JLG G6-42A, G9-43A & G10-43A Telehandler Service Manual (ANSI) - 31200151

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This service manual PDF download for the G6-42A, G9-43A & G10-43A JLG Telescopic Handlers has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG G6-42A
Before S/N 0160048658

JLG G9-43A & JLG G10-43A
Before S/N 0160048671
including 0160048773


TABLE OF CONTENTS :

    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
        1.6 Safety Instructions
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torque Charts
        2.3 Specifications
        2.4 Fluid and Lubricant Capacities
        2.5 Service and Maintenance Schedule
        2.6 Lubrication Schedule
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System - Three Section
        3.3 Boom Assembly Maintenance
        3.4 Complete Boom Removal/ Installation
        3.5 Boom Section Removal/ Installation
        3.6 Extend/Retract Chain Removal/Installation
        3.7 Push Beam - Extend/Retract Cylinder Removal/ Installation
        3.8 Boom Adjustments
        3.9 Quick Switch Assembly
        3.10 Boom Head - Mounted Winch
        3.11 Boom Wear Pads
        3.12 Boom Extend and Retract Chains
        3.13 Forks
        3.14 Emergency Boom Lowering Procedure
        3.15 Troubleshooting
        3.16 Push Beam Temporary Brackets
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
        4.2 Operator Cab
        4.3 Cab Components
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
        5.4 Drive Shafts
        5.5 Wheels and Tires
        5.6 Brakes
        5.7 Towing a Disabled machine
            
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Serial Number
        6.3 Transmission Specifications and Maintenance Information
        6.4 Transmission Replacement
        6.5 Engine Drive Plate
        6.6 Transmission Cooler Thermal Bypass Valve
        6.7 Troubleshooting
            
    Section 7 Engine
        7.1 Introduction - John Deere
        7.2 Introduction - Perkins
        7.3 Introduction - Cummins
        7.4 Engine Cooling System
        7.5 Engine Electrical System
        7.6 Fuel System
        7.7 Engine Exhaust System
        7.8 Air Cleaner Assembly
        7.9 Engine Replacement
        7.10 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
        8.4 Hydraulic Circuits
        8.5 Hydraulic Reservoir
        8.6 Implement Pump
        8.7 Control Valves
        8.8 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Safety Information
        9.4 Fuses and Relays
        9.5 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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200151
Total Pages : 246


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31200151_H_G6-42A G9-43A G10-43A_JLG_Service
    Effectivity Page
    Table of Contents
    
