JLG G6-42A, G9-43A & G10-43A Telehandlers Service Manual (ANSI) - 31200792

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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
S/N 0160048658 & After

JLG G9-43A & JLG G10-43A
S/N 0160048671 & After
excluding 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 Thread Locking Compound
        2.3 Torque Charts
        2.4 Specifications
        2.5 Fluid and Lubricant Capacities
        2.6 Service and Maintenance Schedule
        2.7 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 Wear Pads
        3.11 Boom Extend and Retract Chains
        3.12 Forks
        3.13 Emergency Boom Lowering Procedure
        3.14 Troubleshooting
        3.15 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 Axle Serial Number
        5.3 Axle Specifications And Maintenance Information
        5.4 Axle Replacement
        5.5 Drive Shafts
        5.6 Wheels and Tires
        5.7 Brakes
        5.8 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 Transmission Cooler Thermal By-Pass Valve
        6.6 Torque Convertor Diaphragm
        6.7 Troubleshooting
        
    Section 7 Engine
        7.1 Introduction—Cummins
        7.2 Engine Cooling System
        7.3 Engine Electrical System
        7.4 Fuel System
        7.5 Engine Exhaust System
        7.6 Air Cleaner Assembly
        7.7 Engine Replacement
            
    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 Engine Start Circuit
        9.7 Charging Circuit
        9.8 Window Wiper/Washer Windshield Wiper Motor
        9.9 Cab Heater and Fan
        9.10 Solenoids, Sensors and Senders
        9.11 Display Gauge and Dash Switches
        9.12 Hand Held Analyzer - G9-43A and G10-43A
        9.13 SAE Diagnostic Trouble and Fault Codes


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200792
Total Pages : 206


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31200792_C_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 Thread Locking Compound
        2.3 Torque Charts
            2.3.1 SAE Fastener Torque Chart
            2.3.2 Metric Fastener Torque Chart
            2.3.3 Hydraulic Hose Torque Chart
        2.4 Specifications
            2.4.1 Travel Speeds
            2.4.2 Hydraulic Cylinder Performance
            2.4.3 Electrical SystemEngine System
            2.4.4 Engine Specifications
            2.4.5 Tires
        2.5 Fluid and Lubricant Capacities
            2.5.1 Fluids (if Equipped for ULS)
            2.5.2 Fluids (if Equipped for LS)
            2.5.3 Capacities
        2.6 Service and Maintenance Schedule
            2.6.1 10, 1st 50 & 50 Hour
            2.6.2 1st 250, 250 & 500 Hour
            2.6.3 1000, 1500 & 2000 Hour
        2.7 Lubrication Schedule
            2.7.1 50 Hour
            2.7.2 250 Hour
            2.7.3 1000 Hour
            
    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 Hydraulic Quick Switch Removal
            3.9.2 Quick Switch Removal
            3.9.3 Quick Switch Installation
        3.10 Boom Wear Pads
            3.10.1 Wear Pad Inspection
            3.10.2 Wear Pad Installation and Lubrication
            3.10.3 Boom Section Wear Pad Pathway Lubrication:
        3.11 Boom Extend and Retract Chains
            3.11.1 Boom Chain Inspection
            3.11.2 Expose Chains for Inspection
            3.11.3 Inspection Guidelines
            3.11.4 Chain Lubrication
        3.12 Forks
        3.13 Emergency Boom Lowering Procedure
            3.13.1 Equipment and Supplies Required
            3.13.2 Lowering Procedure
        3.14 Troubleshooting
        3.15 Push Beam Temporary Brackets
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
            4.1.1 General Overview—G6-42A/G9-43A
            4.1.2 General Overview—G10-43A
        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 Accelerator Pedal
            4.3.4 Boom Joystick Assembly
            4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and (G10-43A) Outrigger 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
            5.1.1 G6-42A Components
            5.1.2 G9-43A & G10-43A Components
        5.2 Axle Serial Number
        5.3 Axle Specifications And Maintenance Information
        5.4 Axle Replacement
            5.4.1 Axle Removal
            5.4.2 Axle Installation
            5.4.3 Axle Assembly and Drive Shaft Troubleshooting
        5.5 Drive Shafts
            5.5.1 Drive Shaft Inspection and Service
            5.5.2 Drive Shaft Maintenance
            5.5.3 Drive Shaft Removal
            5.5.4 Drive Shaft Cleaning and Drying
            5.5.5 Drive Shaft Installation
        5.6 Wheels and Tires
            5.6.1 Wheel and Tire Assembly Removal
            5.6.2 Wheel and Tire Assembly Installation
        5.7 Brakes
        5.8 Towing a Disabled Machine
            5.8.1 Manually Releasing the Park Brake
            5.8.2 Manually Resetting the Park Brake
            
