voltage High
24
100
4
Engine Oil Pressure Input Voltage Low
25
105
3
Manifold Air Temperature Input Voltage High
26
105
4
Manifold Air Temperature Input Voltage Low
28
629
13
ECU Error
32
N/A
N/A
Signifies Start of Active Fault Codes
33
N/A
N/A
Signifies Start of Previously Active Fault Codes
37
174
3
Fuel Temperature Input Voltage High
38
174
4
Fuel Temperature Input Voltage Low
39
637
2
Crank Position Input Noise
22
9-40
G10-55A, G12-55A
Electrical System
Fault Codes
42
SPN Codes
190
FMI Codes
Definition
10
Crank Position Input Pattern Error
Engine Overspeed Extreme
16
Engine Overspeed Moderate
54
158
17
ECU Power Down Error
55
639
13
CAN Error
62
110
15
Engine Coolant Temperature High Least Service
63
110
16
Engine Coolant Temperature High Moderately Service
64
100
18
Engine Oil Pressure Moderately Low
65
100
1
Engine Oil Pressure Extremely Low
66
105
16
Manifold Air Temperature Moderately High
68
1569
31
Fuel Derate
69
110
Engine Coolant Temperature High Most Severe
71
1076
Pump Control Valve Closure Too Long
72
1076
1
Pump Control Valve Closure Too Short
73
1076
5
Pump Solenoid Circuit Open
74
1076
6
Pump Solenoid Circuit Severely Shorted
75
1076
7
Pump Control Valve Closure Not Detected
76
1076
10
Pump Solenoid Circuit Moderately Shorted
77
1076
3
Pump Solenoid Current High
78
200
13
Security Violation
79
2000
6
Internal ECU Error
81
174
16
Fuel Temperature Moderately High
82
1110
31
Engine Protection Shutdown
83
970
31
Auxiliary Engine Shutdown Switch Active
84
158
17
ECU Power Down Error
971
31
External Derate Switch Active
N/A
N/A
Signifies No Fault Codes Are In Buffer
88
G10-55A, G12-55A
9-41
Electrical System
9.14
ENGINE INDICATOR LAMPS - PERKINS
Warning Lamp
Shutdown Lamp
Lamp State
Lamp Indication
ON
ON
Bulb Check
When the ignition is turned on, the EMS shall illuminate each bulb for 2 seconds and extinguish them afterwards
Key on, but engine has yet to be cranked
OFF
OFF
No Faults Present
With both lamps off whilst engine is running then are no currently active warnings, diagnostics or events
Engine is running with no detected faults
ON
OFF
Active Diagnostic
Should the warning lamp illuminate during engine running, this indicates that an Active diagnostic (Electrical fault) is present
Engine is running normally, but has one or more faults with engine management system
ON
FLASH
Derate (Invoked by Active Diagnostic)
Should the warning lamp illuminate and the shutdown lamp flash during engine running, this indicates that an Active diagnostic (Electrical fault) is present. The diagnostic is sufficiently serious to invoke engine derate
Engine is running, but has one or more Active diagnostic events that have initiated engine derate
FLASH
OFF
Warning (Warning only)
Should the warning lamp flash during engine running, this indicates that one or more of the engine protection strategy warning values have been exceeded, but not to a level that will invoke Derate or Shutdown
Engine is running normally, but has one or more monitored engine parameters outside of the acceptable range
FLASH
FLASH
Derate (Warning and Derate)
Should both the Warning Lamp and Shutdown Lamp flash during engine running, this indicates that one, or more of the engine protection strategy values have been exceeded beyond the level required to invoke engine derate
Engine is running, but one or more of the monitored engine parameters has gone beyond that of warning only and has now exceeded those set for engine derate
ON
ON
Engine Shutdown
Should both the Warning Lamp and Shutdown Lamp illuminate during engine running this indicates that either:
Engine is either shutdown or shutdown is imminent, one of more monitored engine parameters have gone beyond that of warning or derate and have now exceeded those set for engine shutdown, or a serious Active diagnostic has been detected
1. One or more of the engine protection strategy shutdown values has been exceeded 2. A serious Active diagnostic has been detected Shortly after (time duration to be agreed) engine will shutdown
9-42
Engine State
G10-55A, G12-55A
Electrical System
9.15
SAE DIAGNOSTIC TROUBLE CODES AND FAULT CODES - CUMMINS