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
            1.5.1 Safety Alert System and Signal Words
        1.6 Safety Instructions
            1.6.1 Personal Hazards
            1.6.2 Equipment Hazards
            1.6.3 General Hazards
            1.6.4 Operational Hazards
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torque Charts
            2.2.1 SAE Fastener Torque Chart
            2.2.2 Metric Fastener Torque Chart
            2.2.3 Hydraulic Hose Torque Chart
        2.3 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
        2.4 Fluid and Lubricant Capacities
        2.5 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
        2.6 Lubrication Schedule
            2.6.1 G6-42A
            2.6.2 G9-43A / G10-43A
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System - Three Section
            3.2.1 Boom System Operation
        3.3 Boom Assembly Maintenance
        3.4 Complete Boom Removal/ Installation
            3.4.1 Complete Boom Removal
            3.4.2 Complete Boom Installation
        3.5 Boom Section Removal/ Installation
            3.5.1 Second and Third Boom Section Removal
            3.5.2 Third Boom Section Removal
            3.5.3 Push Beam - Extend/Retract Cylinder Removal
            3.5.4 Push Beam - Extend/Retract Cylinder Installation and Third Boom Section Assembly
            3.5.5 Third Boom Section Installation
            3.5.6 Second and Third Boom Section Installation
        3.6 Extend/Retract Chain Removal/Installation
            3.6.1 Extend/Retract Chain Removal
            3.6.2 Extend/Retract Chain Installation
        3.7 Push Beam - Extend/Retract Cylinder Removal/ Installation
            3.7.1 Push Beam - Extend/Retract Cylinder Removal
            3.7.2 Push Beam - Extend/Retract Cylinder Installation
        3.8 Boom Adjustments
            3.8.1 Chain Tension Inspection—G6-42A
            3.8.2 Chain Tension Adjustment—G6-42A
            3.8.3 Chain Tension Inspection— G9-43A/G10-43A
            3.8.4 Chain Tension Adjustment— G9-43A/G10-43A
        3.9 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
        3.10 Boom Head - Mounted Winch
            3.10.1 Boom Head-Mounted Winch Removal
            3.10.2 Boom Head-Mounted Winch Installation
        3.11 Boom Wear Pads
            3.11.1 Wear Pad Inspection
            3.11.2 Wear Pad Installation and Lubrication
        3.12 Boom Extend and Retract Chains
            3.12.1 Boom Chain Inspection
            3.12.2 Inspection Guidelines
            3.12.3 Chain Lubrication
        3.13 Forks
        3.14 Emergency Boom Lowering Procedure
            3.14.1 Equipment and Supplies Required
            3.14.2 Lowering Procedure
        3.15 Troubleshooting
        3.16 Push Beam Temporary Brackets
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
            4.1.1 General Overview
            4.1.2 General Overview
        4.2 Operator Cab
            4.2.1 Cab Safety
            4.2.2 Serial Number Decal
        4.3 Cab Components
            4.3.1 Steering Column and Orbitrol Valve
            4.3.2 Service Brake Pedal
            4.3.3 Throttle Pedal
            4.3.4 Boom Joystick Assembly
            4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and Outriggers (G10-43A) Joysticks
            4.3.6 Windshield Wiper Assembly
            4.3.7 Heater/Air Conditioning System (if equipped)
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
            5.3.1 Axle Serial Number Plate
            5.3.2 Axle Specifications
            5.3.3 Axle Internal Service
            5.3.4 Axle Maintenance
            5.3.5 Axle Removal
            5.3.6 Axle Installation
            5.3.7 Axle Assembly and Drive Shaft Troubleshooting
        5.4 Drive Shafts
            5.4.1 Drive Shaft Inspection and Service
            5.4.2 Drive Shaft Maintenance
            5.4.3 Drive Shaft Removal
            5.4.4 Drive Shaft Cleaning and Drying
            5.4.5 Drive Shaft Installation
        5.5 Wheels and Tires
            5.5.1 Removing Wheel and Tire Assembly from Machine
            5.5.2 Installing Wheel and Tire Assembly onto Machine
        5.6 Brakes
        5.7 Towing a Disabled machine
            5.7.1 Manually Releasing the Park Brake
            5.7.2 Manually Resetting the Park Brake
            
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
            6.1.1 General Overview
        6.2 Transmission Serial Number
        6.3 Transmission Specifications and Maintenance Information
        6.4 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
        6.5 Engine Drive Plate
            6.5.1 G6-42A - Before S/N 0160040678 G9-43A/G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672
            6.5.2 G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672
        6.6 Transmission Cooler Thermal Bypass Valve
            6.6.1 Thermal Bypass Valve Removal
            6.6.2 Thermal Bypass Valve Installation
        6.7 Troubleshooting
            6.7.1 Transmission Troubleshooting
            
