JLG G6-42P Telehandler Service Manual (ANSI) - 9140-4002

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This service manual PDF download for the G6-42P JLG Telescopic Handler 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 G6-42P
Starting Serial No. 0189001 thru 0189345
& 0160000230 thru Current


TABLE OF CONTENTS :

    OPERATORS INSTRUCTION & LUBRICATION
    TESTING & ADJUSTING
    AXLES
    TRANSMISSION
    MISCELLANEOUS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 9140-4002
Total Pages : 508


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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9140-4002 G6-42P SERVICE MANUAL

    OPERATORS INSTRUCTION & LUBRICATION
        31200148_G6-42P_Gradall_Operator-Safety.pdf
            Revision Log
            Read This First
            Table of Contents
            
            Section 1 - General Safety Practices
                1.1 Hazard Classification system
                    Safety Alert System and Safety Signal Words
                1.2 General Precautions
                1.3 Operation Safety
                    Electrical Hazards
                    Tip Over Hazard
                    Travel Hazard
                    Load Falling Hazard
                    Lifting Personnel
                    Driving Hazards on Slopes
                    Pinch Points and Crush Hazards
                    Fall Hazard
                    Chemical Hazards
                    
            Section 2 - Pre-Operation and Inspection
                2.1 Pre-Operation Check and Inspection
                2.2 Safety Decals
                2.3 Walk-Around Inspection
                2.4 Warm-Up and Operational Checks
                    Warm-Up Check
                    Operational Check
                2.5 Operator Cab
                2.6 Windows
                    Cab Door Window (if equipped)
                    
            Section 3 - Controls and Indicators
                3.1 General
                3.2 Controls
                    Transmission Control Lever
                    Ignition Switch
                    Boom Joystick
                    Attachment Tilt and Frame Sway Lever
                    Auxiliary Control Joystick (if equipped)
                    Dash Controls and Indicators
                    Park Brake Switch
                    Parking Procedure
                    Heater
                3.3 Operator Seat
                    Seat Adjustments
                    Seat Belt
                3.4 Boom Angle and Extension Indicators
                3.5 Mirror
                
            Section 4 - Operation
                4.1 Engine
                    Starting the Engine
                    Cold Weather Starting Aids
                    Battery Boosted Starting
                    Normal Engine Operation
                    Shut-Down Procedure
                4.2 Operating with a Load
                    Lift Load Safely
                    Picking Up a Load
                    Transporting the Load
                    Leveling Procedure
                    Placing the Load
                    Disengaging the Load
                4.3 Operating with a Suspended Load
                    Lift Load Safely
                    Picking Up a Suspended Load
                    Transporting a Suspended Load
                    Leveling Procedure
                    Placing a Suspended Load
                    Disengaging a Suspended Load
                4.4 Loading and Securing for Transport
                    Tiedown
                    Lifting
                    
            Section 5 - Attachments
                5.1 Approved Attachments
                5.2 Unapproved Attachments
                5.3 Telehandler/Attachment/Fork Capacity
                5.4 Use of the Capacity Chart
                    Capacity Indicator Locations
                    Sample Capacity Chart
                    Example
                5.5 Attachment Installation
                5.6 Adjusting/Moving Forks
                5.7 Attachment Operation
                    Carriage w/Forks
                    Crane Hook
                    Bucket
                    Truss Boom
                    Boom Head-Mounted Winch
                    6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m) Carriage
                    6 ft (1,8 m) - 100˚ Swing Mast W/Side Shift
                    Swing Carriage
                    Side Tilt Carriage
                    Personnel Work Platform
                    
            Section 6 - Emergency Procedures
                6.1 Towing a Disabled Product
                    Moving Short Distances
                    Moving Longer Distances
                6.2 Emergency Lower of Boom
                6.3 Emergency Exit from Enclosed Cab
                
            Section 7 - Lubrication and Maintenance
                7.1 Introduction
                    Clothing and Safety Gear
                7.2 General Maintenance Instructions
                7.3 Service and Maintenance Schedules
                    10 & 1st 50 Hour Maintenance Schedule
                    50, 250 & 500 Hour Maintenance Schedule
                    1000 & 1500 Hour Maintenance Schedule
                7.4 Lubrication Schedules
                    50 Hour Lubrication Schedule
                    250 Hour Lubrication Schedule
                7.5 Operator Maintenance Instructions
                    Fuel System
                    Air Intake System
                    Engine Oil
                    Hydraulic Oil
                    Tires
                    Hydraulic Return Filter
                    Engine Cooling System
                    Battery
                    
            Section 8 - Additional Checks
            
            Section 9 - Specifications
                9.1 Product Specifications
                    Fluid and Lubrication Capacities
                    Tires
                    Performance
                    Dimensions
            Index
            Inspection, Maintenance and Repair Log
            
