JLG G6-42A Service Manual

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An Oshkosh Corporation Company

Service Manual

Models

G6-42A, G9-43A

& G10-43A

G6-42A

Before S/N 0160048658

G9-43A & G10-43A

Before S/N 0160048671

including 0160048773

31200151

Revised

July 11, 2014

EFFECTIVITY PAGE

May 12, 2006 - A - Original Issue Of Manual

April 19, 2007 -B- Revised pages 2.9, 2.12, 3.14, 5.11, 6.3 & 8.4.

May 1, 2009 - C - Added G10-43A information. Revised covers and pages 1.3, 1.4, 2.3 thru 2.19, 3.2, 3.3, 3.7, 3.12, 4.2,

4.3, 4.7, 4.9, 5.3, 5.4, 5.5, 5.10, 6.3, 6.4, 6.6, 6.7, 7.5, 7.6, 7.7, 7.11, 8.2, 8.3, 8.6 thru 8.12, 8.16, 8.17, 8.21, 8.22, 8.26,

9.3 & 9.18 thru 9.27.

September 20, 2011 - D - Revised page numbering and pages 1-3, 2-1, 2-3 thru 2-9, 2-13 thru 2-26, 3-1, 3-13 thru 3-15, 4-1, 4-2, 4-6, 4-7, 4-10 thru 4-12, 6-3, 6-7, 7-1, 7-6 thru 7-8, 7-13, 7-14, 8-6 thru 8-17, 8-23, 9-3, 9-4, 9-7, 9-8, 9-31 thru 9-36, 9-38, 9-41, 9-43, 9-47, 9-51, 9-55, 9-57 thru 9-74.

August 9, 2012 - E - Revised pages 3-1 thru 3-34.

October 31, 2012 - F - Revised cover and page 3-23.

July 15, 2013 - G - Friction Modifier Page 2-16, Emergency Boom Lowering Procedure Pages 3-30 and 3-31.

July 11, 2014 - H - Revised pages 3-20 thru 3-23.

31200151 G6-42A, G9-43A, G10-43A i

EFFECTIVITY PAGE

G6-42A, G9-43A, G10-43A 31200151ii

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

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

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 Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.11 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.12 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.13 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

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

3.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3.16 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Section 4

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

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

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

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

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 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Section 6

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

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

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.5 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.6 Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

Section 7

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

7.1 Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

Section 8

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

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

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19

8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45

9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-46

9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47

9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48

9.11 Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49

9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55

9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-56

9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After

including 0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58

9.15 Hand Held Analyzer(G9-43A/G10-43A S/N 0160040675 and After including

0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60

9.16 Joystick Fault Codes (G9-43A/G10-43A S/N 0160040675 and After including

0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62

9.17 Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67

9.18 SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . . . . . . 9-68

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

iii

Section Subject Page

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

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

1-1

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

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

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.

proceeding.

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 the 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

1.6.4 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 TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

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.

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.

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

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

Section 2

General Information and Specifications

Contents

PARAGR APH TITLE PAGE

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

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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

2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.3 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.5.3 1000, 1500 & 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6.1 G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6.2 G9-43A / G10-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

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

2-1

General Information and Specifications

MY0070

DO NOT GO NEAR LEAKS

10814B

* High pressure oil easily punctures skin causing serious injury, gangrene or death. * If injured, seek emergency medical help. Immediate surgery is required to remove oil. * Do not use finger or skin to check for leaks. * Lower load or relieve hydraulic pressure before loosening fittings.

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.