    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
            6.4.1 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 Transmission Cooler Thermal By-Pass Valve
            6.5.1 Thermal ByPass Valve Cartridge Removal
            6.5.2 Thermal By-Pass Valve Cartridge Installation
        6.6 Torque Convertor Diaphragm
            6.6.1 Torque Convertor Diaphragm Removal
            6.6.2 Torque Convertor Diaphragm Installation
        6.7 Troubleshooting
        
    Section 7 Engine
        7.1 Introduction—Cummins
            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 Engine Cooling System
            7.2.1 Surge Tank Cap
            7.2.2 Thermostat Replacement
            7.2.3 Radiator Assembly and Replacement
        7.3 Engine Electrical System
        7.4 Fuel System
            7.4.1 Diesel Fuel
            7.4.2 Fuel Tank
            7.4.3 After Fuel System Service
        7.5 Engine Exhaust System
            7.5.1 Exhaust System Removal—ULS
            7.5.2 Exhaust System Installation—ULS
            7.5.3 Exhaust System Removal—LS
            7.5.4 Exhaust System Installation—LS
        7.6 Air Cleaner Assembly
            7.6.1 Air Cleaner Assembly Removal—ULS
            7.6.2 Air Cleaner Assembly Installation —ULS
            7.6.3 Air Cleaner Assembly Removal—LS
            7.6.4 Air Cleaner Assembly Installation—LS
        7.7 Engine Replacement
            7.7.1 Engine Removal
            7.7.2 Engine Installation
            
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
            8.1.1 G6-42A Components
            8.1.2 G9-43A & G10-43A Components
        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—G6-42A Options
            8.4.6 Hydraulic Schematic—G9-43A &G10-43A
            8.4.7 Hydraulic Schematic Manual Controls—G9-43A &G10-43A
            8.4.8 Anti-Stall System
        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 Service Brake Bleeding
            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 Distribution Unit (VEC)
            9.4.4 Optional Power Distribution Unit (VEC)
        9.5 Electrical System Schematics
            9.5.1 Cab Schematic
            9.5.2 Options Schematic
            9.5.3 Accessory Module Schematic—G9-43A & G10-43A
            9.5.4 Chassis Schematic
            9.5.5 Engine Schematic (if equipped for ULS)
            9.5.6 Engine Schematic (if equipped for LS)
        9.6 Engine Start Circuit
            9.6.1 Starter
        9.7 Charging Circuit
            9.7.1 Alternator—ULS
            9.7.2 Alternator—LS
        9.8 Window Wiper/Washer Windshield Wiper Motor
            9.8.1 Windshield Wiper Motor
            9.8.2 Windshield/Rear Window Washer Reservoir
        9.9 Cab Heater and Fan
            9.9.1 Cab Heater Controls
        9.10 Solenoids, Sensors and Senders
            9.10.1 Park Brake Solenoid Valve
            9.10.2 Transmission Solenoid Valve
            9.10.3 Transmission Temperature Sender
            9.10.4 Engine Coolant Temperature Sender
            9.10.5 Fuel Level Sender
        9.11 Display Gauge and Dash Switches
            9.11.1 Display Gauge
            9.11.2 Ignition Key Switch
            9.11.3 Dash Switches
        9.12 Hand Held Analyzer - G9-43A and G10-43A
            9.12.1 Analyzer Usage
            9.12.2 Analyzer Joystick Software Version P1.2
            9.12.3 Analyzer Pump Software Version P1.2
        9.13 SAE Diagnostic Trouble and Fault Codes
            9.13.1 Gauge Fault Code Display
            9.13.2 Fault Codes
            
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