Jlg Telehandlers G6 42a G9 43a G10 43a Ansi Factory Service Repair Workshop Manual Instant Download

Service Manual Models G6-42A G9-43A G10-43A 31200151 Revised August 9, 2012

An Oshkosh Corporation Company

EFFECTIVITY PAGE May 12, 2006 - A - Original Issue Of Manual April 19, 2007 -B- Revised pages 2.9, 2.12, 3.14, 5.11, 6.3 & 8.4.

May 1, 2009 - C - Added G10-43A information. Revised covers and pages 1.3, 1.4, 2.3 thru 2.19, 3.2, 3.3, 3.7, 3.12, 4.2, 4.3, 4.7, 4.9, 5.3, 5.4, 5.5, 5.10, 6.3, 6.4, 6.6, 6.7, 7.5, 7.6, 7.7, 7.11, 8.2, 8.3, 8.6 thru 8.12, 8.16, 8.17, 8.21, 8.22, 8.26, 9.3 & 9.18 thru 9.27.

September 20, 2011 - D - Revised page numbering and pages 1-3, 2-1, 2-3 thru 2-9, 2-13 thru 2-26, 3-1, 3-13 thru 3-15, 4-1, 4-2, 4-6, 4-7, 4-10 thru 4-12, 6-3, 6-7, 7-1, 7-6 thru 7-8, 7-13, 7-14, 8-6 thru 8-17, 8-23, 9-3, 9-4, 9-7, 9-8, 9-31 thru 9-36, 9-38, 9-41, 9-43, 9-47, 9-51, 9-55, 9-57 thru 9-74.

August 9, 2012 - E - Revised pages 3-1 thru 3-34.

31200151

G6-42A, G9-43A, G10-43A

i

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EFFECTIVITY PAGE

-ii

G6-42A, G9-43A, G10-43A

31200151

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 Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 2-3 2-11 2-15 2-18 2-21

...........................................................

3-1

Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Push Beam - Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . .

Boom Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 3-4 3-4 3-5 3-6 3-14 3-16 3-20 3-24 3-25 3-25 3-26 3-29 3-30 3-33

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 3.15

4.1 4.2 4.3 4.4 4.5

Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G6-42A, G9-43A, G10-43A

4-2 4-5 4-5 4-11 4-12

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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 5-10 5-11 5-12 5-12

Section 6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.1 6.2 6.3 6.4 6.5 6.6 6.7

Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . .

Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-4 6-4 6-4 6-7 6-8 6-10

...........................................................

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

ii

Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 8-3 8-4 8-5 8-17 8-18 8-19 8-25

G6-42A, G9-43A, G10-43A

Section

Subject

Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11 Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . .

9.15 Hand Held Analyzer (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . .

9.16 Joystick Fault Codes (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . .

9.17 Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18 SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . . . . . .

G6-42A, G9-43A, G10-43A

Page

9-1 9-3 9-5 9-5 9-5 9-10 9-38 9-45 9-46 9-47 9-48 9-49 9-55 9-56 9-58 9-60 9-62 9-67 9-68

iii

Section

iv

Subject

Page

G6-42A, G9-43A, G10-43A

Section 1 Safety Practices

Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6

1.7

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G6-42A, G9-43A, G10-43A

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 JLG 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 and 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 JLG distributor before proceeding.

1-2

G6-42A, G9-43A, G10-43A

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, it is recommended 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.

G6-42A, G9-43A, G10-43A

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

G6-42A, G9-43A, G10-43A

Section 2 General Information and Specifications

Contents PARAGRAPH 2.1 2.2

2.3

2.4 2.5

2.6

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 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3 1000, 1500 & 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1 G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2 G9-43A / G10-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G6-42A, G9-43A, G10-43A

PAGE 2-2 2-3 2-3 2-7 2-10 2-11 2-11 2-11 2-12 2-13 2-14 2-15 2-18 2-18 2-19 2-20 2-21 2-21 2-24

2-1

General Information and Specifications

2.1

REPLACEMENT PARTS AND WARRANTY INFORMATION

DO NOT GO NEAR LEAKS C

1

1

* High pressure oil easily punctures skin causing serious injury, gangrene or death. * If injured, seek emergency medical help. Immediate surgery is required to remove oil. * Do not use finger or skin to check for leaks. * Lower load or relieve hydraulic pressure before loosening fittings.

10814B

MY0070

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

G6-42A, G9-43A, G10-43A

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

G6-42A, G9-43A, G10-43A

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

G6-42A, G9-43A, G10-43A

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

G6-42A, G9-43A, G10-43A

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

G6-42A, G9-43A, G10-43A

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