JLG G6-42A Service Manual

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

An Oshkosh Corporation Company

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

i

READ THIS FIRST

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.

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387 A

1

OY2700

REAR VIEW OF CAB

ii

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

31200792

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

i

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

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

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

iii

Section	Subject	Page

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

Section 1

Safety Practices

Contents

PARAGRAPH		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

1-1

Safety Practices

1.1INTRODUCTION

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.

1.2DISCLAIMER

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.

1.3OPERATION & 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.

1.4DO 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.

1.5SAFETY 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.

1.5.1Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

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.

1-2	G6-42A, G9-43A, G10-43A

Safety Practices

1.6SAFETY 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.

1.6.1Personal 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.

1.6.2Equipment 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.

1.6.3General 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

1-3

Safety Practices

1.6.4Operational 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.

1.7SAFETY 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

Section 2

General Information and Specifications

Contents

PARAGRAPH		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

General Information and Specifications

2.1REPLACEMENT PARTS AND WARRANTY INFORMATION

-10

40 2030 10

0
8
60	70
50
	1
	MY8100

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure.

Note: The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG Distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.

2.2THREAD LOCKING COMPOUND

JLG P/N	Loctite®	ND Industries	Description
0100011	242TM	Vibra-TITETM121	Medium Strength (Blue)
1001095650	243TM	Vibra-TITETM122	Medium Strength (Blue)
0100019	271TM	Vibra-TITETM140	High Strength (Red)
0100071	262TM	Vibra-TITETM131	Medium - High Strength (Red)

Loctite® 243TM can be substituted in place of Loctite® 242TM. VibraTITETM 122 can be substituted in place of Vibra-TITETM 121.

2-2	G6-42A, G9-43A, G10-43A

General Information and Specifications

2.3TORQUE CHARTS

2.3.1SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

										Torque			Torque
			Tensile	Clamp	Torque			Torque		(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia											(Loctite® 262TM or
			Stress Area	Load	(Dry)			Lubricated		or Vibra-TITE		TM	Vibra-TITETM 131)
										111 or 140)
		In	Sq In	LB	IN-LB		[N.m]	IN-LB	[N.m]	IN-LB	[N.m]		IN-LB	[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-LB		[N.m]	FT-LB	[N.m]	FT-LB	[N.m]		FT-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
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

General Information and Specifications

2.3.1SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

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

					Torque			Torque			Torque
									TM	TM			TM
Size	TPI	Bolt Dia	Tensile Stress	Clamp Load	(Dry or Loctite® 263)			(Loctite® 242		or 271 or	(Loctite® 262			or
			Area		K=0.20			Vibra-TITETM111or140)			Vibra-TITETM 131)
								K=0.18			K=0.15
		In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[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	FT-LB		[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
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

General Information and Specifications

2.3.1SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

						Torque			Torque			Torque
Size	TPI	Bolt Dia	Tensile Stress	Clamp Load				(Loctite® 242TM or 271TM or			(Loctite® 262TM or
			Area			(Dry)		Vibra-TITETM111or140)			Vibra-TITETM 131)
						K=0.17
									K=0.16			K=0.15
		In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[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
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

General Information and Specifications

2.3.1SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

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

					Torque				Torque			Torque
Size	TPI	Bolt Dia	Tensile Stress	Clamp Load				(Loctite® 242TM or 271TM or			(Loctite® 262TM or
			Area		(Dry or Loctite® 263)			Vibra-TITETM111or140)			Vibra-TITETM 131)
					K=0.17
									K=0.16			K=0.15
		In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[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
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

General Information and Specifications

2.3.1SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SOCKET HEAD CAP SCREWS

										Torque			Torque
	Size	TPI	Bolt Dia	Tensile Stress	Clamp Load		Torque		(Loctite® 242TM or 271TM or			(Loctite® 262TM or
				Area	See Note 4	(Dry) K=0.17			Vibra-TITETM 111 or 140) or			Vibra-TITETM 131)
									Precoat® 85 K=0.16				K=0.15
			In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[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
	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

