JLG G6-42A Service Manual

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Page 1

An Oshkosh Corporation Company

Service Manual

Models

G6-42A, G9-43A

& G10-43A

G6-42A

S/N 0160048658 & After

G9-43A & G10-43A

S/N 0160048671 & After

excluding 0160048773

31200792

Revised

October 13, 2014

Page 2

Page 3

EFFECTIVITY PAGE

February 15, 2013 - A - Original Issue Of Manual

July 15, 2014 - B - Revise page ii, Added 3-32, 3-33, 4-8, Revised Pages 2-2 thru 2-12, 3-20 thru 3-23, 4-8, 6-2, 6-4, 8-5,

9-3, 9-4, 9-19.

October 13, 2014 - C - Revise pages 1-4, 2-16, 2-17, 7-2

31200792 G6-42A, G9-43A, G10-43A

Page 4

READ THIS FIRST

OY2700

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387 A

REAR VIEW OF CAB

Modifications

Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations. Any modification must be approved by JLG.

Machine Configuration

Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.

• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra Low Sulfur (ULS) from this point forward.

•If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Low Sulfur (LS) from this point forward.

G6-42A, G9-43A, G10-43A 31200792

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SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Replacement Parts and Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.5 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.6 Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.7 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Boom System—Three Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7 Push Beam—Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . 3-16

3.8 Boom Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.11 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.13 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3.15 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

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

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Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 Axle Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Section 6

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Specifications And Maintenance Information. . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Transmission Cooler Thermal By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.6 Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Section 7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Introduction—Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.3 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.6 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.7 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

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

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Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15

9.8 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

9.9 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

9.10 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9.11 Display Gauge and Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9.12 Hand Held Analyzer - G9-43A and G10-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

9.13 SAE Diagnostic Trouble and Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

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

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Section Subject Page

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

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Section 1

Safety Practices

Contents

PARAGR APH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

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Safety Practices

1.1 INTRODUCTION

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.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.

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.

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.

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.

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

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.

1.5 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.

1.5.1 Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

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 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.

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

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury.

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

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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.

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.

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 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.

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

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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 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.

Engine fuel lines are pressurized. DO NOT attempt repairs unless specific training has been completed. Refer to the engine manufacturers’ manual for specific details concerning the fuel system.

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.

COOLANT SYSTEM CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the coolant system cap while the cooling system is hot. Wear safety glasses. Turn the coolant system cap to 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.

Properly disconnect battery(s) prior to servicing the fuel or hydraulic systems.

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.

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.

1-4

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

Page 13

Section 2

General Information and Specifications

Contents

PARAGR APH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.3 Electrical SystemEngine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.4.4 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.4.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.5 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.1 Fluids (if Equipped for ULS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.2 Fluids (if Equipped for LS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.5.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.6 Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2.6.3 1000, 1500 & 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.7 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.7.1 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.7.2 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.7.3 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

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

2-1

Page 14

General Information and Specifications

MY8100

-10

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

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.

2.2 THREAD LOCKING COMPOUND

242

243

271

262

ND Industries Description

Vibra-TITETM121

Vibra-TITETM122

Vibra-TITETM140

Vibra-TITETM131

Medium Strength (Blue)

Medium - High Strength (Red)

High Strength (Red)

JLG P/N

0100011

1001095650

0100019

0100071

Loctite

Loct ite® 243TM can be substituted in place of Loctite® 242TM. Vibra-

122 can be substituted in place of Vibra-TITETM 121.

TITE

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

Page 15

General Information and Specifications

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

T o r q u e

Size TPI Bolt Dia

In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT - L B [N.m] FT-LB [N.m] F T -L B [N.m] F T - LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

Tensile

Stress Area

Clamp

Load

T o r q u e

(Dry)

T o r q u e

Lubricated

(Loctite® 242

or Vibra-TITE

111 or 140)

or 271TM

T o r q u e

(Loctite® 262

Vibra-TITE

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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

2-3

Page 16

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Vibra-TITE

T o r q u e

or 271TM or

1 1 1 o r 1 4 0 )

K=0.18

Size TPI Bolt Dia

In Sq In LB I N - LB [N.m] IN - L B [N.m] I N- L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 43 5

10 24 0.1900 0.01750 1580 60 7

32 0.1900 0.02000 1800 68 8

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB F T-L B [N.m] FT- LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

Tensile Stress

Area

Clamp Load

Torque

(Dry or Loctite® 263)

K=0.20

(Loctite® 242

Torque (Loctite® 262 Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

2-4

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

Page 17

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Vibra-TITE

T o r q u e

or 271TM or

111 or 140)

K=0.16

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604 380 7 0.8

48 0.1120 0.00661 420 8 0.9

6 32 0.1380 0.00909 580 14 1.5

40 0.1380 0.01015 610 14 1.6

8 32 0.1640 0.01400 900 25 2.8

36 0.1640 0.01474 940 26 2.9

10 24 0.1900 0.01750 1120 36 4.1

32 0.1900 0.02000 1285 42 4.7

1/4 20 0.2500 0.0318 2020 86 9.7 80 9

28 0.2500 0.0364 2320 99 11.1 95 11

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20

24 0.3125 0.0580 3700 15 20 15 21 15 20

3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34

24 0.3750 0.0878 5600 30 40 28 38 25 34

7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48

20 0.4375 0.1187 7550 45 60 44 60 40 54

1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75

20 0.5000 0.1599 10700 75 100 71 97 65 88

9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109

18 0.5625 0.2030 12950 105 145 97 132 90 122

5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156

18 0.6250 0.2560 16300 145 195 136 185 125 170

3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272

16 0.7500 0.3730 23800 255 345 238 324 225 306

7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435

14 0.8750 0.5090 32400 400 545 378 514 355 483

1 8 1.0000 0.6060 38600 545 740 515 700 480 653

12 1.0000 0.6630 42200 600 815 563 765 530 721

1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809

12 1.1250 0.8560 47500 755 1025 713 969 670 911

1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142

12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265

1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496

12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707

1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992

12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237

Tensile Stress

Area

Clamp Load

Torque

(Dry)

K=0.17

(Loctite® 242

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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

2-5

Page 18

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Vibra-TITE

T o r q u e

or 271TM or

111 or 140)

K=0.16

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 37 4

10 24 0.1900 0.01750 1580 51 6

32 0.1900 0.02000 1800 58 7

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

Torque

( D r y o r L o c t i t e ® 2 6 3 )

K=0.17

(Loctite® 242

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

2-6

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

Page 19

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SOCKET HEAD CAP SCREWS

T o r q u e

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

See Note 4

Torque

(Dry) K=0.17

(Loctite® 242

Vibra-TITE

Precoat® 85 K=0.16

or 271TM or

111 or 140) or

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

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

2-7

Page 20

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS

T o r q u e

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

See Note 4

Torque

(Dry) K=0.17

(Loctite® 242

Vibra-TITE

Precoat® 85 K=0.16

or 271TM or

111 or 140) or

Torque

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

2-8

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

Page 21

General Information and Specifications

2.3.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

T o r q u e

Size Pitch

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 2 115 50.0 140 105 126 154

16 2 157 68.3 219 164 197 241

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

33 3.5 694 302.0 1990 1490 1790 2090

36 4 817 355.5 2560 1920 2300 2690

42 4.5 1120 487.0 4090 3070 3680 4290

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

)

Torque (Lub)

(Loctite® 262

Vibra-TITE

271

131)

271

T o r q u e

(Loctite® 242

or Vibra-TITETM

111 or 141)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

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

2-9

Page 22

General Information and Specifications

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS,

CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

T o r q u e

Size Pitch

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 23 19

8 1.25 36.60 22.8 37 33 27

10 1.5 58.00 36.1 70 65 55

12 1.75 84.30 52.5 125 115 95

14 2 115 71.6 200 180 150

16 2 157 97.8 315 280 235

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

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

K=0.20

)

(Lub or Loctite®

or 271TM or

242

Vibra-TITE

K=0.18

111 or 140)

T o r q u e

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

2-10

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

Page 23

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Size Pitch

30.55.03

3.5 0.6 6.78

40.78.78

5 0.8 14.20

6 1 20.10

7 1 28.90

8 1.25 36.60

10 1.5 58.00

12 1.75 84.30

14 2 115

16 2 157

18 2.5 192

20 2.5 245

22 2.5 303

24 3 353

27 3 459

30 3.5 561

33 3.5 694

36 4 817

42 4.5 1120

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

2.19 1.1 1.1 1.0

2.95 1.8 1.7 1.5

3.82 2.6 2.4 2.3

6.18 5.3 4.9 4.6

8.74 9 8.4 7.9

12.6 15 14 13

15.9 22 20 19

25.2 43 40 38

36.7 75 70 66

50.0 119 110 105

68.3 186 175 165

83.5 256 240 225

106.5 362 340 320

132.0 494 465 435

153.5 627 590 555

199.5 916 860 810

244.0 1245 1170 1100

302.0 1694 1595 1495

355.5 2176 2050 1920

487.0 3477 3275 3070

(Dry or Loctite® 263

General Information and Specifications

Torque

K=0.17

)

T o r q u e

(Lub or Loctite®

or 271

242

Vibra-TITE

K=0.16

111 or 140)

T o r q u e (Loctite® 262 Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

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

2-11

Page 24

General Information and Specifications

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,

CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*

T o r q u e

Size Pitch

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 13 12 11

7 1 28.90 18.0 21 20 19

8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 55

12 1.75 84.30 52.5 105 100 95

14 2 115 71.6 170 160 150

16 2 157 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 3 353 222.0 905 850 800

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

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load See

Note 4

Torque

(Dry or Loctite® 263

K=0.17

)

(Lub or Loctite®

or 271TM or

242

Vibra-TITE

K=0.18

111 or 140)

T o r q u e

(Loctite® 262

Vibra-TITE

K=0.15

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

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.

2-12

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

Page 25

General Information and Specifications

2.3.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

Size ORFS JIC Flats Method

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

136 lb-ft

(100 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

136 lb-ft

(100 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

1.5 to 1.75

1 to 1.5

1.5 to 1.75

1.0 to 1.5

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 swivel nut flats and another dot in line on hex of adapter it’s connecting to.

3. Use double wrench method while tightening to avoid hose twist.

4. After connection has been properly tightened, mark a straight line across the connecting parts, not covering dots indicating that connection has been properly tightened.

32 N/A

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 connection has been properly tightened, mark a straight line across connecting parts indicating that connection has been properly tightened.

270 lb-ft

(366 Nm)

0.75 to 1.0

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

2-13

Page 26

General Information and Specifications

2.4 SPECIFICATIONS

2.4.1 Travel Speeds

Gear

ULS LS ULS LS

First 3.8 mph (6,1 km/h) 3.4 mph (6,1 km/h) 3.4 mph (5,5 km/h) 3.5 mph (5,6 km/h)

Second 6.8 mph (12,9 km/h) 6.8 mph (10,9 km/h) 6.1 mph (9,8 km/h) 6.3 mph (10,1 km/h)

Third 15.5 mph (25,9 km/h) 15.1 mph (24,3 km/h) 13.9 mph (22,4 km/h) 14.2 mph (22,9 km/h)

Fourth 23.2 mph (32,9 km/h) 22.2 mph (35,7 km/h) 19.8 mph (31,9 km/h) 18.3 mph (29,5 km/h)

G6-42A G9-43A & G10-43A

2.4.2 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.

a. G6-42A

Approximate Times (seconds)

Function

Min Time Max Time Min Time Max Time

Boom Extend (Boom Level) 13.6 14.7 14.0 14.8

Boom Retract 7.41 14.8 12.3 13.1

Boom Lift 11.9 12.8 12.6 13.4

ULS LS

Boom Lower 8.8 9.0 9.2 10.0

Attachment Tilt Forward 3.8 3.8 3.4 3.9

Attachment Tilt Rearward 3.2 3.2 3.9 4.4

Frame Level - Full Right to Left 7.4 7.4 6.3 6.9

Frame Level - Full Left to Right 5.8 5.8 8.6 9.6

2-14

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

Page 27

b. G9-43A & G10-43A

General Information and Specifications

Approximate Times (seconds)