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

2.2 TORQUE CHARTS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

Description

0100011

242

Vibra-TITETM121

Medium Strength (Blue)

0100019

271

Vibra-TITETM140

High Strength (Red)

0100071

262

Vibra-TITETM131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

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

Values for Zinc Yellow Chromate Fasteners

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

Lubricated

3. * ASSEMBLY USES HARDENED WASHER

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

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

MY4650J

JLG P/N Loctite® P/N

ND Industries P/N

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart

General Information and Specifications

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

2-3

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

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

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

Values for Zinc Yellow Chromate Fasteners

3. * ASSEMBLY USES HARDENED WASHER

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

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

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

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

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000 45 60 40 55 35 50 7900 50 70 45 60 35 50 9550 70 95 65 90 50 70

10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120

16400 155 210 140 190 115 155

18250 170 230 155 210 130 175

20350 210 285 190 260 160 220

23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310

77000 1445 1965 1300 1770 1085 1475 87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

K=.18

K=0.15

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

Torque

(Dry or Loctite® 263)

K= 0.20

MY4660J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart (Continued)

2-4

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

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

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 320 435 300 410 280 380

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

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.

SOCKET HEAD CAP SCREWS

Magni Coating*

Torque

(Dry) K = .17

K=0.16

K=0.15

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

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

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

MY4670J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

OR Precoat 85®

2.2.1 SAE Fastener Torque Chart (Continued)

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

2-5

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

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 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 775 1055 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

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.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TMor 271

OR Vibra-TITETM111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners*

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

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

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

MY4680J

2.2.1 SAE Fastener Torque Chart (Continued)

2-6

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

2.2.2 Metric Fastener Torque Chart

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

Torque

(Lub)

Sq mm KN [N.m] [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

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.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAW ALUMINUM

Values for Zinc Yellow Chromate Fasteners

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

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

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

MY4690J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

General Information and Specifications

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

2-7

General Information and Specifications

Size PITCH

Tensile

Stress

Area

Clamp

Load

K = 0.20

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 25.2 22.7 18.9

8 1.25 36.60 22.8 36.5 32.8 27.4

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

Values for Zinc Yellow Chromate Fasteners

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

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.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAW ALUMINUM

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT

METHODS TOLERANCE = ±10%

MY4700J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque Dry

Loctite® 263™

Torque

Lube OR Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

2.2.2 Metric Fastener Torque Chart (Continued)

2-8

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

2.2.2 Metric Fastener Torque Chart

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

K = .17

K = .16

K = .15

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03

3.5 0.6 6.78

4 0.7 8.78

5 0.8 14.20

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 54

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 3 353 220.0 900 845 790

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

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

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.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAW ALUMINUM

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

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

Magni Coating*

MY4710J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Lube OR Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

Torque Dry

Loctite® 263™

(Continued)

General Information and Specifications

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

2-9

General Information and Specifications

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

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

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

270 lb-ft

(366 Nm)

0.75 to 1.0

2-10

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

General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

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

First Gear 3.7 mph (5,6 km/h) 3.2 mph (5,1 km/h)

Second Gear 8.0 mph (12,9 km/h) 7.0 mph (11,2 km/h)

Third Gear 16.1 mph (25,9 km/h) 14.0 mph (22,5 km/h)

Fourth Gear 20.5 mph (32,9 km/h) 19.5 mph (31,4 km/h)

2.3.2 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.

Function

Boom Extend (Boom Level) 13.8 13.4

Boom Retract 13.4 10.2

Boom Lift 12.6 10.7

Boom Lower 9.4 8.6

Attachment Tilt Forward 3.8 3.5

Attachment Tilt Rearward 3.4 3.1

Frame Level - Full Right to Left 7.7 9.3

Frame Level - Full Left to Right 3.5 10.7

Outriggers Down (Boom Level- No Load) N/A 5.8 (G10-43A Only)

Outriggers Up (Boom Level- No Load) N/A 4.4 (G10-43A Only)

Approximate Times (seconds)

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

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

2-11

General Information and Specifications

2.3.3 Engine Performance Specifications

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

a. John Deere

G6-42A (Before S/N 0160007869) G9-43A (Before S/N 0160007868)

Description G6-42A Naturally Aspirated G6-42A - G9-43A Turbo

Engine Make/Model John Deere PE 4045D150 John Deere PE 4045TF150

Displacement 276 in³ (4,5 liters) 276 in³ (4,5 liters)