Fault Codes
SPN Codes
FMI Codes
Lamp Color
SPN Description
Cummins Description
111
629
12
Red
Controller #1
Engine Control Module Critical internal failure Bad intelligent Device or Component
115
612
2
Red
System Diagnostic Code #2
Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic pickup sensor - Data Erratic, Intermittent, or incorrect
122
102
3
Amber
Boost Pressure
Intake Manifold Pressure Sensor Circuit Voltage Above Normal, or Shorted to High Source
123
102
4
Amber
Boost Pressure
Intake Manifold Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source
124
102
16
Amber
Boost Pressure
Intake Manifold 1 Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level
131
91
3
Red
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source
132
91
4
Red
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
133
974
3
Red
Remote Accelerator
Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source
134
974
4
Red
Remote Accelerator
Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
135
100
3
Amber
Engine Oil Pressure
Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
141
100
4
Amber
Engine Oil Pressure
Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
143
100
18
Amber
Engine Oil Pressure
Oil Pressure Low - Data Valid but Below Normal Operational Range - Moderately Severe Level
144
110
3
Amber
Engine Coolant Temperature
Coolant Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source
145
110
4
Amber
Engine Coolant Temperature
Coolant Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
G10-55A, G12-55A
9-43
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
146
110
16
147
91
148
SPN Description
Cummins Description
Amber
Engine Coolant Temperature
Coolant Temperature High - Data Valid but Above Normal Operational Range - Moderately Severe Level
1
Red
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period
91
Red
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period
151
110
Red
Engine Coolant Temperature
153
105
3
Amber
Intake Manifold #1 Temp
Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source
154
105
4
Amber
Intake Manifold #1 Temp
Intake Manifold Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
155
105
Red
Intake Manifold #1 Temp
Intake Manifold Air Temperature High - Data Valid but Above Normal Operational Range Most Severe Level
187
3510
4
Amber
5 Volts DC Supply
Sensor Supply Voltage #2 Circuit - Voltage Below Normal, or Shorted to Low Source
193
520199
3
Amber
Cruise Control
Cruise Control (Resistive) Signal Circuit Voltage Above Normal, or Shorted to High Source
194
520199
4
Amber
Cruise Control
Cruise Control (Resistive) Signal Circuit Voltage Below Normal, or Shorted to Low Source
195
111
3
Amber
Coolant Level
Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High Source
196
111
4
Amber
Coolant Level
Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
197
111
18
Amber
Coolant Level
Coolant Level - Data Valid but Below Normal Operational Range - Moderately Severe Level
199
1661
4
Amber
Engine Automatic Start Lamp
211
1484
31
None
J1939 Error
9-44
Coolant Temperature Low - Data Valid but Above Normal Operational Range - Most Severe Level
Engine Automatic Start Lamp Driver Circuit Voltage Above Normal, or Shorted to High Source Additional Auxiliary Diagnostic Codes logged Condition Exists
G10-55A, G12-55A
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
SPN Description
212
175
3
Amber
Oil Temperature
Engine Oil Temperature Sensor 1 Circuit Voltage Above Normal, or Shorted to High Source
213
175
4
Amber
Oil Temperature
Engine Oil Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low Source
214
175
Red
Oil Temperature
Engine Oil Temperature - Data Valid but Above Normal Operational Range - Most Severe Level
221
108
3
Amber
Barometric Pressure
Barometric Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
222
108
4
Amber
Barometric Pressure
Barometric Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
227
3510
3
Amber
5 Volts DC Supply
Sensor Supply Voltage #2 Circuit - Voltage Above Normal, or Shorted to High Source
231
109
3
Amber
Coolant Pressure
Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