Function

ULS LS

Min Time Max Time Min Time Max Time

Boom Extend (Boom Level) 14.4 16.5 14.4 15.9

Boom Retract 11.0 20.0 16.8 18.6

Boom Lift 10.2 12.4 11.3 12.5

Boom Lower 9.3 14.0 9.2 10.2

Attachment Tilt Forward 6.0 8.5 7.2 8.0

Attachment Tilt Rearward 6.0 9.0 6.8 7.5

Frame Level - Full Right to Left 10.5 13.0 11.9 13.1

Frame Level - Full Left to Right 10.9 12.1 11.0 12.1

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

2-15

Page 28

General Information and Specifications

2.4.3 Electrical SystemEngine System

Battery (if equipped for ULS)

Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free

Cold Cranking Amps @ 0° F (-18° C) 950

Cranking Amps @ 32° F (-18° C) 1190

Reserve Capacity Minutes @ 25 Amps 185

Group/Series Group 31

Alternator 12V, 120 Amps

Battery (if equipped for LS)

Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free

Cold Cranking Amps @ 0° F (-18° C) 700

Cranking Amps @ 32° F (-18° C) 840

Reserve Capacity Minutes @ 25 Amps 180

Group/Series Group 31

Alternator 12V, 120 Amps

Battery: Arctic if Equipped (2)

Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free

Cold Cranking Amps @ 0° F (-18° C) 750

Cranking Amps @ 32° F (-18° C) 1000

Reserve Capacity Minutes @ 25 Amps 310

2.4.4 Engine Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting

Description

If Equipped for ULS If Equipped for LS

Engine Make/Model Cummins QSB3.3 Cummins QSB3.3

Displacement 201 in³ (3,3 liters) 201 in³ (3,3 liters)

Low Idle 1000 rpm 1000 rpm

High Idle 2600 rpm 2600 rpm

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

Horsepower 100 HP (74,6 kW) @ 2600 rpm 99 HP (74 kW) @ 2600 rpm

Peak Torque 306 lb-ft (415 Nm) @ 1600 rpm 306 lb-ft (415 Nm) @ 1600 rpm

Fuel Delivery Fuel Injection

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2-16

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

Page 29

General Information and Specifications

2.4.5 Tires

Note: Standard wheel lug nut torque is 350–400 lb-ft (475–542 Nm)

Note: Pressures for foam filled tires are for initial fill ONLY.

a. G6-42A

Size Tire Type

13.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply

15.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply

370/75-28 DuraForce 14 Ply

b. G9-43A

Size Tire Type

13.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply

15.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply

370/75-28 DuraForce 14 Ply

Minimum Ply/

Star Rating

Minimum Ply/

Star Rating

Fill Type Pressure

Pneumatic 65 psi (4,5 bar)

Foam—Approximately 542 lb (246 kg)

Pneumatic 58 psi (4,0 bar)

Foam—Approximately 600 lb (272 kg)

Pneumatic 76 psi (5,2 bar)

Foam—Approximately 464 lb (210 kg)

Fill Type Pressure

Pneumatic 65 psi (4,5 bar)

Foam—Approximately 542 lb (246 kg)

Pneumatic 65 psi (4,0 bar)

Foam—Approximately 600 lb (272 kg)

Pneumatic 76 psi (5,2 bar)

Foam—Approximately 464 lb (210 kg)

c. G10-43A

Size Tire Type

14.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply

400/75-28 DuraForce 14 Ply

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

Minimum Ply/

Star Rating

Fill Type Pressure

Pneumatic 65 psi (4,8 bar)

Foam—Approximately 720 lb (327 kg)

Pneumatic 76 psi (5,2 bar)

Foam—Approximately 570 lb (259 kg)

2-17

Page 30

General Information and Specifications

2.5 FLUID AND LUBRICANT CAPACITIES

2.5.1 Fluids (if Equipped for ULS)

Ambient

Temperature

Compartment or System Type and Classification Viscosities

Min

Engine Crankcase API CJ-4 Plus

Transmission and Transfer

Case

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

SAE 15W-40 5 120 -15 49

SAE 0W-40 -40 0 -40 -20

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

SAE140 50 122 10 50

80W-140 85W-140

SAE90

SAE90LS

80W-90 85W-90

75W-90 -40 104 -40 40

75W -40 50 -40 10

Axle Differential and Wheel

End

Hydraulic System

API GL4 with

LS Additives

API GL5 with

LS Additives

Mobilfluid 424 10W-30 0 104 -20 40

Exxon Univis HVI -40 0 -40 -20

Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40

Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40

Boom Chain Lubricant Schaffer 200S Silver Streak

Engine Coolant

Ethylene Glycol

and Water

50/50 Mix Standard 60/40 Mix Cold Weather

#2 Diesel

Ultra Low

Sulfur

(S ≤ 15 mg/

kg)

Fuel

B5 Biodiesel

Blend #1 diesel and #2 diesel fuels

("winterized" #2)

B5 Biodiesel with Winter Conditioner

Note: Friction Modifier may be added to front axle differentials, see Section 2.5.3, “Capacities.”

Range

°F °C

Min

14 122 -10 50

32 104 0 40

-4 104 -20 40

Standard

Cold Weather

2-18

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

Page 31

General Information and Specifications

2.5.2 Fluids (if Equipped for LS)

Ambient

Temperature

Compartment or System Type and Classification Viscosities

Engine Crankcase API CI-4 Multigrade

Transmission and Transfer

Case

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

SAE 15W-40 5 120 -15 49

SAE 0W-40 -40 0 -40 -20

Mobilfluid 424 10W-30 0 104 -20 40

Mobilfluid LT 75W-80 -40 0 -40 -20

SAE140 50 122 10 50

80W-140 85W-140

SAE90

SAE90LS

80W-90 85W-90

75W-90 -40 104 -40 40

75W -40 50 -40 10

Axle Differential and Wheel

End

Hydraulic System

API GL4 with

LS Additives

API GL5 with

LS Additives

Mobilfluid 424 10W-30 0 104 -20 40

Exxon Univis HVI -40 0 -40 -20

Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40

Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40

Boom Chain Lubricant Schaffer 200S Silver Streak

Engine Coolant

Ethylene Glycol

and Water

50/50 Mix Standard 60/40 Mix Cold Weather

#2 Diesel

Fuel

B5 Biodiesel

Blend #1 diesel and #2 diesel fuels

("winterized" #2)

Low Sulfur

(S ≤ 500 mg/

kg)

B5 Biodiesel with Winter Conditioner

Note: Friction Modifier may be added to front axle differentials, see Section 2.5.3, “Capacities.”

Range

°F °C

Min

14 122 -10 50

32 104 0 40

-4 104 -20 40

Min

Standard

Cold Weather

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

2-19

Page 32

General Information and Specifications

2.5.3 Capacities

Engine Crankcase Oil

Capacity with Filter Change 8.0 quarts (7,6 liters)

Fuel Tank

Capacity 38 gallons (144 liters)

Cooling System

System Capacity 15 quarts (14,2 liters)

Hydraulic System

System Capacity

G6-42A 43 gallons (163 liters)

G9-43A & G10-43A 44 gallons (168 liters)

Reservoir Capacity to Middle of Sight Gage 24.5 gallons (93 liters)

Auxiliary Hydraulic Circuit Max Flow Not Available at Publication

Transmission

Capacity with Filter Change 16 quarts (15,1 liters)

Transfer Case

Capacity 2.1 quarts (2,0 liters)

Axles

Differential Housing Capacity

G6-42A 8.5 quarts (8 liters)

Friction Modifier (Front differential only) 13.6 ounces (402,2 milliliter)

G9-43A & G10-43A

Front 8.2 quarts (7,8 liters)

Rear 13 quarts (12,3 liters)

Friction Modifier (Front differential only) 13.12 ounces (372,7 milliliter)

Wheel End Capacity

G6-42A 1.7 quarts (1,6 liters)

G9-43A & G10-43A 1.75 quarts (1,65 liters)

Air Conditioning System (if equipped)

System Capacity 2.5 lb (1134 g)

2-20

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

Page 33

2.6 SERVICE AND MAINTENANCE

MY7680

Check

Transmission

Oil Level

Check Hydraulic

Oil Level

Air Filter

Restriction

Indicator

Check Fuel

Level

Check Engine

Oil Level

EVERY

Check Tire

Condition &

Pressure

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

EVERY

Drain Fuel/

Water

Separator

Check Engine

Coolant Level

Check

Battery

Lubrication

Schedule

Check Washer

Fluid Level

(if equipped)

SCHEDULE

2.6.1 10, 1st 50 & 50 Hour

General Information and Specifications

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

2-21

Page 34

General Information and Specifications

OY3430

250

EVERY

Change Engine

Oil and Filter

Check Axle

Oil Level

Check Wheel

End Oil Levels

Air Filter

Vacuator

Valve

Check

Fan Belt

Check Boom

Wear Pads

Check Transfer

Case Oil Level

Check

Rear Axle

Stabilization

Lubrication

Schedule

Change

Axle Oil

Change Wheel

End Oil

Change

Transmission

Oil & Filter

Change

Transfer Case

Oil

250

500

EVERY

Change Fuel

Filters

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

2.6.2 1st 250, 250 & 500 Hour

2-22

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

Page 35

2.6.3 1000, 1500 & 2000 Hour

OY3440

1500

EVERY

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

1000

EVERY

Change

Transmission

Oil & Filter

Change

Axle Oil

Change Wheel

End Oil

Change

Transfer Case

Oil

Check

Boom Chains

Lubrication

Schedule

Check

Air Intake

System

Engine Valve Lash Adjustment

Change

Engine Coolant

2000

EVERY

Change Crankcase

Vent Filter (if

equipped for ULS)

General Information and Specifications

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

2-23

Page 36

General Information and Specifications

OY2550

EVERY

G10-43A

2.7 LUBRICATION SCHEDULE

2.7.1 50 Hour

2-24

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

Page 37

2.7.2 250 Hour

OY2560

EVERY

250

G10-43A

General Information and Specifications

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

2-25

Page 38

General Information and Specifications

OY2570

EVERY

1000

G10-43A

2.7.3 1000 Hour

2-26

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

Page 39

Section 3

Boom

Contents

PARAGR APH TITLE PAGE

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Boom System—Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Complete Boom Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.5.1 Second and Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.5.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.5.3 Push Beam—Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . 3-9

3.5.4 Push Beam—Extend/Retract Cylinder Installation and Third Boom Section

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.5.5 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.5.6 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . 3-13

3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.6.1 Extend/Retract Chain Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.6.2 Extend/Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7 Push Beam—Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . 3-16

3.7.1 Push Beam Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . 3-16

3.7.2 Push Beam—Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . 3-18

3.8 Boom Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.8.1 Chain Tension Inspection—G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.8.2 Chain Tension Adjustment—G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.8.3 Chain Tension Inspection— G9-43A/G10-43A . . . . . . . . . . . . . . . . . . . . . 3-23

3.8.4 Chain Tension Adjustment— G9-43A/G10-43A . . . . . . . . . . . . . . . . . . . . 3-23

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

3-1

Page 40

Boom

3.9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.9.1 Hydraulic Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.9.2 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.9.3 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10.3 Boom Section Wear Pad Pathway Lubrication: . . . . . . . . . . . . . . . . . . . . 3-27

3.11 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.11.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.11.2 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.11.3 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.11.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.12 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.13 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.13.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.13.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3.15 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-2

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

Page 41

3.1 BOOM SYSTEM

MY7730

EXTEND/RETRACT

CYLINDER

(INSIDE PUSH BEAM)

SECOND BOOM

SECTION

THIRD BOOM

SECTION

RETRACT CHAIN

(INSIDE BOOM)

EXTEND CHAIN (INSIDE BOOM)

QUICK

SWITCH

FIRST BOOM

SECTION

HOSE SHEAVE

(INSIDE BOOM)

TILT

CYLINDER

PUSH BEAM

ASSEMBLY

STRONG BACK

PIVOT PIN

COMPONENT TERMINOLOGY

The following illustrations identify the components that are referred to throughout this section.

Boom

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

3-3

Page 42

Boom

3.2 BOOM SYSTEM—THREE SECTION

3.2.1 Boom System Operation

The three section boom consists of the first, second and third assemblies with a single extend chain, and a single retract chain.

As the extend/retract cylinder, which is anchored at the rear of the first boom section, and the front of the push beam begins to extend, it forces the second and third boom sections out of the first boom section.

The boom sections are connected by extend and retract chains. These chains are routed around sheaves on the front of the push beam and the rear of the second boom section. As the extend/retract cylinder is forced out hydraulically, the second boom section is pulled out by the push beam, and third boom section is pulled out by the extend chain.