Low Idle (with A/C) 825 to 875 rpm (950 to 1000 rpm) 825 to 875 rpm (950 to 1000 rpm)

High Idle 2,675 to 2,750 rpm 2,675 to 2,750 rpm

Horsepower 80 HP (60 kW) @ 2500 rpm 100 HP (75 kW) @ 2500 rpm

Peak Torque 215 lb-ft (292 Nm) @ 1200 rpm 274 lb-ft (372 Nm) @ 1400 rpm

Fuel Delivery Fuel Injection Fuel Injection

Average Fuel Consumption (depending on load/duty)

Air Cleaner

b. John Deere or Perkins Engine

G6-42A (S/N 0160007869 thru 0160040677) G9-43A & G10-43A (S/N 016007868 thru 0160040674 excluding 0160040468 & 0160040672)

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

Engine Make/Model John Deere PE 4045TF270

Displacement 275 in³ (4,5 liters)

Low Idle (with A/C) 800 to 900rpm

High Idle 2600 rpm

Horsepower 99 HP (74 kW) @ 2500 rpm

Peak Torque 272 lb-ft (369 Nm) @ 1400 rpm

Fuel Delivery Fuel Injection

Average Fuel Consumption (depending on load/duty)

Dry Type, Replaceable Primary and

2.6 gal/hr (9,8 l/hr) 3.0 gal/hr (11,4 l/hr)

Dry Type, Replaceable Primary and

Safety Elements

3.2 gal/hr (12,1 l/hr)

Safety Elements

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2-12

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

General Information and Specifications

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

Engine Make/Model Perkins 1104-C 44T

Displacement 268 in³ (4,4 liters)

Low Idle 800 to 850 rpm

High Idle 2475 to 2525 rpm

Horsepower 99 HP (74 kW) @ 2500 rpm

Peak Torque 372 lb-ft (504 Nm) @ 1400 rpm

Fuel Delivery Fuel Injection

Average Fuel Consumption (depending on load/duty)

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

c. Cummins Engine

G6-42A (S/N 0160040678 & After) G9-43A & G10-43A (S/N 0160040675 including 0160040468 & 0160040672)

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

Engine Make/Model Cummins QSB3.3

Displacement 201 in³ (3,3 liters)

Low Idle 1000 rpm

High Idle 2600 rpm

Horsepower 99 HP (74 kW) @ 2600 rpm

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

Fuel Delivery Fuel Injection

Average Fuel Consumption (depending on load/duty)

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

Not Available

2.3.4 Electrical System

Battery:

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

Quantity 1

Reserve Capacity 1000 Cold Cranking Amps @ 0° F (-18° C)

Group/Series Group 31

Alternator (with Optional A/C) 12V, 65 Amps (12V, 105 Amps)

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

2-13

General Information and Specifications

2.3.5 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 & G9-43A

Size Tire Type

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

13.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply

13.00 x 24 G-2/L-2 Radial 1 Star

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

15.50 x 25 G-3/L-3 Bias Ply Rock 12 Ply

15.50 x 25 G-2/L-2 Radial 1 Star

370/75x28 DuraForce 14 Ply

Minimum Ply/

Star Rating

Fill Type Pressure

Pneumatic 65 psi (4,5 bar)

Foam - Approx. 542 lb (246 kg) 60 psi (4,1 bar)

Pneumatic 65 psi (4,5 bar)

Foam - Approx. 542 lb (246 kg) 65 psi (4,5 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx. 542 lb (246 kg) 70 psi (4,8 bar)

Pneumatic 58 psi (4,0 bar)

Foam - Approx. 600 lb (272 kg) 58 psi (4,0 bar)

Pneumatic 65 psi (4,5 bar)

Foam - Approx. 600 lb (272 kg) 65 psi (4,5 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx. 600 lb (272 kg) 70 psi (4,8 bar)