232
109
4
Amber
Coolant Pressure
Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
233
109
18
Amber
Coolant Pressure
Coolant Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level
234
190
Red
Engine Speed
Engine Speed High - Data Valid but Above Normal Operational Range - Most Severe Level
235
111
1
Red
Coolant Level
Coolant Level Low - Data Valid but Below Normal Operational Range - Most Severe Level
237
644
2
Amber
External Speed Input
External Speed Input (Multiple Unit Synchronization) - Data Erratic, Intermittent, or Incorrect
238
3511
4
Amber
System Diagnostic code #1
Sensor Supply Voltage #3 Circuit - Voltage Below Normal, or Shorted to Low Source
239
3511
3
Amber
System Diagnostic code #2
Sensor Supply Voltage #3 Circuit - Voltage Above Normal, or Shorted to High Source
241
84
2
Amber
Wheel-based Vehicle Speed
Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect
242
84
10
Amber
Wheel-based Vehicle Speed
Vehicle Speed Sensor Circuit tampering has been detected - Abnormal Rate of Change
244
623
4
Amber
Red Stop Lamp
G10-55A, G12-55A
Cummins Description
Red Stop Lamp Driver Circuit - Voltage Below Normal, or Shorted to Low Source
9-45
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
245
647
4
249
171
256
SPN Description
Cummins Description
Amber
Fan Clutch Output Device Driver
Fan Control Circuit - Voltage Below Normal, or Shorted to Low Source
3
Amber
Ambient Air Temperature
Ambient Air Temperature Sensor Circuit Voltage Above Normal, or Shorted to High Source
171
4
Amber
Ambient Air Temperature
Ambient Air Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low Source
261
174
16
Amber
Fuel Temperature
Engine Fuel Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level
263
174
3
Amber
Fuel Temperature
AEB15.60 Page 149 of 157 Engine Fuel Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted to High Source
265
174
4
Amber
Fuel Temperature
Engine Fuel Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low Source
268
94
2
Amber
Fuel Delivery Pressure
Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
271
1347
4
Amber
Fuel Pump Pressurizing Assembly #1
High Fuel Pressure Solenoid Valve Circuit Voltage Below Normal, or Shorted to Low Source
272
1347
3
Amber
Fuel Pump Pressurizing Assembly #1
High Fuel Pressure Solenoid Valve Circuit Voltage Above Normal, or Shorted to High Source
281
1347
7
Amber
Fuel Pump Pressurizing Assembly #1
High Fuel Pressure Solenoid Valve #1 Mechanical System Not Responding Properly or Out of Adjustment
284
1043
4
Amber
Internal Sensor Voltage Supply
285
639
9
Amber
SAE J1939 Datalink
SAE J1939 Multiplexing PGN Timeout Error Abnormal Update Rate
286
639
13
Amber
SAE J1939 Datalink
SAE J1939 Multiplexing Configuration ErrorOut of Calibration
287
91
19
Red
Accelerator Pedal Position
SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error - Received Network Data In Error
288
974
19
Red
Remote Accelerator
SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error - Received Network Data In Error
9-46
Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit - Voltage Below Normal, or Shorted to Low Source
G10-55A, G12-55A
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
292
441
14
293
441
294
SPN Description
Cummins Description
Red
Auxiliary Temperature 1
Auxiliary Temperature Sensor Input 1 - Special Instructions
3
Amber
OEM Temperature
Auxiliary Temperature Sensor Input #1 Circuit Voltage Above Normal, or Shorted to High Source
441
4
Amber
OEM Temperature
Auxiliary Temperature Sensor Input #1 Circuit Voltage Below Normal, or Shorted to Low Source
295
108
2
Amber
Barometric Pressure
Barometric Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
296
1388
14
Red
Auxiliary Pressure
Auxiliary Pressure Sensor Input 1 - Special Instructions
297
1388
3
Amber
Auxiliary Pressure
Auxiliary Pressure Sensor Input #2 Circuit Voltage Above Normal, or Shorted to High Source
298
1388
4
Amber
Auxiliary Pressure
Auxiliary Pressure Sensor Input #2 Circuit Voltage Below Normal, or Shorted to Low Source
319
251
2
Maint
Real Time Clock Power
Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect
322
651
5
Amber
Injector Cylinder #01
Injector Solenoid Cylinder #1 Circuit - Current Below Normal, or Open Circuit
323
655
5
Amber
Injector Cylinder #05
Injector Solenoid Cylinder #5 Circuit - Current Below Normal, or Open Circuit
324
653
5
Amber
Injector Cylinder #03
Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit
325
656
5
Amber
Injector Cylinder #06
Injector Solenoid Cylinder #6 Circuit - Current Below Normal, or Open Circuit
331
652
5
Amber
Injector Cylinder #02
Injector Solenoid Cylinder #2 Circuit - Current Below Normal, or Open Circuit
332
654
5
Amber
Injector Cylinder #04
Injector Solenoid Cylinder #4 Circuit - Current Below Normal, or Open Circuit
334
110
2
Amber
Engine Coolant Temperature
Coolant Temperature Sensor Circuit - Data Erratic, Intermittent, or Incorrect
338
1267
3
Amber
Vehicle Accessories Relay Driver
Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Above Normal, or Shorted to High Source
339
1267
4
Amber
Vehicle Accessories Relay Driver
Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Below Normal, or Shorted to Low Source
G10-55A, G12-55A
9-47
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
SPN Description
Cummins Description
341
630
2
Amber
Calibration Memory
Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect
342
630
13
Red
Calibration Memory
Electronic Calibration Code Incompatibility - Out of Calibration
343
629
12
Amber
Controller #1
349
191
16
Amber
Transmission Output Shaft Speed
Transmission Output Shaft Speed - Data Valid but Above Normal Operational Range Moderately Severe Level
351
627
12
Amber
Controller #1
Injector Power Supply - Bad Intelligent Device or Component
352
3509
4
Amber
5 Volts DC Supply
Sensor Supply Voltage #1 Circuit - Voltage Below Normal, or Shorted to Low Source
386
3509
3
Amber
5 Volts DC Supply
Sensor Supply Voltage #1 Circuit - Voltage Above Normal, or Shorted to High Source
415
100
1
Red
Engine Oil Pressure
418
97
15
Maint.
Water in Fuel Indicator
Water in Fuel Indicator High - Data Valid but Above Normal Operational Range - Least Severe Level
422
111
2
Amber
Coolant Level
Coolant Level - Data Erratic, Intermittent, or Incorrect
425
175
2
Amber
Oil Temperature
428
97
3
Amber
Water in Fuel Indicator
Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to High Source
429
97
4
Amber
Water in Fuel Indicator
Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
431
558
2
Amber
Accelerator Pedal Low Idle Switch
Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Intermittent, or Incorrect
432
558
13
Red
Accelerator Pedal Low Idle Switch
Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration
435
100
2
Amber
Engine Oil Pressure
Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
441
168
18
Amber
Electrical Potential (Voltage)
9-48
Engine Control Module Warning internal hardware failure - Bad Intelligent Device or Component
Oil Pressure Low - Data Valid but Below Normal Operational Range - Most Severe Level
Engine Oil Temperature - Data Erratic, Intermittent, or Incorrect
Battery #1 Voltage Low - Data Valid but Below Normal Operational Range - Moderately Severe Level
G10-55A, G12-55A
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
442
168
16
449
157
451
SPN Description
Cummins Description
Amber
Electrical Potential (Voltage)
Battery #1 Voltage High - Data Valid but Above Normal Operational Range - Moderately Severe Level
Red
Injector Metering Rail 1 Pressure
Fuel Pressure High - Data Valid but Above Normal Operational Range - Moderately Severe Level
157
3
Amber
Injector Metering Rail 1 Pressure
Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
452
157
4
Amber
Injector Metering Rail 1 Pressure
Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
488
105
16
Amber
Intake Manifold
Intake Manifold 1 Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level
489
191
18
Amber
Transmission Output Shaft Speed
Transmission Output Shaft Speed - Data Valid but Below Normal Operational Range Moderately Severe Level
497
1377
2
Amber
Switch Circuit
AEB15.60 Page 151 of 157 Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or Incorrect
523
611
2
Amber