    Section 7 Engine
        7.1 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
        7.2 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
        7.3 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
        7.4 Engine Cooling System
            7.4.1 Radiator Pressure Cap
            7.4.2 Thermostat Replacement
            7.4.3 Radiator/Oil Cooler and Replacement
        7.5 Engine Electrical System
        7.6 Fuel System
            7.6.1 Diesel Fuel
            7.6.2 Fuel Tank
            7.6.3 After Fuel System Service
        7.7 Engine Exhaust System
            7.7.1 Exhaust System Removal
            7.7.2 Exhaust System Installation
        7.8 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)
        7.9 Engine Replacement
            7.9.1 Engine Removal
            7.9.2 Engine Installation
        7.10 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
            8.3.1 Pressure Checks and Adjustments
        8.4 Hydraulic Circuits
            8.4.1 Hydraulic Pressures
            8.4.2 Pressure Specifications - G6-42A
            8.4.3 Pressure Specifications - G9-43A & G10-43A
            8.4.4 Hydraulic Schematic - G6-42A
            8.4.5 Hydraulic Schematic - G9-43A & G10-43A
        8.5 Hydraulic Reservoir
            8.5.1 Hydraulic Oil Reservoir Draining
            8.5.2 Hydraulic Oil Reservoir Filling
            8.5.3 Hydraulic Oil Reservoir Removal/ Installation
        8.6 Implement Pump
            8.6.1 Implement Pump Replacement
        8.7 Control Valves
            8.7.1 Main Control Valve
            8.7.2 Service Brake Valve
            8.7.3 Brake Test
            8.7.4 Steering Orbitrol Valve
            8.7.5 Steer Select Valve
            8.7.6 Outrigger Valve (G10-43A)
        8.8 Hydraulic Cylinders
            8.8.1 General Cylinder Removal Instructions
            8.8.2 Cylinder Pressure Checking
            8.8.3 Steering Cylinders
            8.8.4 Cylinder Torque Specifications - G6-42A
            8.8.5 Cylinder Torque Specifications - G9-43A & G10-43A
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
            9.1.1 General Overview
        9.2 Specifications
        9.3 Safety Information
        9.4 Fuses and Relays
            9.4.1 Engine Compartment
            9.4.2 Cab
            9.4.3 Power Control Board
            9.4.4 VEC Module - S/N 0160040675 & After including 0160040468 & 0160040672
            9.4.5 VEC Module - Options S/N 0160040675 & After including 0160040468 & 0160040672
        9.5 Electrical System Schematics
            9.5.1 Before S/N 0160011059
            9.5.2 G6-42A - S/N 0160011059 Thru 0160021194 G9-43A - S/N 0160011059 Thru 0160020822
            9.5.3 G6-42A - S/N 0160021195 Thru 0160040678 G9-43A/G10-43A - S/N 0160020823 Thru 0160040465 Excluding 0160040468 & 0160040672
            9.5.4 G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040465 & After including 0160040468 & 0160040672
        9.6 Circuit Breakdowns
            9.6.1 Constant Power Circuit from Battery
            9.6.2 Start Circuit
            9.6.3 Charging Circuit
        9.7 Engine Start Circuit
            9.7.1 Starter
        9.8 Charging Circuit
            9.8.1 Alternator
        9.9 Window Wiper/Washer Windshield Wiper Motor
            9.9.1 Windshield/Rear Window Washer Reservoir
        9.10 Cab Heater and Fan
            9.10.1 Cab Heater Controls
        9.11 Solenoids and Senders
            9.11.1 Fuel Shut-off Solenoid
            9.11.2 Park Brake Solenoid Valve
            9.11.3 Transmission Solenoid Valves
            9.11.4 Transmission Temperature Sender
            9.11.5 Engine Coolant Temperature Sender / Switch
            9.11.6 Engine Oil Pressure Sender
            9.11.7 Fuel Level Sender
            9.11.8 Front and Rear Axle Proximity Sensors
        9.12 Display Monitor and Gauges
            9.12.1 Analog Gauges
        9.13 Dash Switches
            9.13.1 Ignition Key Switch
            9.13.2 Dash Switches
        9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672)
            9.14.1 Pump Displacement Analyzer Software Version A
            9.14.2 Diagnostics Menu
        9.15 Hand Held Analyzer (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672)
            9.15.1 Analyzer Usage
            9.15.2 Analyzer Software - Version A
        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
        
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