As hydraulic pressure is applied to the retract port on the extend/retract cylinder, the retract chain pulls the third boom section and the push beam pulls the second boom section back into the first boom section.

The mechanical linkage formed by the chains and supporting hardware, extend and retracts the second and third boom sections at the same rate.

The boom section lifts and lowers via action of the lift/ lower cylinder.

3.3 BOOM ASSEMBLY MAINTENANCE

These instructions provide the complete boom assembly removal and installation or the second and third boom sections removal and installation.

Before beginning, conduct a visual inspection of machine and work area, and review task about to be undertaken. Read, understand and follow these instructions. Boom assembly consists of 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 machine and work area, and review 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 3.10, “Boom Wear Pads.”)

2. Check hose sheaves and chain rollers.

3. Apply grease at all lubrication points (grease fittings). (Refer to Section 2.6, “Lubrication Schedules.”)

4. Check for the proper operation by operating all the boom functions through their full ranges of motion several times.

Note: Depending on your particular circumstance, the following procedures explain the removal/installation of individual boom sections or removal/installation of the

complete boom

3-4

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.

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

Page 43

Boom

MY1520

3.4 COMPLETE BOOM REMOVAL/ INSTALLATION

3.4.1 Complete Boom Removal

1. Remove any attachment from quick switch assembly.

2. Remove the quick switch assembly. Refer to Section

3.9, “Quick Switch Assembly.”

3. Park machine on a hard, level surface, level machine, fully retract boom, level boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF.

4. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

5. Open engine cover. Allow system fluids to cool.

6. Properly disconnect battery.

7. Using a suitable sling or hoist, support the boom.

8. Label, disconnect and cap the hydraulic hoses at the rear of the boom. Cap all fittings to keep dirt and debris from entering the hydraulic system.

9. Label and disconnect any electrical cables (if equipped) at the rear of the boom.

10. Remove the pin from the rod end of the compensation cylinder being careful not to drop the cylinder. Lower the cylinder onto the frame rails.

11. Remove the pin from the rod end of the lift/lower cylinder. Lower the cylinder onto the frame rails.

12. Confirm that boom assembly is balanced with sling and remove the boom assembly pivot pin (1).

13. Lift boom assembly from machine and lower onto suitable supports.

3.4.2 Complete Boom Installation

1. 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. Install the boom pivot pin (1).

2. With the sling still in place, install the compensation cylinder, pins and bolts. Apply Loctite torque lock bolt to 100-110 lb-ft (135-149 Nm).

3. With the sling still in place, install the rod end of the lift/lower cylinder, pin and lock bolt. Apply Loctite

and torque lock bolt to 200-215 lb-ft

242 (271-291 Nm).

Note: Raising boom up or down with sling my be necessary so boom, compensation and lift/lower cylinder bores can be aligned for easier pin installation.

Note: Grease the boom pivot bore, compensation cylinder rod end, lift/lower cylinder rod end and pins before installing.

4. Uncap and reconnect the previously labeled hydraulic hoses to the extend/retract cylinder.

5. Uncap and connect and remaining hydraulic fittings to their appropriate locations.

6. Recheck wear pad gaps to ensure they meet the minimum gap requirement. Shim if necessary.

7. Ensure that the boom chains are properly adjusted. Refer to Section 3.8, “Boom Adjustments.”

8. Properly connect the battery.

9. Install the quick switch assembly. Refer to Section

3.9, “Quick Switch Assembly.”

10. Start engine and operate all boom functions several times. Check for leaks, and check hydraulic fluid level in reservoir; add fluid if required.

11. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

12. Close and secure the engine cover.

13. Remove Do Not Operate Tags from both ignition key switch and the steering wheel.

14. Install the previously removed attachment to the quick switch assembly.

242TM and

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

3-5

Page 44

Boom

MAL2660

G6-42A

G9-43A

G10-43A

MY3860

3.5 BOOM SECTION REMOVAL/INSTALLATION

3.5.1 Second and Third Boom

Section Removal

Note: Refer to Section 3.13.2, 3.15. “Push Beam Temporary Brackets,” for diagrams of the Temporary Extend Bracket and Temporary Retract Bracket designed to hold the chains in place on the push beam during disassembly and reassembly.

These brackets are NOT a purchasable part and must be manufactured locally.

They are solely designed to aid in the removal and installation of the push beam assembly.

Note: Refer to Section 8.8, “Hydraulic Cylinders.” for general tilt cylinder removal.

1. Remove the access cover from the rear of the first boom section.

4. Slowly loosen and remove the extend/retract cylinder counterbalance valve (3). Plug (M27x1.5) open port on extend/retract cylinder to prevent dirt and debris from entering hydraulic system.

5. Remove retaining clips from extend/retract cylinder mounting pin (4), remove extend/retract cylinder pin.

6. Remove four mounting bolts securing the strong back (5) to the first boom section.

7. Remove strong back (5) from rear of boom.

8. Remove right or left side wear pads, shims and backing plates (6) from rear of second boom section. Label and tag each set of wear pads being removed.

9. Remove the top wear pads, shims and backing plates (7) from the rear of the second boom section. Label and tag each set of wear pads being removed.

2. Remove the locknut, adjustment nut and six belleville washers (1) from the extend chain clevis rod at the rear of the boom.

3. Loosen and remove both extend/retract cylinder tubes (2) from rear of boom. Cap and/or plug all open hoses, tubes and/or fittings to prevent dirt and debris from entering the hydraulic system.

10. Loosen and remove the four bolts (8) securing the retract chain anchor plate (9).

11. Between bottom front of first and second boom sections, feed a rope or wire to retract chain anchor plate and secure to second or third boom section.

12. Disconnect both tilt tubes (10) and (if equipped) both auxiliary tubes from fittings on hose retainer brackets (11) at bottom front inside the boom. Plug the tube ends to prevent dirt and debris from entering the hydraulic system.

13. Disconnect both tilt hoses (not shown) and (if equipped) both auxiliary hoses from hose retainer brackets at bottom front inside the boom. Plug hose ends to prevent dirt and debris from entering the hydraulic system.

14. Loosen and remove the hose retainer brackets (11) and (if equipped) both auxiliary take-up brackets.

3-6

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

Page 45

Boom

MY3840

MY3880

MY4070

15. Between bottom front of first and second boom sections, feed a rope or wire to both tilt hoses (not shown) and (if equipped) both auxiliary hoses and secure to the second or third boom section.

16. Place a suitable sling around the second boom section. Slowly pull the second and third boom sections approximately 25% out of the first boom section. Lower the second and third boom sections onto a suitable support.

3.5.2 Third Boom Section Removal

1. Loosen and remove the tilt cylinder hose guide (1) and if equipped, the auxiliary hose guide from the rear of the third second section.

Note: The hose guide mounting bolts also hold the push pin beams in place.

2. Loosen and remove all retract chain sheave components (2) and the hydraulic hose rollers and components.

17. Remove all wear pads, shims and backing plates (12) from the front inside of the first boom section. Label and tag each set of wear pads being removed.

18. Remove the top and bottom mounting plates (13) from the front inside of the first boom section. Label and tag each mounting plate being removed.

19. Relocate sling or using two slings for better stability, balance two boom sections and slowly pull them out of first boom section being careful not to damage hydraulic hoses or chains. Lower second and third boom sections onto suitable supports.

Note: Offset the extend chain rod to the left or right of the push beam assembly allowing the push beam to be raised enough to allow the removal of the chain and hose sheaves.

3. Attach the Temporary Extend Chain Retention Bracket (3) between the extend chain rod (4) and the push beam tube (5). Snug in place. Do Not tighten.

Note: Refer to Section 3.15, “Push Beam Temporary Brackets,” for Temporary Extend Chain Bracket diagram.

4. At the rear of the boom, remove the retract chain (6) from the chain clevis.

3-7

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

Page 46

Boom

MY4110

MY3890

MY3870

5. Loosen and remove the tilt hoses and (if equipped) auxiliary hoses from the hose retainers (7 & 8) at the front of the third boom section.

6. Loosen and remove tilt hose and auxiliary hose retainers (7 & 8) from front of third boom section.

10. Remove all wear pads, shims and backing plates (11) from front inside of second boom section. Label and tag each set of wear pads being removed.

11. Remove wear pad mounting plates (12) from front inside of second boom section.

12. Relocate sling or using two slings for better stability, balance third boom section and slowly pull third boon section out of second boom section. Lower third boom section onto suitable supports.

7. Remove right or left side wear pads, shims and backing plates (9) from rear of third boom section. Label and tag each set of wear pads being removed.

8. Remove the top wear pads, shims and backing plates (10) from rear of third boom section. Label and tag each set of wear pads being removed.

9. Place a suitable sling around the third boom section. Slowly pull the third boom section approximately 25% out of the second boom section. Lower the third boom section onto a suitable support.

3-8

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

Page 47

Boom

MY4060

MY3930

3.5.3 Push Beam—Extend/Retract Cylinder Removal

CAUTION

The complete push beam assembly weighs over 1,200 lb (545 kg).

1. Loosen the Temporary Extend Chain Retention Bracket (13) and push the push beam (14) forward 3-4 in (76,2-101,6 mm).

2. Attach the Temporary Extend Chain Retention Bracket (15) between the chain clevis (16) and the end of the push beam (14).

Note: Refer to Section 3.15, “Push Beam Temporary Brackets,” for Temporary Extend Chain Bracket diagram.

3. Lift push beam (14) to unload clevis pin (17) and remove pin securing clevis to third boom section.

4. Tighten the Temporary Extend Chain Retention Bracket (13) to remove any slack in the extend chain.

5. Secure a rope or wire to front of push beam and pull push beam (14) towards front of boom.

6. Support push beam assembly with pry bars using access holes on each side of third boom section.

7. Remove the guide bar (18) and chain retainer (19). Remove the push beam wear pad (20).

8. Lower push beam assembly and remove pry bars.

9. Push/pull push beam assembly along with extend chain, to front of third boom section.

NOTICE

Guide the push beam/extend/retract cylinder assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components.

10. Place a sling around the push beam assembly. Lift and slowly pull the push beam assembly approximately half way out of the third boom section. Lower the push beam onto a suitable support.

11. Relocate sling or using two slings for better stability, balance push beam assembly and slowly pull push beam assembly out the front of third boom section.

12. Lower push beam assembly onto suitable supports.

13. Remove all remaining brackets, clevises, hoses, wear pads, shims, backing plates and hardware from the second and third boom sections. Label all parts and hardware being removed from each section.

Note: Inspect all chains, hoses and sheaves for wear and/or damage and replace as needed.

3.5.4 Push Beam—Extend/Retract Cylinder

Installation and Third Boom Section Assembly

Note: Inspect the wear pad surfaces of the second and third boom sections. Verify all areas are clean and free of any weld spatter, paint, etc., before beginning the reassembly procedure.

Note: Inspect and lubricate all extend and retract chains before re-assembly. Refer to Section 3.11, “Boom Extend and Retract Chains,” for detailed information.

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

1. Place the third boom section onto suitable supports.

2. Clean and lubricate the bottom and sides of third boom section where push beam guide bar travels.

3. Place a sling or using two slings for better stability, lift and slowly push the push beam assembly approximately half way into the third boom section. Lower the push beam onto a suitable support.

3-9

Page 48

Boom

MY3930

MY4060

MY3940

MY3900

4. Relocate the sling and slowly insert the push beam assembly into the front of the third boom section.

NOTICE

Guide the push beam/extend/retract cylinder assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components.

11. Install tilt cylinder hoses and (if equipped) auxiliary hoses through front of third boom section.

Note: Verify tilt cylinder hoses and (if equipped) auxiliary hoses are routed UNDER hose guide (12) at rear of third boom section at retract chain clevis bracket.

12. Snug the Temporary Extend Chain Bracket (9).

5. Install the push beam wear pad (4) to the previously removed chain retainer (5) using two bolts and two washers. Torque as required.

6. Lift the push beam assembly (6) with pry bars using the access holes on each side of the third boom section and install the guide bar (7) and chain retainer (5) using the previously removed hardware (8). Torque to 25-30 lb-ft (34-41 Nm).