        20004 Liquid Coolant Test Manual
            Engine Coolant Specifications
            Testing Diesel Engine Coolant
            Replenishing Supplemental Coolant Additives Between Coolant Changes
            Operating in Warm Temperature Climates
            Flush & Service Cooling System
            Disposing of Coolant
            
    TESTING & ADJUSTING
        Machine Start-Up Procedure
        Hydraulic Schematic
        GSD-1102 Gresen Model V20 Sectional Body Directional Control Valve Service & Parts Manual
        HN21AD02 Danfoss Hydrostatic Steering Unit
        HS-19 Commercial Intertech Hydraulic Pumps & Motors Service Manual
        RDE 91604-01-R Rexroth Drive Motors
        
    AXLES
        FMM9D Meritor PRA 352 Series Planetary Axles
            Service Notes
            Illustrations with parts list of Model:
                PRA 352 - Trumpet Variation No. 1
                PRA 352 - Trumpet Variation No. 2
                PRA 353-383
                PROA 352-382 (with Mechanical Drive Option
                PROA 352/382
            Section 1 Introduction
            Section 2 Removal & Disassembly
            Section 3 Prepare Parts for Assembly
            Section 4 Assembly & Installation
            Section 5 Adjustments
            Section 6 Specifications
        CA357248 Carraro 28.46M Axles
            A INFORMAZIONI GENERALI
                A.1 Utilizzo del manuale
                A.2 Proprietà delle informazioni
                A.3 Convenzioni e definizioni
                A.4 Indicazioni generali
                A.5 Indicazioni generali per le operazioni di riparazione
            A General information
                A.1 Manual use
                A.2 Information property
                A.3 Agreements and definitions
                A.4 General description
                A.5 Recommendations for repair operations
            B INFORMAZIONI SULLA SICUREZZA
                B.1 Indicazioni generali per la sicurezza
                B.2 Simboli di sicurezza
                B.3 Precauzioni generali
            B Safety instructions
                B.1 General safety recommendations
                B.2 Safety symbols
                B.3 General precautions
            C CARATTERISTICHE GENERALI
                C.1 Usi previsti
                C.2 Identificazione del prodotto
                C.3 Descrizione generale
                C.4 Caratteristiche Tecniche
                C.5 Cambio olio e verifiche
                C.6 Coppie di serraggio
            C General specifications
                C.1 Foreseen uses
                C.2 Product identification
                C.3 General description
                C.4 Technical Features
                C.5 Oil change and checks
                C.6 Tightening torques
            D OPERAZIONI DI MONTAGGIO E SMONTAGGIO
                D.1 Gruppo flangia
                D.2 Gruppo riduttore epicicloidale
                D.3 Gruppo mozzo ruota
                D.4 Gruppo trombe trave
                D.5 Freno e supporto differenziale
                D.6 Gruppo differenziale
                D.7 Gruppo pignone
                D.8 Sbloccaggio freno parcheggio
                D.9 Riattivazione freno parcheggio
                D.10 Prove dopo montaggio
            D Disassembly and assembly operations
                D.1 Flange group
                D.2 Epicyclic reduction gear group
                D.3 Wheel hub group
                D.4 Axle beam trumpets group
                D.5 Brake and differential support
                D.6 Differential group
                D.7 Pinion group
                D.8 Parking brakes release
                D.9 Re-activating parking brakes
                D.10 Testing after assembly
            E RICERCA GUASTI
                E.1 Controllo ed esame dei guasti
                E.2 Diagnosi per problemi all'assale
            E Troubleshooting
                E.1 Troubleshooting
                E.2 Axle problems and diagnosis
            F ATTREZZATURE SPECIALI
                F.1 Attrezzature speciali
            F Special tools
                F.1 Special tools
                
    TRANSMISSION
        RA 92003-S Rexroth Application & Service
            Name Tag Information
            Type Code
            Technical Data
            Filtration Options
            High Pressure Relief Valve
            Pump Controls
            Pump Installation
            Start-Up Procedure
            Troubleshooting Procedure
            Charge Pressure Relief Adjustments
            Mechanical Centering of Pump
            Hydraulic Centering of Control Modules
            Adjustments of Pressure Override Valve
            Adjustments of High Pressure Relief Valves
            Tow Option Engagement
            Removal & Inspection of Charge Pump
            Removal & Installation of Shaft Seal
            Filter Replacement
            Routine Maintenance
            Replacement Subassemblies & Parts
            Filter Configuration
            
    MISCELLANEOUS
        29903 Kenhar User Fork Wear Standards
        0009 Rim & Wheel Safety Manual
        Electrical Schematic
        F114004 Donaldson Cyclopac Service Procedure
        81-460-047 Mico Hydraulic Power Brake Valve
            System Schematic
            Representative Performance Data
            Description & Operation of Power Brake Valve
            External Dimensional Views
            Installation of Power Brake Valve
            Cross Sectional Views of Three Power Brake Valve Designs
            Specification Chart
            Primary Cup Design
            Teflon Seal Design
            Sliding Piston Design
            Service Diagnosis
            Bleeding
            
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