System Diagnostic code #1
527
702
3
Amber
Circuit - Voltage
528
93
2
Amber
Switch - Data
529
703
3
Amber
Circuit - Voltage
Auxiliary Input/Output 3 Circuit - Voltage Above Normal, or Shorted to High Source
546
94
3
Amber
Fuel Delivery Pressure
Fuel Delivery Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
547
94
4
Amber
Fuel Delivery Pressure
Fuel Delivery Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
551
558
4
Amber
Accelerator Pedal Low Idle Switch
Accelerator Pedal or Lever Idle Validation Circuit - Voltage Below Normal, or Shorted to Low Source
553
157
16
Amber
Injector Metering Rail 1 Pressure
Injector Metering Rail #1 Pressure High - Data Valid but Above Normal Operational Range Moderately Severe Level
G10-55A, G12-55A
OEM Intermediate (PTO) Speed switch Validation - Data Erratic, Intermittent, or Incorrect Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High Source Auxiliary Alternate Torque Validation Switch Data Erratic, Intermittent, or Incorrect
9-49
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
554
157
2
Amber
Injector Metering Rail 1 Pressure
Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect
559
157
18
Amber
Injector Metering Rail 1 Pressure
Injector Metering Rail #1 Pressure Low - Data Valid but Below Normal Operational Range Moderately Severe Level
584
677
3
Amber
Starter Solenoid Lockout Relay Driver Circuit
Starter Relay Circuit - Voltage Above Normal, or Shorted to High Source
585
677
4
Amber
Starter Solenoid Lockout Relay Driver Circuit
Starter Relay Circuit - Voltage Below Normal, or Shorted to Low Source
595
103
16
Amber
Turbocharger 1 Speed
Turbocharger #1 Speed High - Data Valid but Above Normal Operational Range - Moderately Severe Level
596
167
16
Amber
Alternate Potential (voltage)
Electrical Charging System Voltage High - Data Valid but Above Normal Operational Range Moderately Severe Level
597
167
18
Amber
Alternate Potential (voltage)
Electrical Charging System Voltage Low - Data Valid but Below Normal Operational Range Moderately Severe Level
598
167
1
Red
Alternate Potential (voltage)
Electrical Charging System Voltage Low - Data Valid but Below Normal Operational Range Most Severe Level
599
640
14
Red
Engine External Protection Input
Auxiliary Commanded Dual Output Shutdown Special Instructions
649
1378
31
Maint
Engine Oil Change Interval
687
103
18
Amber
Turbocharger 1 Speed
Turbocharger #1 Speed Low - Data Valid but Below Normal Operational Range - Moderately Severe Level
689
190
2
Amber
Engine Speed
Primary Engine Speed Sensor Error - Data Erratic, Intermittent, or Incorrect
691
1172
3
Amber
Turbocharger #1 Compressor Inlet Temperature
Turbocharger #1 Compressor Inlet Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source
692
1172
4
Amber
Turbocharger #1 Compressor Inlet Temperature
Turbocharger #1 Compressor Inlet Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
697
1136
3
Amber
Sensor Circuit Voltage
9-50
SPN Description
Cummins Description
Change Lubricating Oil and Filter - Condition Exists
ECM Internal Temperature Sensor Circuit Voltage Above Normal, or Shorted to High Source G10-55A, G12-55A
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
698
1136
4
Amber
Sensor Circuit Voltage
719
22
3
Amber
Crankcase Pressure
AEB15.60 Page 152 of 157 Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal, or Shorted to High Source
729
22
4
Amber
Crankcase Pressure
Extended Crankcase Blow-by Pressure Circuit Voltage Below Normal, or Shorted to Low Source
731
723
7
Amber
Engine Speed Sensor #2
Engine Speed/Position #2 mechanical misalignment between camshaft and crankshaft sensors - Mechanical System Not Responding Properly or Out of Adjustment
757
2802
31
Amber
Electronic Control Module
Electronic Control Module data lost - Condition Exists
778
723
2
Amber
Engine Speed Sensor #2
Engine Speed Sensor (Camshaft) Error - Data Erratic, Intermittent, or Incorrect
779
703
11
Amber
Auxiliary Equipment Sensor Input
Warning Auxiliary Equipment Sensor Input #3 (OEM Switch) - Root Cause Not Known
951
166
2
None
Cylinder Power
1117
627
2
None
Power Supply
1139
651
7
Amber
Injector Cylinder #01