7. Loosen the Temporary Extend Chain Bracket (9).

8. Apply thread lubricant to clevis mounting pin (10).

9. Lift push beam and install pin and retaining clips (10) securing clevis to third boom section.

10. Remove the Temporary Retract Chain Bracket (11).

13. Install the hose retainer assembly (13) using existing hardware. Torque as required.

14. Remove caps from the hose retainer fittings and plugs from the tilt cylinder hoses and (if equipped) the auxiliary hoses.

15. Connect tilt cylinder hoses and (if equipped) the auxiliary hoses to their proper locations. Torque as required.

3-10

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

Page 49

Boom

MY3890

14 14

MY3870

16. Install the previously removed wear pads, shims and spacers (14) at the bottom rear of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

17. Install previously removed wear pad and spacer (15) on left or right side of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

3.5.5 Third Boom Section Installation

Note: Using a straight bar approximately 20 in (508 mm) long will aid in the installation of the wear pads located on the inside front of each boom section.

1. Place second boom section onto suitable supports.

2. Lubricate bottom of third boom section where wear pads of the second boom section contact the third boom section.

3. Place sling, or two slings for better stability, around third boom section and insert tilt cylinder hoses and if equipped, auxiliary hoses into second boom section, followed slowly by third boom section being careful not to damage any surrounding components.

4. Lower the third boom section onto a suitable support, relocate one sling and insert the third boom section assembly approximately 75% into the second boom section.

5. Install the previously removed wear pad mounting plate (1) with existing hardware at the bottom front of the second boom section. Torque as required

6. Install previously removed wear pads, shims and spacers (2) with existing hardware at bottom front of second boom section. Torque as required.

7. Install wear pad mounting plate (3) with existing hardware at inside top front of the second boom section. Torque as required.

8. Install previously removed wear pads, spacers and shims on each side at front of the second boom section (4). Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

9. Install wear pads, spacer (5) using bolts and washers at top front of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

10. Feed the tilt cylinder hoses and if equipped, auxiliary hoses through the access holes at the rear of the second boom section.

11. Push the third boom section the remainder of the way into the second boom section.

12. Feed the retract chain through the access holes at the rear of the second boom section.

13. Connect the retract chain to the chain clevis at the rear of the second boom section using the existing pin and retaining clips.

14. Secure the retract chain, tilt cylinder hoses and if equipped, auxiliary hoses to the bottom of the boom head with rope or wire.

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

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Boom

MY3960

MY3970

MY3880

MY3910

Note: Keep the retract and extend chain free of any dirt and/or contaminates.

15. Remove the Temporary Extend Chain Bracket.

16. Install previously removed pin (6), chain roller (7), tilt hose sheave (8) and if equipped, auxiliary hose sheave assemblies at rear of the second boom section with existing hardware and shim as required.

20. Align push beam bores with second boom section bores and install previously removed pins (11).

Note: Verify the cross holes in push beam pins align with holes in each pin bore on the second boom section.

21. Install the previously removed tilt cylinder hose guide (12) and if equipped, the auxiliary hose guide at the rear of the third boom section using the existing hardware. Torque as required.

17. Thrust washers (9) are to be used as required to shim the hose sheave and retract chain sheave within 0.0625 in (1,6 mm) of a tight fit. At least one thrust washer (9) is required at each noted location.

18. Center the retract chain sheave (10) between the mounting plates.

19. Feed the tilt cylinder hoses and (if equipped) the auxiliary hoses over and around the hose sheaves.

3-12

22. Install previously removed wear pad and spacer (13) on left or right side of third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

23. Install previously removed wear pad and spacer (14) on top of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

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24. Install previously removed wear pad and

MY3880

MY3840

MY3980

spacer (15) on the bottom rear of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

25. Install the previously removed wear pad and spacer (16) on the left or right side of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

26. Install the previously removed counterbalance valve (17). Torque to 44 lb-ft (59,7 Nm).

27. Torque all wear pad mounting bolts as required.

3.5.6 Second and Third Boom

Section Installation

Note: Using a straight bar approximately 20 in (508 mm) long will aid in the installation of the wear pads located on the inside front of each boom section.

1. Lubricate the bottom of the second boom section where the wear pads of the first boom section contact the second boom section.

2. Place the sling, or two slings for better stability, around the third boom section and slowly insert the second and third boom section into the first boom section being careful not to damage hoses, chains and/or surrounding components.

3. Lower the second and third boom section onto a suitable support, relocate one sling and insert the second and third boom section assembly allowing access for the installation of the bottom plate, wear pads, spacers and shims at the front of the first boom section.

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

Boom

4. Remove any rope or wire securing the retract chain and tilt hoses and (if equipped) auxiliary hoses as the second and third boom sections are installed into the first boom section.

5. Install previously removed mounting plate (1) at the bottom front of the first boom section. Torque as required.

6. Install the previously removed wear pads, spacers and shims at the bottom front of the first boom section (2). Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

7. Install previously removed mounting plate (3) at top front of first boom section. Torque as required.

8. Install previously removed wear pads, Spacers (4) P/N 298-1729 and shims at top front of first boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

9. Install previously removed wear pads, spacers and shims at both sides on front of first boom section (5). Snug mounting bolts.

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Boom

MY3990

MY3890

MAL2660

G6-42A

G9-43A

G10-43A

10. Install the anchor plate (6) using existing hardware (7) into the first boom section. Torque as required.

11. Install the previously removed tilt hose retainer bracket (8) and (if equipped) both auxiliary hose retainer at the bottom of the first boom section using mounting bolts (9). Torque as required.

12. Remove plugs from the previously removed tilt hoses (10) and (if equipped) both auxiliary hoses.

13. Connect both tilt hoses (10) and (if equipped) both auxiliary hoses to the fittings on the hose retainer bracket. Torque as required.

14. Connect both tilt tubes (11) and (if equipped) both auxiliary tubes to the fittings on the hose retainer bracket. Torque as required.

15. Push the second and third boom sections the remainder of the way into the first boom section.

16. Install the previously removed wear pad and spacer (12) on the left or right side of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section

3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

3-14

17. Install previously removed wear pad and spacer (13) on top of second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication,” for detailed information.

18. Install the previously removed strong back (16) with the existing hardware. Torque as required.

19. Install extend/retract cylinder pin (17) through strong back (16). Secure pin with retaining rings.

20. Apply thread lubricant to extend chain clevis rod threads (18).

21. Install extend chain clevis rod into strong back (16).

22. Install belleville washers (19) as previously removed (cupped washer facing strong back). Install adjustment nut and lock nut. Snug, but Do Not tighten at this time.

23. Remove the caps and plugs from the extend/retract cylinder fittings and the extend/retract tubes (20).

24. Install both extend/retract tubes (20) and torque as required.

25. Uncap and reconnect the previously labeled hydraulic hoses to the extend/retract cylinder.

26. Uncap and connect and remaining hydraulic fittings to their appropriate locations.

27. Recheck wear pad gaps to ensure they meet the minimum gap requirement. Shim if necessary.

28. Ensure that the boom chains are properly adjusted. Refer to Section 3.8, “Boom Adjustments.”

29. Properly connect the battery.

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30. Start engine and operate all boom functions several

MY0580

MY1540

times. Check for leaks, and check hydraulic fluid level in reservoir; add fluid if required.

31. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

32. Close and secure the engine cover.

33. Remove Do Not Operate Tags from both ignition key switch and steering wheel.

3.6 EXTEND/RETRACT CHAIN

REMOVAL/INSTALLATION

3.6.1 Extend/Retract Chain Removal

The following section explains the removal of the extend/ retract chains without removing or disassembling the boom assembly.

1. Park machine on a hard, level surface, level machine, fully retract boom, level boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow system fluids to cool.

4. Properly disconnect battery.

5. Remove cover from the rear of first boom section.

Boom

9. Remove the retract chain adjustment and lock nuts (7) from the front of the first boom section.

10. Remove the strong back mounting bolts and remove the strong back from the boom.

11. Remove push beam mounting pins from rear of second boom section.

12. Place chain clevis rod to one side of push beam.

13. Lift the push beam to gain access to the chain clevis at the rear of the third boom section.

14. Reaching inside the rear of the boom at the chain anchor bracket, remove the cotter pin and pin from the retract chain clevis. Remove the cotter pin and pin from the extend chain.

15. Connect wire or rope (approximately 30 ft (9,1 m) to the end of the extend chain.

16. Lower push beam. Center chain clevis rod on push beam to aid in removal.

17. Pull push beam/extend chain from rear of boom. Disconnect wire or rope from extend chain.

18. Pull the retract chain from the rear of the boom.

6. Remove extend/retract cylinder hydraulic tubes (4). Plug tube ends and cap the fittings to keep dirt & debris from entering hydraulic system.

7. Remove extend/retract cylinder mounting pin (5) from strong back.

8. Remove extend chain adjustment nut and lock nut (6) from strong back.

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

3.6.2 Extend/Retract 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. Push the retract chain through the boom from the rear to the chain adjusting block (7) on the first boom section. Do not tighten the adjustment and lock nut at this time. Thread the nut on the clevis enough to keep the chain in place.

2. Connect the extend chain to the wire or rope at the rear of the boom.

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Boom

MAL1310

3. Slowly pull the wire or rope guiding the extend chain over the push beam, around the extend chain sheave, under the push beam and stopping at the extend chain/retract chain clevis.

4. Remove wire or rope secured to extend chain.

5. Place chain clevis rod to one side of push beam.

6. Lift the push beam to gain access to the chain clevis at the rear of the third boom section.

7. Reaching inside rear of the boom at chain anchor bracket, install cotter pin and pin from extend chain clevis. Install cotter pin and pin from retract chain.

8. Lower the push beam. Center the chain clevis rod on the push beam.

9. Place extend chain rod through strong back and place strong back in place at the rear of the first boom section.

10. Install and torque strong back mounting bolts to 240-265 lb-ft (325-359 Nm).

11. Install extend/retract cylinder mounting pin and secure with retaining clips.

12. Install adjustment and lock nuts on chain clevis rod. Do not tighten at this time.

13. Uncap and connect the extend/retract cylinder hydraulic tubes to their appropriate locations.

14. Adjust the chain as needed. Refer to Section 3.8, “Boom Adjustments.”

15. Install the cover on the rear of the boom.

16. Properly connect the battery.

17. Close and secure the engine cover.

18. Remove Do Not Operate Tags from both ignition key switch and steering wheel.

3.7 PUSH BEAM—EXTEND/RETRACT CYLINDER REMOVAL/ INSTALLATION

CAUTION

The complete push beam - extend/retract cylinder assembly weighs over 1,200 lb (545 kg).

This section explains removal of push beam extend/ retract cylinder through front of boom assembly without removing or disassembling boom assembly.

3.7.1 Push Beam Extend/Retract

Cylinder Removal

1. Park machine on a hard, level surface, level machine, fully retract boom, level boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow system fluids to cool.

4. Remove cover from rear of first boom section.

3-16

5. Disconnect both tilt hoses (1) and both auxiliary hoses (not shown) from the hose retainer brackets (2) at the bottom front inside the boom. Plug the hose ends to prevent dirt and debris from entering the hydraulic system.

6. Remove both hose retainer brackets (2).

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Page 55

7. Loosen and remove the lock nut, adjustment nut (3)

MAL2670

G6-42A

G9-43A

G10-43A

MAL2660

G6-42A

G9-43A

G10-43A

MAL1290

and belleville washers (4) from the retract chain (5) at the bottom front of the first boom section.

Note: Note position of belleville washers for reassembly.

8. Secure a rope or wire to the retract chain (5).

Boom

Note: Disconnecting one or both extend/retract hydraulic tubes (9) may be required to gain access to the hose guide mounting bolts. After removing both hose guides, re-connect one or both extend/retract hydraulic tubes BEFORE proceeding.

10. Loosen and remove the tilt cylinder hose guide (10) and if equipped, the auxiliary hose guide from the rear of the third second section.

Note: The hose guide mounting bolts also hold the push pin beams in place.

11. Remove the left and right push beam pins (11).

12. Start the machine and SLOWLY extend the extend/ retract cylinder 1–2 ft (305–609 mm) or until the push beam assembly can be accessed through the front of the third boom section.

Note: Only the push beam extend/retract cylinder

9. Loosen and remove the lock nut, adjustment nut (6) and belleville washers (7) from the extend chain anchor (8) at the rear of the first boom section.

Note: Note position of belleville washer for reassembly.

assembly should move during this procedure.