Pneumatic 76 psi (5,2 bar)

Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)

a. G10-43A

Size Tire Type

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

14.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply

400/75-28 DuraForce 16 Ply

2-14

Minimum Ply/

Star Rating

Fill Type Pressure

Pneumatic 70 psi (4,8 bar)

Foam - Approx. 720 lb (327 kg) 62 psi (4,3 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx. 720 lb (327 kg) 62 psi (4,3 bar)

Pneumatic 76 psi (5,2 bar)

Foam-Approx 570 lb (2259 kg) 73 psi (5,0 bar)

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

2.4 FLUID AND LUBRICANT CAPACITIES

Engine Crankcase Oil

Capacity with Filter Change

G6-42A - Before S/N 0160040678

G9-43A & G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672

John Deere

Before S/N 0160007869 14.5 quarts (13,7 liters)

S/N 0160007869 thru 0160040674 15.5 quarts (14,7 liters)

Perkins 7 quarts (6,5 liters)

G6-42A - S/N 0160040678 & After

G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672

Cummins 7.6 quarts (7,2 liters)

Oil Type

General Information and Specifications

0° to 104° F (-20° to 40° C) 15W-40 CH

-40° to 0° F (-40° to -20° C) 0W-40 CH

Fuel Tank

Capacity 38 gallons (144 liters)

Type of Fuel

0° to 104° F (-20° to 40° C) Low Sulfur Diesel #2

-40° to 0° F (-40° to -20° C) Low Sulfur Diesel #1

Anti-gel Fluid

-40° to 0° F (-40° to -20° C) 16 ounce (0,5 liters)

Cooling System

System Capacity

G6-42A - Before S/N 0160040678 15.2 quarts (14,4 liters)

G6-42A - S/N 0160040678 & After 18 quarts (17 liters)

G9-43A & G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672

G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672

22 quarts (20,8 liters)

18 quarts (17 liters)

Overflow Bottle Capacity

G6-42A - S/N 0160040678 & After

G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672

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

2.5 quart (2,4 liters)

2-15

General Information and Specifications

Type of Fluid

0° to 104° F (-20° to 40° C) 50/50 ethylene glycol & water

-40° to 0° F (-40° to -20° C) 60/40 ethylene glycol & water

Coolant Conditioner (refer engine manual) 0.5 quarts (0,47 liters)

Transmission

Capacity with Filter Change

G6-42A 4.2 gallons (15,8 liters)

G9-43A & G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672

G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672

3.4 gallons (12,9 liters)

4.2 gallons (15,8 liters)

Type of Fluid

0° to 104° F (-20° to 40° C) Mobilfluid 424

-40° to 0° F (-40° to -20° C) Mobilfluid

Tractor Hydraulic Fluid (ISO 46)

LT (75W-80) Hydraulic Fluid

Transfer Case

Capacity

G6-42A - Before S/N 0160040678 0.8 quarts (0,8 liters)

G6-42A - S/N 0160040678 & After

1.5 quarts (1,4 liters)

G9-43A & G10-43A

Type of Fluid

0° to 104° F (-20° to 40° C) Mobilfluid 424

-40° to 0° F (-40° to -20° C) Mobilfluid

Tractor Hydraulic Fluid (ISO 46)

LT (75W-80) Hydraulic Fluid

Axles

G6-42A - Differential Housing Capacity

Front 9.0 quarts (8,5 liters)

Rear 8.5 quarts (8,0 liters)

Friction Modifier (Front differential only) 14.4 ounce (425,8 milliliter)

Wheel End Capacity 1.7 quarts (1,6 liters)

G9-43A/G10-43A - Differential Housing Capacity

Front 8.7 quarts (8,2 liters)

Rear 13.0 quarts (12,3 liters)

Friction Modifier (Front differential only) 13.9 ounce (411,0 milliliter)