Injector Cylinder #1 - Mechanical System Not Responding Properly or Out of Adjustment
1141
652
7
Amber
Injector Cylinder #02
Injector Cylinder #2 - Mechanical System Not Responding Properly or Out of Adjustment
1142
653
7
Amber
Injector Cylinder #03
Injector Cylinder #3 - Mechanical System Not Responding Properly or Out of Adjustment
1143
654
7
Amber
Injector Cylinder #04
Injector Cylinder #4 - Mechanical System Not Responding Properly or Out of Adjustment
1144
655
7
Amber
Injector Cylinder #05
Injector Cylinder #5 - Mechanical System Not Responding Properly or Out of Adjustment
1145
656
7
Amber
Injector Cylinder #06
Injector Cylinder #6 - Mechanical System Not Responding Properly or Out of Adjustment
1239
2623
3
Amber
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Above Normal, or Shorted to High Source
G10-55A, G12-55A
SPN Description
Cummins Description ECM Internal Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low Source
Cylinder Power Imbalance Between Cylinders Data Erratic, Intermittent, or Incorrect Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect
9-51
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
1241
2623
4
Amber
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Below Normal, or Shorted to Low Source
1242
91
2
Red
Accelerator Pedal Position
Accelerator Pedal or Lever Position Sensor 1 and 2 - Data Erratic, Intermittent, or Incorrect
1256
1563
2
Amber
Control Module Identification Input State
Control Module Identification Input State Error Data Erratic, Intermittent, or Incorrect
1257
1563
2
Red
Control Module Identification Input State
Control Module Identification Input State Error Data Erratic, Intermittent, or Incorrect
1852
97
16
Amber
Water in Fuel Indicator
Water in Fuel Indicator - Data Valid but Above Normal Operational Range - Moderately Severe Level
1911
157
Amber
Injector Metering Rail
2111
52
3
Amber
Coolant Temperature
Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted to High Source
2112
52
4
Amber
Coolant Temperature
Coolant Temperature 2 Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
2113
52
16
Amber
Coolant Temperature
Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Moderately Severe Level
2114
52
Red
Coolant Temperature
Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Most Severe Level
2115
2981
3
Amber
Coolant Pressure
Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted to High Source
2116
2981
4
Amber
Coolant Pressure
AEB15.60 Page 153 of 157 Coolant Pressure 2 Circuit - Voltage Below Normal, or Shorted to Low Source
2117
2981
18
Amber
Coolant Pressure
Coolant Pressure 2 - Data Valid but Below Normal Operational Range - Moderately Severe Level
2182
1072
3
Amber
Engine Brake Output #1
Engine Brake Actuator Driver 1 Circuit - Voltage Above Normal, or Shorted to High Source
2183
1072
4
Amber
Engine Brake Output #1
Engine Brake Actuator Driver 1 Circuit - Voltage Below Normal, or Shorted to Low Source
2185
3512
3
Amber
System Diagnostic code #1
9-52
SPN Description
Cummins Description
Injector Metering Rail 1 Pressure - Data Valid but Above Normal Operational Range - Most Severe Level
Sensor Supply Voltage #4 Circuit - Voltage Above Normal, or Shorted to High Source G10-55A, G12-55A
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
2186
3512
4
Amber
System Diagnostic code #1
Sensor Supply Voltage #4 Circuit - Voltage Below Normal, or Shorted to Low Source
2195
703
14
Red
Auxiliary Equipment Sensor
Auxiliary Equipment Sensor Input 3 Engine Protection Critical - Special Instructions
2215
94
18
Amber
Fuel Delivery Pressure
Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level
2216
94
1
Amber
Fuel Delivery Pressure
Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level
2217
630
31
Amber
Calibration Memory
2249
157
1
Amber
Injector Metering Rail 1 Pressure
Injector Metering Rail 1 Pressure - Data Valid but Below Normal Operational Range - Most Severe Level
2261
94
15
Maint
Fuel Delivery Pressure
Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational Range - Least Severe Level
2262
94
17
Maint
Fuel Delivery Pressure
Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range - Least Severe Level
2263
1800
16
Amber
Battery Temperature
Battery Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level
2264
1800
18
Amber
Battery Temperature
Battery Temperature - Data Valid but Below Normal Operational Range - Moderately Severe Level
2265
1075
3
Amber
Electric Lift Pump for Engine Fuel
Fuel Priming Pump Control Signal Circuit Voltage Above Normal, or Shorted to High Source
2266
1075
4
Amber
Electric Lift Pump for Engine Fuel
Fuel Priming Pump Control Signal Circuit Voltage Below Normal, or Shorted to Low Source
2292
611
16
Amber
Fuel Inlet Meter Device
Fuel Inlet Meter Device - Data Valid but Above Normal Operational Range - Moderately Severe Level
2293
611
18
Amber
Fuel Inlet Meter Device
Fuel Inlet Meter Device flow demand lower than expected - Data Valid but Below Normal Operational Range - Moderately Severe Level
2311
633
31
Amber
Fuel Control Valve #1
G10-55A, G12-55A
SPN Description
Cummins Description
ECM Program Memory (RAM) Corruption Condition Exists
Fueling Actuator #1 Circuit Error - Condition Exists 9-53
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
SPN Description
2321
190
2
None
Engine Speed
Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect
2322
723
2
None
Engine Speed Sensor #2
Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect
2345
103
10
Amber
Turbocharger 1 Speed
Turbocharger speed invalid rate of change detected - Abnormal Rate of Change
2346
2789
15
None
System Diagnostic Code #1
Turbocharger Turbine Inlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level
2347
2790
15
None
System Diagnostic Code #1
Turbocharger Compressor Outlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level
2363
1073
4
Amber
Engine Compression Brake Output #2
Engine Brake Actuator Circuit #2 - Voltage Below Normal, or Shorted to Low Source
2365
1112
4
Amber
Engine Brake Output #3
Engine Brake Actuator Driver Output 3 Circuit Voltage Below Normal, or Shorted to Low Source
2367
1073
3
Amber
Engine Compression Brake Output #2
Engine Brake Actuator Circuit #2 - Voltage Above Normal, or Shorted to High Source
2368
1112
3
Amber
Engine Brake Output #3
Engine Brake Actuator Driver 3 Circuit - Voltage Above Normal, or Shorted to High Source
2372
95
16
Amber
Engine Fuel Filter Differential Pressure
Fuel Filter Differential Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level
2373
1209
3
Amber
Exhaust Gas Pressure
Exhaust Gas Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
2374
1209
4
Amber
Exhaust Gas Pressure
Exhaust Gas Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
2375
412
3
Amber
Exhaust Gas Recirculation Temperature
Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source
2376
412
4
Amber
Exhaust Gas Recirculation Temperature
Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
2377
647
3
Amber
Fan Clutch Output Device Driver
Fan Control Circuit - Voltage Above Normal, or Shorted to High Source
2425
730
4
Intake Air Heater #2
Intake Air Heater 2 Circuit - Voltage Below Normal, or Shorted to Low Source
2426
730
3
Intake Air Heater #2
Intake Air Heater 2 Circuit - Voltage Above Normal, or Shorted to High Source
9-54
Cummins Description
G10-55A, G12-55A
Electrical System
Fault Codes
SPN Codes
FMI Codes
Lamp Color
2555
729
3
Amber
Inlet Air Heater Driver #1
Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source
2556
729
4
Amber
Inlet Air Heater Driver #1
Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source
2557
697
3
Amber
Auxiliary PWM Driver #1
Auxiliary PWM Driver #1 - Voltage Above Normal, or Shorted to High Source
2558
697
4
Amber
Auxiliary PWM Driver #1
Auxiliary PWM Driver #1 - Voltage Below Normal, or Shorted to Low Source
2963
110
15
None
Engine Coolant Temperature
Engine Coolant Temperature High - Data Valid but Above Normal Operational Range - Least Severe Level
2973
102
2
Amber
Boost Pressure
Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
G10-55A, G12-55A
SPN Description
Cummins Description
9-55
Electrical System
This Page Intentionally Left Blank
9-56
G10-55A, G12-55A
3126019
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