NOTICE

The extend chain rod will move toward the front of boom. Do Not allow the rod to come into contact with the chain and/or chain roller.

13. Shut machine OFF.

14. Properly disconnect the battery.

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

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Boom

MY3930

MAL1290

15. Loosen and remove four bolts (12), guide bar (13) and chain retainer (14) from front of push beam.

16. Disconnect extend chain (15) from anchor rod (16) and lay flat on bottom of third boom section. Remove anchor rod (16) from front of boom.

Note: It may be necessary to lift the extend /retract cylinder through the access holes in the sides of the third boom section to remove the chain retainer (14).

20. Place a sling around push beam—extend/retract cylinder assembly. Lift and slowly pull push beam— extend/retract cylinder assembly approximately half way out the front of boom assembly.

21. Lower push beam onto a suitable support.

NOTICE

Guide the push beam extend/retract cylinder assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components.

22. Relocate sling or using two slings for better stability, balance push beam extend/retract cylinder assembly and slowly pull push beam extend/retract cylinder assembly out towards the front of boom assembly.

23. Lower the push beam extend/retract cylinder assembly onto suitable supports.

24. Remove the extend/retract cylinder as required.

3.7.2 Push Beam—Extend/Retract

Cylinder Installation

17. At rear of boom, remove both retaining clips (17) from extend/retract cylinder pin (18). Remove extend/retract cylinder pin from strong back (19).

18. Loosen and remove eight bolts (20) from the strong back (19).

19. Remove both extend/retract cylinder hydraulic tubes. Plug tube ends and cap the fittings to prevent dirt and debris from entering hydraulic system.

Remove strong back.

1. Clean and lubricate bottom and sides of third boom section where push beam guide bar travels.

2. Place a sling or using two slings for better stability, lift and slowly push the push beam—extend/retract cylinder assembly approximately half way into the front of the boom assembly.

3. Lower the push beam onto a suitable support.

4. Relocate the sling and slowly insert the push beam—extend/retract cylinder assembly into the

front of the boom assembly.

NOTICE

Guide the push beam extend/retract cylinder assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components.

5. Remove the plugs and caps from extend/retract cylinder hydraulic tubes. Install both extend/retract cylinder hydraulic tubes.

3-18

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

Page 57

6. Install the strong back (1) with the previously

MAL1290

MY3930

MAL1290

MAL2660

G6-42A

G9-43A

G10-43A

removed hardware (2) and torque as required.

7. Align the extend/retract cylinder bore with the strong back bores and install the extend/retract cylinder pin (3) and secure with the retaining clips (4).

8. Install anchor rod through front of boom assembly.

Boom

14. Install both push beam pins (10) being careful to align the pin mounting bolt holes.

Note: Disconnecting one or both extend/retract hydraulic tubes (11) may be required to gain access to the hose guide mounting bolts. After installing both hose guides, re-connect one or both extend/retract hydraulic tubes BEFORE preceding.

15. Install tilt cylinder hose guide (12) and auxiliary hose guide from rear of third second section.

9. Connect the extend chain (5) to the anchor rod (6).

10. Install the guide bar (7) and chain retainer (8) to the front of the push beam with the previously removed hardware (9).

11. Properly connect the battery.

12. Start the machine and SLOWLY retract the extend/ retract cylinder until the push beam assembly bores can be aligned with boom sections access bores.

13. Properly disconnect the battery.

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

Note: Note position of belleville washers for reassembly.

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Boom

MAL2670

G6-42A

G9-43A

G10-43A

MAL1310

MAL2561

16. Install the belleville washers (13) to the extend chain anchor (14) as previously removed at the rear of the first boom section.

17. Install adjustment and lock nut, (15) to extend chain anchor (14) at the rear of first boom section.

18. Remove the rope or wire from the retract chain (16).

19. Install the belleville washers (17) to the retract chain clevis (16) as previously removed at the bottom front of the first boom section.

20. Install adjustment and lock nut (18) to retract chain clevis (16) at bottom front of first boom section.

25. Adjust the chain as needed. Refer to Section 3.8, “Boom Adjustments.”

26. Install the cover on the rear of the boom.

27. Close and secure the engine cover.

28. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3.8 BOOM ADJUSTMENTS

3.8.1 Chain Tension Inspection—G6-42A

1. Park machine on level ground. Place transmission control lever in (N) NEUTRAL, engage parking brake and level boom.

2. Place a Do Not Operate Tag on both ignition key switch and steering wheel.

3. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract the boom. Verify boom is level.

4. Measure the following three dimensions; A, B & C.

Note: Note position of belleville washer for reassembly.

21. Install both hose retainer brackets (19).

22. Remove the plugs and caps from the tilt hoses and auxiliary hoses.

23. Connect both tilt hoses (20) and both auxiliary hoses (not shown) to the hose retainer brackets (19) at the bottom front inside the boom.

24. Properly connect the battery.

5. At the boom head, verify dimension “A” is between

11.500-11.812 in (292,1-300,0 mm).

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Page 59

Boom

MAL2601

MAL2611

MAL2571

MAL2551

3.8.2 Chain Tension Adjustment—G6-42A

6. At the bottom front of the boom, verify dimension “B”

0.712-0.725 in (18,1-18,4 mm) of the washer stack on the retract chain clevis.

7. At the back of the boom, verify dimension “C” is not less than 2.850 in (72,4 mm) on the extend chain clevis.

Note: Belleville washers are shown in the uncompressed state.

8. Boom adjustment will be required if the above dimensions are not met.

1. Remove the extend chain lock nut (1) and loosen adjustment nut (2) until the belleville washers (3) are free to turn on the extend rod.

2. Verify the belleville washers (3) are in the correct order as shown. Remove the extend chain adjustment nut (2) and correct if required.

3. Remove lock nut (4) from retract chain clevis (5).

4. Set the retract chain adjustment nut face (6) flush with the end of the retract clevis.

5. Verify the belleville washers (7) are in the correct order as shown. Remove the retract chain adjustment nut (6) and correct if required.

Note: Belleville washers are shown in the un-compressed state.

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

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Boom

MAL2561

MAL2571

MAL2551

6. If dimension “A” is greater than 11.625 in (295,2 mm), push the third section boom IN until dimension “A” is less than 11.625 in (295,2 mm).

9. Tighten the retract chain adjustment nut (6) until the belleville washers (7) become fully compressed to dimension “B” 0.712-0.725 in (18,1-18,4 mm). Do Not Overtighten.

10. Install and temporarily tighten the retract chain lock nut (4).

11. Start the machine and at low idle, fully extend and retract the boom three times. Verify boom is fully retracted and level. Shut machine Off.

12. Recheck the Belleville washers (7) to verify they are fully compressed to dimension “B” 0.712-0.725 in (18,1-18,4 mm). If required, re-tighten the retract chain adjustment nut (6) until dimension “B” is obtained.

7. With dimension “A” less than 11.625 in (295,2 mm), verify the extend rod Belleville washers (3) and the retract chain Belleville washers are loose. Tighten the extend chain rod adjusting nut (2) until dimension “A” is 12.063-12.188 in (306,4-309,5 mm).

8. Install and temporarily tighten the extend chain lock nut (1).

Note: If dimension “B” requires adjustment, continue to step 13. If dimension “B” does NOT require adjustment, continue to step 14.

13. Start the machine and at low idle, fully extend and retract the boom three times. Verify boom is fully retracted and level. Shut machine Off.

14. Verify dimension “A” 11.500-11.812 in (292,1- 300,0 mm). Verify dimension “C” is not less than 2.850 in (72,4 mm).

Note: Re-adjust boom if dimensions “A” & “C” are not met. Contact the local JLG Distributor if the procedure cannot be obtained.

15. Loosen the retract chain lock nut and the extend

chain lock nut and apply Loctite

242TM.

16. Torque each retract chain lock nut (4) and extend chain lock nut (1) without adding any additional spring load. Torque each lock nut to 100 lb-ft (135 Nm).

3-22

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Page 61

3.8.3 Chain Tension Inspection—

MAL2740

MAL2621

MAL2630

MAL2580

G9-43A/G10-43A

1. Park machine on level ground. Place transmission control lever in (N) NEUTRAL, engage parking brake and level boom.

2. Place a Do Not Operate Tag on both ignition key switch and steering wheel.

3. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract the boom. Verify boom is level.

4. Measure the following three dimensions; A, B & C.

Boom

7. At the back of the boom, verify dimension “C”

3.069 in (77,9 mm) on the extend chain clevis.

Note: Belleville washers are shown in the un-compressed state.

8. Boom adjustment will be required if the above dimensions are not met.

5. At the boom head, verify dimension “A” is between

17.000-17.312 in (421,8-439,7 mm).

3.8.4 Chain Tension Adjustment— G9-43A/G10-43A

1. Remove extend chain lock nut (1) and loosen adjustment nut (2) until belleville washers (3) are free to turn on extend rod.

2. Verify the belleville washers (3) are in the correct order as shown. Remove the extend chain adjustment nut (2) and correct if required.

6. At the bottom front of the boom, verify dimension “B” is 1.500-1.512 in (38,1-38,4 mm) of the washer stack on the retract chain clevis.

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

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Page 62

Boom

MAL2591

MAL2740

MAL2580

MAL2591

3. Remove lock nut (4) from retract chain clevis (5).

4. Set the retract chain adjustment nut face (6) flush with the end of the retract clevis.

5. Verify the belleville washers (7) are in the correct order as shown. Remove the retract chain adjustment nut (6) and correct if required.

Note: Belleville washers are shown in the un-compressed state.

6. If dimension “A” is greater than 17.000 in (421,8 mm), push the third section boom IN until dimension “A” is less than 17.000 in (421,8 mm).

7. With dimension “A” less than 17.000 in (421,8 mm), verify the extend rod Belleville washers and retract chain Belleville washers are loose. Tighten the extend chain rod adjusting nut (2) until dimension “A” is 17.438-17.562 in (443,0-446,1 mm).

8. Install and temporarily tighten the extend chain lock nut (1).

9. Tighten the retract chain adjustment nut (6) until the belleville washers (7) become fully compress to distance of “B” 1.500-1.512 in (38,1- 38,4 mm). Do Not Overtighten.

10. Install and temporarily tighten the retract chain lock nut (4).

11. Start the machine and at low idle, fully extend and retract the boom three times. Verify boom is fully retracted and level. Shut machine Off.

12. Recheck the Belleville washers (7) to verify they are fully compressed to dimension “B” 1.500-1.512 in (38,1- 38,4 mm). If required, re-tighten the retract chain adjustment nut (6) until dimension “B” is obtained.

3-24

Note: If dimension “B” requires adjustment, continue to step 13. If dimension “B” does NOT require adjustment, continue to step 14.

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

Page 63

Boom

MY7390

13. Start the machine and at low idle, fully extend and retract the boom three times. Verify boom is fully retracted and level. Shut machine Off.

14. Verify dimension “A” 17.000-17.312 in (421,8-439,7 mm). Verify dimension “C” is not less than 3.069 in (77,9 mm).

Note: Re-adjust boom if dimensions “A” & “C” are not met. Contact the local JLG Distributor if the procedure cannot be obtained.

15. Loosen the retract chain lock nut and the extend

chain lock nut and apply Loctite

242TM.

16. Torque the retract chain lock nut (5) and extend chain lock nut (1) without adding any additional spring load. Torque each lock nut to 100 lb-ft (135 Nm).

3.9 QUICK SWITCH ASSEMBLY

3.9.1 Hydraulic Quick Switch Removal

5. Remove lock bolt (8) holding tilt cylinder rod end pin (9) to quick switch assembly (10). Remove tilt cylinder rod end pin.

6. Support quick switch assembly (10). Remove capscrew (11) and locknut (12) securing head pin (13) to boom head (14).

7. Remove the head pin (13) and the quick switch assembly (10)

8. Inspect 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 pin must be replaced.Hydraulic Quick Switch Installation

1. Assemble quick switch assembly (10) to boom head (14). Line up quick switch between mounts on boom head. The quick switch should be centered in the boom head.

2. Coat head pin (13) with an anti-seize compound. Insert head pin through quick switch and boom head. Secure with capscrew (11) and locknut (12).

3. Align quick switch with tilt cylinder rod end and insert tilt cylinder rod end pin (9). Align tilt cylinder rod end pin and screw in locking bolt (8). Torque as required.