Wheel End Capacity 1.75 quarts (1,65 liters)

Type of Fluid

0° to 104° F (-20° to 40° C) Mobilfluid 424

-40° to 0° F (-40° to -20° C) Mobilfluid

Tractor Hydraulic Fluid (ISO 46)

LT (75W-80) Hydraulic Fluid

2-16

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

General Information and Specifications

Hydraulic System

System Capacity

G6-42A 43 gallons (163 liters)

G9-43A & G10-43A 40 gallons (151 liters)

Reservoir Capacity

G6-42A 20 gallons (75,7 liters)

G9-43A & G10-43A 23.3 gallons (88,2 liters)

Type of Fluid

0° to 104° F (-20° to 40° C) Mobilfluid 424

-40° to 0° F (-40° to -20° C) Exxon Univis HVI All Season Hydraulic Fluid

Air Conditioning System (if equipped)

System Capacity 2.5 lb (1134 g)

Tractor Hydraulic Fluid (ISO 46)

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

2-17

General Information and Specifications

MY6040

Check

Transmission

Oil Level

Check Hydraulic Return

Filter Indicator (Before

S/N 0160040675)

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)

2.5 SERVICE AND MAINTENANCE SCHEDULE

2.5.1 10, 1st 50 & 50 Hour

2-18

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

2.5.2 1st 250, 250 & 500 Hour

MY6050

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)

Change Fuel

Strainer (Before

S/N 0160040675)

General Information and Specifications

Note: Engine oil & filter service interval can be extended. See Engine Manual for details.

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

2-19

General Information and Specifications

MY6060

2000

EVERY

Change Engine

Coolant (S/N

0160040675 & After)

Engine Valve

Lash

Adjustment

1500

EVERY

Change Engine Coolant (Before

S/N 0160040675)

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

2.5.3 1000, 1500 & 2000 Hour

2-20

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

2.6 LUBRICATION SCHEDULE

OY2270

EVERY

2.6.1 G6-42A

a. 50 Hour

General Information and Specifications

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

2-21

General Information and Specifications

OY2280

EVERY

250

b. 250 Hour

2-22

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

c. 1000 Hour

OY2290

EVERY

1000

General Information and Specifications

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

2-23

General Information and Specifications

OY2550

EVERY

G10-43A

2.6.2 G9-43A / G10-43A

a. 50 Hour

2-24

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

b. 250 Hour

OY2560

EVERY

250

G10-43A

General Information and Specifications

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

2-25

General Information and Specifications

OY2570

EVERY

1000

G10-43A

c. 1000 Hour

2-26

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

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 . . . . . . . . . . . . . . . . . . . . 3-8

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

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

3.5.5 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6.1 Extend/Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

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 . . . . . . . . . . . . . . . . . . . . . 3-22

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

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

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

3.9.2 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.9.3 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.9.4 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.10 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10.2 Boom Head-Mounted Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.11 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.11.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

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

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

3-1

Boom

3.12 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.12.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.12.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.12.3 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.13 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

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

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

3.14.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.16 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-2

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

3.1 BOOM SYSTEM COMPONENT

MY0110

EXTEND/RETRACT

CYLINDER

(INSIDE BOOM)

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

TERMINOLOGY

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

Boom

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

3-3

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 the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.The boom assembly consists of the 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 coupler.

Before beginning, conduct a visual inspection of the machine and work area, and review the 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 3.11, “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 proper operation by operating all boom functions through their full ranges of motion several times.

3-4

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

complete boom

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

Boom

MY1520

3.4 COMPLETE BOOM REMOVAL/ INSTALLATION

3.4.1 Complete Boom Removal

1. Remove any attachment from the quick coupler assembly. Refer to Section 3.15, “Troubleshooting.”

2. Remove the quick coupler assembly. Refer to Section 3.9.1, “Quick Switch Removal.”

3. If equipped, remove the boom head mounted winch. Refer to Section 3.9.4, 3.10. “Boom Head - Mounted Winch.”

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

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

6. Open the engine cover. Allow the system fluids to cool.

7. Properly disconnect the battery.

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

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

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

11. 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.