General Information and Specifications

2.3.1SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS

										Torque			Torque
	Size	TPI	Bolt Dia	Tensile Stress	Clamp Load		Torque		(Loctite® 242TM or 271TM or			(Loctite® 262TM or
				Area	See Note 4	(Dry) K=0.17			Vibra-TITETM 111 or 140) or			Vibra-TITETM 131)
									Precoat® 85 K=0.16				K=0.15
			In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[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
	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

General Information and Specifications

2.3.2Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

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

							Torque	Torque
Size	Pitch	Tensile Stress	Clamp Load	Torque		Torque (Lub)	(Loctite® 262TM or	(Loctite® 242TM or
		Area	See Note 4	(Dry or Loctite® 263TM)			271TM or	271TM or Vibra-TITETM
							Vibra-TITETM 131)	111 or 141)
		Sq mm	KN	[N.m]			[N.m]	[N.m]
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
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

General Information and Specifications

2.3.2Metric 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*

						Torque	Torque
					Torque	(Lub or Loctite®
			Tensile Stress	Clamp Load			(Loctite® 262TM or
	Size	Pitch			(Dry or Loctite® 263TM)	242TM or 271TM or
			Area	See Note 4			Vibra-TITE	TM	131)
					K=0.20	Vibra-TITETM 111 or 140)
						K=0.18	K=0.15
			Sq mm	KN	[N.m]	[N.m]	[N.m]
	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
	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

General Information and Specifications

2.3.2Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

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

					Torque	Torque
		Tensile Stress	Clamp Load	Torque	(Lub or Loctite®	(Loctite® 262TM or
Size	Pitch			(Dry or Loctite® 263TM)	242TM or 271TM or	Vibra-TITETM 131)
		Area	See Note 4	K=0.17	Vibra-TITETM 111 or 140)	K=0.15
					K=0.16
		Sq mm	KN	[N.m]	[N.m]	[N.m]
3	0.5	5.03	2.19	1.1	1.1	1.0
3.5	0.6	6.78	2.95	1.8	1.7	1.5
4	0.7	8.78	3.82	2.6	2.4	2.3
5	0.8	14.20	6.18	5.3	4.9	4.6
6	1	20.10	8.74	9	8.4	7.9
7	1	28.90	12.6	15	14	13
8	1.25	36.60	15.9	22	20	19
10	1.5	58.00	25.2	43	40	38
12	1.75	84.30	36.7	75	70	66
14	2	115	50.0	119	110	105
16	2	157	68.3	186	175	165
18	2.5	192	83.5	256	240	225
20	2.5	245	106.5	362	340	320
22	2.5	303	132.0	494	465	435
24	3	353	153.5	627	590	555
27	3	459	199.5	916	860	810
30	3.5	561	244.0	1245	1170	1100
33	3.5	694	302.0	1694	1595	1495
36	4	817	355.5	2176	2050	1920
42	4.5	1120	487.0	3477	3275	3070
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

General Information and Specifications

2.3.2Metric 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*

						Torque	Torque
					Torque	(Lub or Loctite®
			Tensile Stress	Clamp Load See			(Loctite® 262TM or
	Size	Pitch			(Dry or Loctite® 263TM)	242TM or 271TM or
			Area	Note 4			Vibra-TITE	TM	131)
					K=0.17	Vibra-TITETM 111 or 140)
						K=0.18	K=0.15
			Sq mm	KN	[N.m]	[N.m]	[N.m]
	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
	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

General Information and Specifications

2.3.3Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

	Size	ORFS	JIC	Flats Method
	4	13 lb-ft	13 lb-ft	1.5 to 1.75
		(18 Nm)	(18 Nm)
	6	23 lb-ft	23 lb-ft	1 to 1.5
		(31 Nm)	(31 Nm)
	8	40 lb-ft	40 lb-ft	1.5 to 1.75
		(54 Nm)	(54 Nm)
	10	60 lb-ft	60 lb-ft	1.5 to 1.75
		(81 Nm)	(81 Nm)
	12	136 lb-ft	136 lb-ft	1.0 to 1.5
		(100 Nm)	(100 Nm)
	16	115 lb-ft	115 lb-ft	0.75 to 1.0
		(156 Nm)	(156 Nm)
	20	170 lb-ft	170 lb-ft	0.75 to 1.0
		(230 Nm)	(230 Nm)
	24	200 lb-ft	200 lb-ft	0.75 to 1.0
		(271 Nm)	(271 Nm)
	32	N/A	270 lb-ft	0.75 to 1.0
			(366 Nm)

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:

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.