4. Uncap and install hydraulic hoses (17) to proper fittings on quick switch assembly (10). torque as required.

5. Secure hoses (17) to cylinder cover (15) with clamp hardware (16).

6. Reinstall cylinder cover (15) with the hardware removed earlier.

1. Remove hardware securing cylinder cover (15) and remove cylinder cover.

2. Remove clamp hardware (16) securing cylinder cover to hydraulic hoses (17).

3. Label and disconnect hydraulic hoses (17) attached to quick switch assembly (10). Drain fluid into suitable container.

4. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

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

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Boom

MY5090

Ma2070

MAM1390

3.9.2 Quick Switch Removal

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.

3.9.3 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.

3.10 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear pads with metal inserts.

A total of 30 wear pads are installed on the boom sections of the G6-42A, G9-43A and G10-43A machines.

3.10.1 Wear Pad Inspection

Inspect all wear pads for wear. If angle indicators (1) on ends of wear pads are visible, 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.

3.10.2 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:

1. Wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Loctite mounting bolts.

2. Apply Loctite

242™ to all wear pad mounting bolts.

242™ and installing

3-26

3. A spacer (2) with holes must be used before any shim (3) is used.

4. A shim (3) must be inserted between spacer (2) and wear pad support plate, block or boom section (4).

5. The number of shims can vary at each shim point.

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

Page 65

Boom

MY5510

MY3620

6. The bottom wear pads must be shimmed equally on each side.

7. Maintain a total boom section clearance (5) of

0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and vertical directions.

3.10.3 Boom Section Wear Pad Pathway Lubrication:

1. Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease.

2. Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.

8. The length of the wear pad bolt depends on the number of shims, spacers and washers being used.

9. The thickness of each threaded wear pad insert is

0.312 in (7,92 mm)(A).

10. 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).

11. Bolt thread engagement in the wear pad insert should be 0.275 ± 0.040 in (6,98 ± 1,0 mm).

12. 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.

13. Use only one hardened washer if mounting bolts are recessed.

14. 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)

15. Torque wear pad bolts after shimming is completed.

16. Lubricate the face and pockets of each wear pad after being installed.

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

3-27

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Boom

3.11 BOOM EXTEND AND RETRACT CHAINS

3.11.1 Boom Chain Inspection

WARNING

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 extend/ retract chains will 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.

Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain.

• 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.

3.11.2 Expose Chains for Inspection

The extend/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 extend/retract chains are damaged, the chains should be removed and inspected. Refer to Section 3.6, “Extend/Retract Chain Removal/ Installation,” for detailed information. Replace chains if necessary.

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.

• Abrasives—Accelerated wearing and scoring of the articulating members of the chain (pins and 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.

3-28

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

Page 67

Boom

MZ1463

MY1360

MZ1466

MZ1465

3.11.3 Inspection Guidelines

Edge Wear

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 chain in section that moves over sheaves because it receives most frequent articulation. Measuring chain near its clevis terminals could give an inaccurate reading. Ends of chains, near clevis terminal, will not have flexed as frequently, if at all, as the middle of chains.

It is best to measure in 12 pin increments from pin center to pin center. For example, if links are one inch from pin center to pin center, distance should be 12 in (305 mm). If links are 3/4 in (9,5 mm) apart, distance after 12 pins should be 9 in (229 mm).

Distorted or Battered Link Plates

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

Examine pin head rivets to determine if “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 chain by welding or driving pin(s) back into 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.

If distance measured (3) is 3% greater than normal length (4), discard and replace chain.

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

3-29

Page 68

Boom

MZ1467

MZ1468

MZ1469

MZ1470

MZ1471

Cracked Plates

Inspect 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.

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:

• Fatigue Cracking—

Fatigue cracks (9) are a result of repeated cyclic loading beyond the chain’s endurance limit.

• Stress Corrosion

Cracking—The

outside link plates are particularly susceptible to stress corrosion cracking (10).

• 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 caused by overloads far in excess of the design load. Either fractured plates (1) or enlarged holes (2) can occur. If either of these failures occurs, the chain should be replaced immediately.

3.11.4 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated. Refer to Section 2.5, “Fluid and Lubricant Capacities.”

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.

Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist, a local JLG Distributor or the vehicle distributor be consulted for guidance.

•Tight Joints —All joints in the chain should flex freely. Tight joints (3) 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.

3-30

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

Page 69

Boom

MH6460

3.12 FORKS

3.13 EMERGENCY BOOM LOWERING PROCEDURE

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

To avoid instability of the machine, the extend/retract cylinder MUST BE fully retracted prior to retracting the lift cylinder. If circumstances prevent retraction of the extend/retract cylinder first, lower the lift cylinder the minimum amount necessary and resume retraction of the extend/retract cylinder as soon as possible in accordance with the machines load chart.

WARNING

Properly support the boom before attempting to proceed with the emergency boom lowering procedure.

WARNING

If possible, safely remove and/or secure the load on the machine before starting the boom lowering

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 local JLG Distributor with fork part number to find manufactured dimensions of fork blade.

4. Ensure the fork length (10) is adequate for the intended loads.

5. Fork markings should be legible, re-stamp if needed.

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).

procedure. If load cannot be removed, the machine load chart MUST be followed.

3.13.1 Equipment and Supplies Required

Auxiliary Hydraulic Power Supply:

• Portable hydraulic unit or another machine with an auxiliary hydraulic power supply with a capacity to hold up to 22 gal (83 L) of hydraulic oil from the machine during lowering process.

Note: If another machine is being used, the hydraulic reservoir must be drained to accept a minimum of 22 gal (83 L) of hydraulic oil before attempting this procedure.

• Standard Mechanic Tools.

NOTICE

EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply hydraulic oil must be compatible with hydraulic oil shown in Section 2.4, “Fluids and Lubricant Capacities.”

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

3-31

Page 70

Boom

MY8630

MY8620

G6-42A

G9-43A

G10-43A

Hoses:

• Two Hydraulic Hoses - Approximately 10 ft (3,0 m) each, with a minimum I.D. of

0.375 in (9,5 mm) and a minimum rating of 4000 psi (275,8 bar).

G6-42A - Fittings:

• Two -10 ORFS Caps

• Two -10 ORFS Plugs

Adaptors:

• Two -10 ORFS 90° Adaptors

G9-43A or G10-43A - Fittings:

• Two -12 ORFS Caps

• Two -12 ORFS Plugs

Adaptors:

• Two -12 ORFS 90° Adaptors

Note: The adaptor size may vary depending on the hose ends of the auxiliary hydraulic power supply.

3.13.2 Lowering Procedure

a. Retract the boom as follows:

1. If equipped with Personal Work Platform, rescue occupants prior to performing procedure.

2. Properly support the boom before attempting to proceed with the emergency boom lowering procedure.

3. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

4. Properly support the boom as required.

5. Place a suitable receptacle under the tube/hose connections.

6. Remove the plastic cover from the main control valve.

Loss of hydraulic oil is limited to the amount trapped within each tube/hose. Slowly loosen each hydraulic

WARNING

tube/hose fitting to release any possible hydraulic oil pressure that may be trapped between the main control valve and the counterbalance valve of the extend/retract cylinder or the lift/lower cylinder.

7. If access is required, loosen and remove any clamps securing the lift/lower cylinder (1 & 2) and extend/ retract cylinder tubes (3 & 4) to the frame.

8. Disconnect the extend/retract cylinder tubes from the extend/retract cylinder hoses (3 & 4). Install caps or plugs in tubes to prevent fluid loss and to keep dirt and debris from entering the hydraulic system.

3-32

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

Page 71

9. Using the hoses and fittings specified, connect the hoses between the auxiliary hydraulic power supply and the extend/retract hoses of the affected machine. Retract hose (3) is the supply and extend hose (4) is the return. Connect the hoses in the proper order to ensure that the cylinder is retracted, not extended.

10. Remove the previously installed boom support.

11. Use the auxiliary power supply to slowly retract the extend/retract cylinder.

12. Properly support the boom as required.

13. Loosen and remove the jumper hoses, caps, plugs and reconnect the extend/retract cylinder hoses. Torque as required.

b. Lower the boom as follows:

1. Place a suitable receptacle under the tube/hose connections.

2. Disconnect the lift/lower cylinder hoses from the lift/ lower cylinder tubes (1 & 2). Install caps or plugs in tubes to prevent fluid loss and to keep dirt and debris from entering the hydraulic system.

3. Using the hoses and fittings specified, connect the hoses between the auxiliary hydraulic power supply and the lift/lower hoses of the affected machine. Lift hose (1) is the return and lower hose (2) is the supply. Connect the hoses in the proper order to ensure that the boom is lowered, not raised.

4. Remove the previously installed boom support.

5. Use the auxiliary power supply to slowly lower the boom.

6. Loosen and remove the jumper hoses, caps, plugs and reconnect the lift/lower cylinder hoses.

7. Install the previously remove clamps securing the lift/ lower cylinder and the extend/retract tubes. Torque as required.

8. Install the plastic cover over the main control valve.

9. Transfer any hydraulic oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

10. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

11. Remove the Do Not Operate Tag on both the ignition key switch and steering wheel.

Boom

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

3-33

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Boom

3.14 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during operation of the boom.

Problem Cause Remedy

1. Boom will not extend or retract.

2. Boom shifts to right or left when extending.

3. Excessive boom pivot pin noise and/or wear.

4. Excessive Compensation cylinder pivot pin noise and/ or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bearing(s). 2. Replace bearing(s) and

1. Insufficient lubrication. 1. Lubricate at regular intervals.

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

8.8, “Hydraulic Cylinders.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.10, “Boom Wear Pads.”

Refer to Section 2.7, “Lubrication Schedule.” Replace worn pins as needed.

lubricate at regular intervals. Refer to Section 2.7, “Lubrication Schedule.”

Refer to Section 2.7, “Lubrication Schedule.” Replace worn pins as needed.

3-34

2. Worn bushing(s). 2. Replace bushing(s) and lubricate at regular intervals.

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

Page 73

Problem Cause Remedy

Boom

5. Drooping chain, or jerky boom extend or retract functions.

6. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes

1. Chain(s) tension not properly adjusted.

2. Chain(s) stretched or binding. 2. Replace chains as needed.

3. Wear pads loose, contaminated, excessively worn or damaged.

4. Contaminated, corroded or rusted wear pad sliding surfaces.

5. Extend/Retract hydraulic system not operating properly.

6. Damaged boom section. 6. Replace the damaged boom

and/or connection leaks.

1. Adjust chain(s).

Refer to Section 3.8, “Boom Adjustments.”

3. Replace wear pad. Refer to Section 3.10, “Boom Wear Pads.”

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. Refer to Section 8.4, “Hydraulic Circuits.”

section. Refer to Section 3.3, “Boom Assembly Maintenance.”

1. Locate break, replace hose(s) or tube(s), tighten connections.

7. Excessive Lift/Lower cylinder pivot pin noise and/or wear.

2. Lift/lower hydraulic system not operating properly.

3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

4. Seized boom pivot pin bearing. 4. Replace bearing.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

2. Refer to Section 8.4, “Hydraulic Circuits.”

8.8.1, “General Cylinder Removal Instructions.”

Refer to Section 2.6, “Service and Maintenance Schedule.” Replace worn pins as needed. Refer to Section 8.8.1, “General Cylinder Removal Instructions.”

lubricate at regular intervals. Refer to Section 2.7, “Lubrication Schedule.”

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

3-35

Page 74

Boom

Problem Cause Remedy

8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and

correct as needed. Refer to Section 3.10, “Boom Wear Pads.”

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

9. Auxiliary hydraulics will not operate.

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer

1. Auxiliary hydraulic system not operating properly.

2. Chain sheave(s) not properly lubricated.

3. Chain sheave(s) not rotating freely.

2. Reduce cycle times.

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. Clean equipment frequently.

1. Refer to Section 8.4, “Hydraulic Circuits.”

to Section 3.8, “Boom Adjustments.”—Replace chains as needed.

2. Lubricate chain sheave. (Refer to Section 2.6, “Service and Maintenance Schedule.”

3. Lubricate chain sheave. Refer to Section 2.6, “Service and Maintenance Schedule.” Repair or replace chain sheave(s) as needed.