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.

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

2-13

General Information and Specifications

2.4SPECIFICATIONS

2.4.1Travel Speeds

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

2.4.2Hydraulic 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		ULS			LS
	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
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

General Information and Specifications

b. G9-43A & G10-43A

			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

General Information and Specifications

2.4.3Electrical 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

2.4.4Engine Specifications

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

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

General Information and Specifications

2.4.5Tires

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		Minimum Ply/		Fill Type		Pressure
				Star Rating
13.00 x 24		G-2/L-2 Bias Ply Traction		12 Ply		Pneumatic		65 psi (4,5 bar)
						Foam—Approximately 542 lb (246 kg)
15.50 x 25		G-2/L-2 Bias Ply Traction		12 Ply		Pneumatic		58 psi (4,0 bar)
						Foam—Approximately 600 lb (272 kg)
370/75-28		DuraForce		14 Ply		Pneumatic		76 psi (5,2 bar)
						Foam—Approximately 464 lb (210 kg)
b.	G9-43A
	Size	Tire Type		Minimum Ply/		Fill Type		Pressure
				Star Rating
13.00 x 24		G-2/L-2 Bias Ply Traction		12 Ply		Pneumatic		65 psi (4,5 bar)
						Foam—Approximately 542 lb (246 kg)
15.50 x 25		G-2/L-2 Bias Ply Traction		12 Ply		Pneumatic		65 psi (4,0 bar)
						Foam—Approximately 600 lb (272 kg)
370/75-28		DuraForce		14 Ply		Pneumatic		76 psi (5,2 bar)
						Foam—Approximately 464 lb (210 kg)
c.	G10-43A
	Size	Tire Type	Minimum Ply/			Fill Type		Pressure
				Star Rating
14.00 x 24		G-2/L-2 Bias Ply Traction		12 Ply		Pneumatic		65 psi (4,8 bar)
						Foam—Approximately 720 lb (327 kg)
400/75-28		DuraForce		14 Ply		Pneumatic		76 psi (5,2 bar)
						Foam—Approximately 570 lb (259 kg)

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

2-17

General Information and Specifications

2.5FLUID AND LUBRICANT CAPACITIES

2.5.1Fluids (if Equipped for ULS)

					Ambient
				Temperature
Compartment or System	Type and Classification	Viscosities			Range
				°F		°C
				Min	Ma	Min	Ma
					x		x
Engine Crankcase	API CJ-4 Plus	SAE 15W-40		5	120	-15	49
		SAE 0W-40		-40	0	-40	-20
Transmission and Transfer	Mobilfluid 424	10W-30		0	104	-20	40
Case	Mobilfluid LT	75W-80		-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
	API GL4 with	80W-140		14	122	-10	50
Axle Differential and Wheel		85W-140
	LS Additives
		SAE90
End	or			32	104	0	40
		SAE90LS
	API GL5 with
	LS Additives	80W-90		-4	104	-20	40
		85W-90
		75W-90		-40	104	-40	40
		75W		-40	50	-40	10
Hydraulic System	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	50/50 Mix			Standard
	and Water	60/40 Mix		Cold Weather
	#2 Diesel	Ultra Low			Standard
	B5 Biodiesel
		Sulfur
Fuel
	Blend #1 diesel and #2 diesel fuels
		(S ≤ 15 mg/
	("winterized" #2)			Cold Weather
		kg)
	B5 Biodiesel with Winter Conditioner
Note: Friction Modifier may be added to front axle differentials, see Section 2.5.3, “Capacities.”

2-18	G6-42A, G9-43A, G10-43A