3-36

4. Improper chain lubrication. 4. Lubricate at regular intervals. Refer to Section 2.6, “Service and Maintenance Schedule.” Replace chains as needed.

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

Page 75

1.50

2.1875

4.0

MY4100

1.50

2.0

2.50

3.0

0.250

5.00

3.125

0.50 0.875

0.1875

7.00

6.875

Tube I.D. 1.3125in - O.D. 2.0in

1.3125

2.0

ALL WELDS SHALL CONFORMTO AWS D1.1

Temporary Extend Chain Bracket

Temporary Retract Chain Bracket

5.00

3.125

0.50 0.875

0.1875

1.0

0.50

3.0

Drill 0.3125 Thru

2.0

1.50

1/4

SEE NOTE A

NOTE A:WELD FROM X-Y ONLY

3/16

A36 STEEL RECOMMENDED

ALL DIMENSIONS ARE IN INCHES

3.15 PUSH BEAM TEMPORARY BRACKETS

Note: The drawings below are only suggested and can be subject to individual interpretation.

Boom

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

3-37

Page 76

Boom

This Page Intentionally Left Blank

3-38

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

Page 77

Section 4

Cab and Covers

Contents

PARAGR APH TITLE PAGE

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.1 General Overview—G6-42A/G9-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.2 General Overview—G10-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.1 Steering Column and Orbitrol Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.3 Accelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.4 Boom Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and (G10-43A) Outrigger

Joysticks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.3.7 Heater/Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . 4-8

4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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

4-1

Page 78

Cab and Covers

MY7700

TRANSMISSION

CONTROL LEVER

INSTRUMENT PANEL

STEERING WHEEL

FRAME LEVEL

INDICATOR

BOOM CONTROL

JOYSTICK

FRAME LEVEL JOYSTICK

AND ATTACHMENT TILT

(IF EQUIPPED)

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

IGNITION

SWITCH

ACCESSORY

CONTROL LEVER

(IF EQUIPPED)

AUXILIARY

HYDRAULIC

JOYSTICK

(G6-42A)

AUXILARY

HYDRAULIC

JOYSTICK

(G9-43A)

RIGHT HAND

PANEL

DECOMPRESSION VALVE

(G9-43A IF EQUIPPED)

4.1 OPERATOR 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.

4.1.1 General Overview—G6-42A/G9-43A

4-2

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

Page 79

4.1.2 General Overview—G10-43A

MY7710

TRANSMISSION

CONTROL LEVER

INSTRUMENT

PANEL

STEERING WHEEL

FRAME LEVEL

INDICATOR

BOOM CONTROL

JOYSTICK

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

IGNITION

SWITCH

ACCESSORY

CONTROL

LEVER

OUTRIGGER

JOYSTICKs

FRAME LEVEL

JOYSTICK

(IF EQUIPPED

RIGHT HAND

PANEL

AUXILIARY

HYDRAULIC

JOYSTICK

DECOMPRESSION

VALV E

Cab and Covers

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

4-3

Page 80

Cab and Covers

MAL1430

WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

4.2 OPERATOR CAB

4.2.1 Cab Safety

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.

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

a. Orbitrol Valve Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open 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 9.12.1, “Gauges.”

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 the Operation & Safety Manual.

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 left side of cab, behind seat. Information specified on serial number plate includes cab model number, cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

5. Label, disconnect and cap four hoses from side of steering valve (1). Cap fittings on steering valve. Label, disconnect and plug load sense hose at front of steering valve. Cap fitting on steering valve.

6. Remove the steering wheel (2).

7. Disconnect and remove the transmission control lever (3).

8. Remove the steering assembly through dash panel opening.

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9. Support the steering valve, and remove the four hex-head capscrews and four lockwashers (4).

Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective.

b. Orbitrol Valve Installation

1. Secure steering valve to steering column with four hex-flange capscrews and four lockwashers.

2. Install steering column through dash panel opening. Position steering valve to its original orientation in the cab.

3. Install 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.

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.

4.3.2 Service Brake Pedal

a. Brake Valve Removal

Refer to Section 8.7.2, “Service Brake Valve,” for removal information.

b. Brake Valve Installation

Refer to Section 8.7.2, “Service Brake Valve,” for installation information.

c. Service Brake Pedal Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

Note: If necessary, install the main dash panel. Refer to Section 9.11, “Display Gauge and Dash Switches.”

7. Properly connect the battery.

8. Carefully examine all connections one last time before engine start-up. Rectify any faulty conditions.

9. Start engine and check operation of steering system. Check for hydraulic fluid leaks. Check hydraulic fluid level in tank and add fluid as required.

10. Close and secure the engine cover.

11. Remove Do Not Operate Tags from both ignition key switch and steering wheel.

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.”

5. Remove the bolt and lockwasher (1) securing the service brake pedal pivot pin (2).

6. Pull pivot pin from service brake pedal bracket (3).

7. Remove service brake pedal from cab.

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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.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.3 Accelerator Pedal

a. Accelerator Pedal Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

Accelerator Pedal Installation

1. Position the accelerator pedal in its mounting location within the cab.

2. Secure accelerator pedal into position with pivot pin.

3. Install pedal ball joint to accelerator pedal.

4. Properly connect the battery.

5. Verify proper accelerator pedal operation.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

5. Disconnect the electrical harness connector (8).

6. Remove the bolts (9) securing the accelerator pedal to accelerator pedal bracket (10).

7. Remove accelerator pedal assembly from cab.

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(If Equipped)

MY8120

MY8130

(If Equipped)

4.3.4 Boom Joystick Assembly

a. Joystick Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and (G10-43A) Outrigger Joysticks

a. Joystick Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Lift joystick’s rubber sleeve (11), remove bolts securing boom joystick to cab.

6. Lift joystick from its mounting position.

7. Label, disconnect and cap hydraulic hoses attached to boom joystick.

8. Disconnect electrical connectors.

9. Remove the joystick.

b. Joystick Installation

1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations.

2. Connect the electrical connectors.

3. Install the bolts securing the joystick to the cab.

4. Properly connect the battery.

5. Test the complete range of joystick functions per control decals in cab or appropriate Operator and Safety Manual.

Note: Check the controls of the auxiliary attachments. See the appropriate Operation & Safety Manual for an approved list of attachments and control instructions.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the

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ignition key switch and the steering wheel.

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5. Remove knob on end of joystick (12) if necessary.

6. Remove screws (13) securing dash panel to cab. Remove dash panel.

7. Remove any hardware securing joystick to cab.

8. Label, disconnect and cap hydraulic fittings or cable(s) attached to joystick.

9. Remove joystick from cab.

b. Joystick Installation

1. Uncap and connect previously labeled hydraulic hoses or cable(s) to their appropriate locations.

2. Install bolts securing joystick to cab.

3. Install dash panel to its original position with previously used hardware.

4. Install joystick knob (if necessary).

5. Properly connect battery.

6. Test the complete range of joystick functions per control decals in cab or appropriate Operator and Safety Manual.

Note: Check the controls of the auxiliary attachments. See the appropriate Operation & Safety Manual for an approved list of attachments and control instructions.

7. Close and secure the engine cover.

8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.7 Heater/Air Conditioning System (if equipped)

a. Heater Assembly Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL position, engage parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Slowly turn surge tank cap to allow any pressure to escape. Remove surge tank cap.

6. Place a suitable container beneath radiator drain.

7. 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.

8. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.

9. Tighten the radiator drain petcock.

10. Remove the bolts that secure the seat to the cab. Remove the seat.

4.3.6 Windshield Wiper Assembly

Refer to Section 9.8, “Window Wiper/Washer Windshield Wiper Motor,” for removal and installation information.

4-8

11. Remove the bolts securing the front plate (14) to the seat riser weldment (15).

12. Remove the bolts securing the seat riser weldment to the cab. Remove the riser weldment.

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13. Loosen the hose clamps, label and disconnect the

MY0200

heater hoses (16). Cap or plug the hoses to prevent debris from entering the heater system.

14. Label and disconnect any electrical connections.

15. Remove the bolts securing the heater assembly to the cab. Remove the heater assembly.

Cab and Covers

b. Heater Assembly Installation

1. Position the heater assembly to its original orientation in the cab. Secure with the previous hardware.

2. Connect the previously labeled electrical connections.

3. Connect the previously labeled heater hoses to their appropriate locations.

4. Install the seat riser weldment.

5. Install the front plate to the seat riser weldment.

6. Install the cab seat.

7. Fill the cooling system completely, allowing time for the coolant to fill the engine block. The cooling system fluid and capacity is listed in Section 2.5, “Fluid and Lubricant Capacities.”

8. Reinstall surge tank cap.

9. Properly connect the battery.

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.

10. Wait for engine to cool and check the coolant level. Add coolant as required to bring the coolant to the proper level.

11. Close and secure the engine cover.

12. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

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4.4 CAB REMOVAL

WARNING

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 machine on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level the machine, fully retract boom, lower boom, place travel select lever in (N) NEUTRAL position, engage park brake and shut 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 engine cover. Allow the system fluids to cool.

4. Properly disconnect 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.

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 cab heater hoses. Refer to Section

4.3.7, “Heater/Air Conditioning System (if equipped).”

9. Remove necessary dash panels to gain access to electrical wiring connections. Label and disconnect harnesses. Push harness connectors through the opening cab.

10. Remove boom joystick from is mounting position. Refer to Section 4.3.4, “Boom Joystick Assembly.” Label, disconnect and cap all hydraulic hoses attached to boom joystick. Cap all fittings and openings to keep dirt and debris from entering hydraulic system.

11. Remove frame level and attachment tilt and auxiliary control joystick. Refer to Section 4.3.5, “Frame Level, Attachment Tilt, Auxiliary Hydraulics and (G10-43A) Outrigger Joysticks.” Label, disconnect and cap all hydraulic hoses attached to the joystick. Cap all fittings and openings to keep dirt and debris from entering hydraulic system.

12. Label, disconnect and cap all hydraulic hoses attached to steering orbital valve. Cap all fittings and openings to keep dirt and debris from entering hydraulic system.

13. 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.

14. Push all hydraulic hoses through opening in cab.

15. Disconnect engine air filter and hydraulic oil reservoir breather from their brackets at top of cab.

16. Move air filter and breather clear from cab so they do not become damaged during cab removal.

17. Remove the fuel tank from the cab. Refer to Section

7.6.2, “Fuel Tank.”

18. Open Cab: Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) under the inner four braces (14) and behind the center cross support above the wind shield or install two lifting eye bolts (15) in the threaded holes on the roof of the cab above the B pillars (16).

19. Enclosed Cab: Install two lifting eye bolts (14) in threaded holes on roof of cab above B pillars (16).

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20. Remove two cab side-mount bolts in cab (17).

21. Remove the four cab-to-frame bolts, flat washers and nuts (18).

22. Remove the mirrors and all other cab components as needed, if not previously removed.

23. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

24. 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.

25. When cab is completely clear of machine, carefully lower it to ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter cab while it is being removed from the machine.

26. Inspect condition of fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

27. Inspect and replace machine parts that are exposed with cab removed. Repair or replace as required.

Cab and Covers

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.

2. Open Cab: Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) under the inner four braces (14) and behind the center cross support above the wind shield or install two lifting eye bolts (15) in the threaded holes on the roof of the cab above the B pillars (16).

3. Enclosed Cab: Install two lifting eye bolts (14) in threaded holes on roof of cab above B pillars (16).

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.

5. Readjust position of sling as needed to help balance cab during installation.

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6. Install the four cab-to-frame mount bolts, washers and nuts (18). Torque to 280-305 lb-ft (379-414 Nm).

7. Install the two cab side mount bolts washers and nuts (17). Torque to 680-720 lb-ft (922-976 Nm).

8. Install the engine air filter and hydraulic oil reservoir breather to their brackets at the top of the cab.

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.”

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 2.5, “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.

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.

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Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGR APH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5-2

5.1.1 G6-42A Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.1.2 G9-43A & G10-43A Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2 Axle Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 Axle Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.1 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.4.3 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-6

5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.6.1 Wheel and Tire Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.6.2 Wheel and Tire Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.8.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.8.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

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FRONT AXLE

ASSEMBLY

FRONT STEERING

CYLINDER

FRONT

DRIVE

SHAFT

REAR

DRIVE

SHAFT

REAR STEERING

CYLINDER

REAR AXLE

ASSEMBLY

TRANSMISSION

DROP BOX

FRONT AXLE

WHEEL HUBS (2)

REAR AXLE

WHEEL HUBS (2)

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

5.1.1 G6-42A Components

5-2

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5.1.2 G9-43A & G10-43A Components

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FRONT

DRIVE

SHAFT

REAR

DRIVE

SHAFT

REAR STEERING

CYLINDER

REAR AXLE

ASSEMBLY

TRANSMISSION

DROP BOX

FRONT AXLE

WHEEL HUBS (2)

REAR AXLE

WHEEL HUBS (2)

FRONT AXLE

ASSEMBLY

FRONT STEERING

CYLINDER

Axles, Drive Shafts, Wheels and Tires

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

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WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

5.2 AXLE SERIAL NUMBER

Front and rear axle serial number plate is located on a mounting pad on front side of center section of each axle. Information on serial number plate is required in correspondence regarding axle.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in the (N) NEUTRAL position, engage 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.

3. Open engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the optional fender assembly.

5.3 AXLE SPECIFICATIONS AND MAINTENANCE INFORMATION

For oil specifications and maintenance information, refer to Section 2, “General Information and Specifications.”

Detailed axle service instructions are provided in the following publications:

G6-42A

• Service Manual (P/N 31200162)

• Parts Manual (P/N 31200727)

G9-43A and G10-43A

• Service Manual (P/N 31200239)

• Parts Manual (P/N 31200727)

5.4 AXLE REPLACEMENT

5.4.1 Axle Removal

Front and rear axle assemblies differ in that front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; rear axle has neither. Following steps outline a typical axle removal procedure, suitable for either front or rear axle assembly.

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.

Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.

6. If axle will be disassembled after removal, place a suitable receptacle under axle (1) and wheel hubs drain plugs (2). Remove drain plugs and allow axle oil to drain into receptacle. Transfer used axle oil into a suitable covered container, and label 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.

8. Block front and rear of both tires on axle that is not being removed. Ensure that machine will remain in place during axle removal before proceeding.

9. Raise machine using a suitable jack or hoist. Place suitable supports under both sides of frame and lower machine onto supports. Ensure that 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.

11. Remove both wheel and tire assemblies from axle being removed. (Refer to Section 5.6.1, “Wheel and Tire Assembly Removal.”)

Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern “arrows” facing in the direction of forward travel.

12. Remove the drive shaft assembly. Refer to Section

5.5.3, “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 bolts and locknuts securing axle to frame.

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LEVEL

15. Remove axles from machine using jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb machine while removing axle. Balance axle and prevent it from tipping, turning or falling while removing it from beneath machine. Place axle on a suitable support or holding stand.

5.4.2 Axle Installation

1. Before proceeding, ensure that machine will remain in place during axle installation. Block front and rear of both tires on the axle that is already installed on the machine.

2. If applicable, raise machine using a suitable jack or hoist. Place suitable supports beneath frame and lower machine onto supports, allowing enough room for axle installation. Ensure that machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove axle from its support or holding stand. Balance axle and prevent it from tipping, turning or falling while positioning it beneath machine. DO NOT raise or otherwise disturb machine while installing axle. Keep axle supported and balanced on jack, hoist or overhead crane and sling throughout the installation procedure.

4. Position axle under frame, and align axle housings with holes in frame.

5. Install four axle bolts and nuts. Tighten and torque to 530-565 lb-ft (718-766 Nm).

6. Move cylinder into position on axle cylinder anchor. Insert a cylinder-mount pin through cylinder and cylinder anchor. Secure the cylinder-mount 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

5.5.5, “Drive Shaft Installation.”)

9. If reinstalling an axle previously removed from the machine, position driveshaft yoke on axle according to alignment marks made earlier. If installing a new axle, note position of driveshaft yoke at transmission. Align driveshaft yoke on axle in same plane as yoke on transmission.

10. Tighten axle oil drain plug, loosen and remove axle oil fill plug (1). (Refer to Section 2.5, “Fluids and Lubricant Capacities,” for proper oil and capacities.

11. Rotate wheel hubs 90 degrees so drain plug (2) becomes fill plug (3). Refer to Section 2.5, “Fluid and Lubricant Capacities,” for proper oil and capacities.

12. Install the wheel and tire assemblies. Refer to Section 5.6.2, “Wheel and Tire Assembly Installation.”

13. Carefully remove jack, hoist or overhead crane and sling supporting the axle.

14. Carefully raise machine using a suitable jack or hoist. Remove supports from beneath frame and lower the machine to ground.

15. Remove blocks from front and rear of both tires on 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 engine. Turn 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.

Note: The service brake and parking brake circuits will need to bled after axle installation. Refer to Section

8.7.4, “Service Brake Bleeding.”

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Axles, Drive Shafts, Wheels and Tires

5.4.3 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

2. Intermittent noise when traveling.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section

2.5, “Fluid and Lubricant Capacities,”

2. Axle and/or wheel end housings filled with incorrect oil or oil level low.

3. Incorrect alignment of ring and pinion gears.

4. Incorrect pinion (input) shaft bearing preload.

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

8. Axle housing damaged. 8. Replace damaged parts.

1. Universal joint(s) worn or damaged. 1. Repair or replace universal joints

2. Drain axle and/or wheel end housings and fill to correct level with hydraulic oil. Refer to Section 2.5, “Fluid and

Lubricant Capacities,”

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by adding or removing shims as needed.

and fill to correct level with hydraulic oil. Refer to Section 2.5, “Fluid and

Lubricant Capacities,”

as needed.

3. Vibration or intermittent noise when traveling.

2. Differential ring and/or pinion gears damaged.

1. Drive shaft universal joint assembly(ies) incorrectly tightened.

2. Drive shaft universal joint(s) worn or damaged.

3. Drive shaft(s) damaged/unbalanced. 3. Replace drive shaft(s) as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

2. Repair or replace universal joints as needed.

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Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

5. Oil leaking from wheel end housing (planet carrier).

1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

3. Replace seal and/or joint coupling fork shaft (axle shaft).

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. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm).

7. Replace housing(s) as needed.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

2. Replace o-ring.

6. Oil leaking from steering cylinder.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

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.

3. Piston rod seal worn or damaged. 3. Replace piston rod seal.

4. Cylinder tube damaged. 4. Replace cylinder tube.

3. Replace seal and/or fork joint shaft.

41 lb-ft (55 Nm).

2. Replace o-rings and seals.

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Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with hydraulic oil.

Refer to Section 2.5, “Fluid and Lubricant Capacities,”

8. High steering effort required.

9. Slow steering response.

10. Excessive noise when brakes are engaged.

11. Brakes will not engage.

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

3. Dragging park brake. 3. Adjust park brake cable as needed.

1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

3. Worn or damaged swivel bearings. 3. Replace swivel bearings as needed.

1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally. 2. Repair or replace steering cylinder

1. Brake discs worn. 1. Check brake discs for wear. Refer to

2. Brake discs damaged. 2. Replace brake discs.

1. Brake (hydraulic) system not operating properly.

2. Drain axle and fill to correct level with hydraulic oil. Refer to Section 2.5, “Fluid

and Lubricant Capacities,”

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Correct bearing preload by adding or removing shims as needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

as needed.

Section 5.7, “Brakes.”

1. Refer to Section 8.4, “Hydraulic Circuits.”

12. Brakes will not hold the machine or braking power reduced.

5-8

2. Brake piston o-rings and seals damaged (leaking).

1. Brake discs worn. 1. Check brake discs for wear. Refer to

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

2. Replace o-rings and seals.

Section 2.5, “Fluid and Lubricant Capacities,”

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Replace o-rings and seals.

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Axles, Drive Shafts, Wheels and Tires

MY8140

5.5 DRIVE SHAFTS

5.5.1 Drive Shaft Inspection and Service

Inspect areas where drive shaft flange yokes and slip yokes mount to 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.

Note: To help ensure optimum performance, drive shaft assemblies are specially balanced as a unit at 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.

Note: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.

5.5.2 Drive Shaft Maintenance

Refer to Section 2.5, “Fluids and Lubricant Capacities,” for information regarding lubrication of drive shafts.

5.5.3 Drive Shaft Removal

1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission control lever in (N) NEUTRAL, engage park brake and shut engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open 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 yoke and axle, transmission and shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of drive shaft must be in same plane to help prevent excessive vibration.

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

7. Remove four bolts and two straps (1) securing bearing cross to the transmission output shaft flange. Discard bolts.

8. Remove four bolts and two straps (2) securing bearing crosses to the axle. Discard bolts.

9. Remove front drive shaft assembly (3).

10. Remove four bolts and two straps (4) securing bearing cross to transmission output shaft flange. Discard bolts.

11. Remove four bolts and two straps (5) securing bearing cross to rear axle. Discard bolts.

12. Remove rear drive shaft assembly (6).

5.5.4 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.

5.5.5 Drive Shaft Installation

1. Raise drive shaft assembly into position. Slip-yoke end of drive shaft mounts toward axle. If reinstalling a drive shaft previously removed, align flange yokes according to 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

3. Install two straps and four new bolts (1) securing front axle (3) bearing crosses to transmission. Torque bolts to 55-60 lb-ft (75-81 Nm).

243TM to all mounting bolts.

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Axles, Drive Shafts, Wheels and Tires

4. Install two straps and four new bolts (2) securing front axle (3) bearing crosses to axle. Torque bolts to 55-60 lb-ft (75-81 Nm).

5. Install two straps and four new bolts (7) securing rear axle (9) bearing crosses to axle. Torque bolts to 55-60 lb-ft (75-81 Nm).

6. Install previously removed bolts, nuts and washers (8) and secure the carrier bearing to frame. Torque to 55 lb-ft (75 Nm).

7. Install two straps and four new bolts (4) securing the rear axle (6) bearing crosses to the transmission. Torque bolts to 55-60 lb-ft (75-81 Nm).

8. Install two straps and four new bolts (4) securing the rear axle (6) bearing crosses to the rear axle (9) at the carrier bearing. Torque bolts to 55-60 lb-ft (75-81 Nm).

9. Properly connect the battery.

10. Close and secure the engine cover.

11. Unblock the wheels.

12. Remove Do Not Operate Tags from both ignition key switch and steering wheel.

5.6 WHEELS AND TIRES

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 same size, ply and brand as originally installed. Refer to 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.

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5.6.1 Wheel and Tire Assembly Removal

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.

3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

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4. Place a suitable jack under axle pad closest to wheel

MY4190

MY4200

being removed. Raise machine and position a suitable support beneath 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 wheel and tire assembly from machine.

5.6.2 Wheel and Tire Assembly Installation

Axles, Drive Shafts, Wheels and Tires

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.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

5.7 BRAKES

Check the brake disks for wear every 1,000 hours of

Note: If the machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel (5).

Note: Verify valve stems face outward on all wheel and tire assemblies.

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.

operation or yearly.

For more information on brake disk inspection, refer to the Axle Repair Manual (P/N 31200240).

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Axles, Drive Shafts, Wheels and Tires

MZ1020

5.8 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.

5.8.1 Manually Releasing the Park Brake

Note: After machine has been towed to a secure location, reactivate parking brake. Carefully follow procedures from start to finish. Contact local JLG Distributor if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation.

5.8.2 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.

1. Loosen the nuts of the screws (5) for the manual release of the braking units. Draw the nuts back approximately 6 mm.

2. Tighten the screws until they are gently seated on the driving plate.

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 other side of differential.

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 screws along with nuts and seals. Replace seals, lubricate screws with a silicone-based grease and re-install screws along with 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 other side of differential.

5. After repairs to machine have been made, start machine and check 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, “Steering Orbitrol Valve.”

5-12

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

JLG G6-42A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

EFFECTIVITY PAGE

1.1 INTRODUCTION

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

1.5 SAFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.3 OPERATION & SAFETY MANUAL

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

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

2.6.1 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

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

3.5.2 Third Boom Section Removal

3.5.3 Push Beam—Extend/Retract Cylinder Removal

3.5.5 Third Boom Section Installation

3.6.1 Extend/Retract Chain Removal

3.6.2 Extend/Retract Chain Installation

3.7 PUSH BEAM—EXTEND/RETRACT CYLINDER REMOVAL/ INSTALLATION

3.8 BOOM ADJUSTMENTS

3.8.1 Chain Tension Inspection—G6-42A

3.8.2 Chain Tension Adjustment—G6-42A

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

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