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

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

14. Lift the boom assembly from the machine and lower onto suitable supports.

3.4.2 Complete Boom Installation

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

2. 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).

3. 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).

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

242

and torque lock bolt to 200-215 lb-ft

(271-291 Nm).

Note: Raising the boom up or down with the sling my be necessary so the 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.

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

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

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

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

9. If equipped, install the boom head mounted winch. Refer to Section 3.9.4, 3.10. “Boom Head - Mounted Winch.”

10. Properly connect the battery.

11. Install the quick coupler assembly. Refer to Section

3.9.2, “Quick Switch Installation.”

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

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

14. Close and secure the engine cover.

242TM and

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

3-5

Boom

MAL2660

G6-42A

G9-43A

G10-43A

MY3860

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

16. Install the previously removed attachment to the quick coupler assembly. Refer to Section 3.15, “Troubleshooting.”

3.5 BOOM SECTION REMOVAL/

INSTALLATION

3.5.1 Second and Third Boom Section

Removal

Note: Refer to Section 3.14.2, 3.16. “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.

all open hoses, tubes and/or fittings to prevent dirt and debris from entering the hydraulic system.

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

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

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

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

8. Remove the right or left side wear pads, shims and backing plates (6) from the rear of the 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.

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

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 the rear of the boom. Cap and/or plug

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

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

12. Disconnect both tilt tubes (10) and (if equipped) both auxiliary tubes from the fittings on the hose retainer brackets (11) at the 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 the hose retainer brackets at the bottom front inside the boom. Plug the 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

Boom

MY3840

MY3880

MY4070

MY4110

15. Between the bottom front of the 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.

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.

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.

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

3.5.2 Third Boom Section Removal

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 3.16, “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.

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.

3-7

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

Boom

MY3890

MY3870

MY4060

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

7. Remove the right or left side wear pads, shims and backing plates (9) from the rear of the 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 the rear of the 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.

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

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).

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

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

3-8

Note: Refer to Section 3.16, “Push Beam Temporary Brackets,” for Temporary Extend Chain Bracket diagram.

3. Lift the push beam (14) to unload the clevis pin (17) and remove the pin securing the clevis to the 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 the front of the push beam and pull the push beam (14) towards the front of the boom.

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

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

7. Remove the guide bar (18) and chain retainer (19).

MY3930

Remove the push beam wear pad (20).

8. Lower the push beam assembly and remove the pry bars.

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

NOTICE

Boom

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 3.12, “Boom Extend and Retract Chains,” for detailed information.

1. Place the third boom section onto suitable supports.

2. Clean and lubricate the bottom and sides of the third boom section where the 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.

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

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 the sling or using two slings for better stability, balance the push beam assembly and slowly pull the push beam assembly out of the third boom section. Lower the push beam assembly onto suitable supports.

12. 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.Safety Information

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. 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).

NOTICE

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

3-9

Boom

MY4060

MY3940

MY3900

MY3890

14 14

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

8. Apply CAT Thread Lubricant to the clevis mounting pin (10).

9. Lift the push beam and install the pin and retaining clips (10) securing the clevis to the 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 the tilt cylinder hoses and (if equipped) the auxiliary hoses to their proper locations. Torque as required.

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

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

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

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

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

17. Install the previously removed wear pad and spacer (15) on the left or right side of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “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 the second boom section onto suitable supports.

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

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

3-10

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

Boom

MY3870

MY3960

MY3970

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

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

8. Install the previously removed wear pads, spacers and shims on each side at the front of the second boom section (4). Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication,” for detailed information.

9. Install wear pads, spacer (5) using bolts and washers at the top front of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “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.

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

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

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

15. Remove the Temporary Extend Chain Bracket.

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

3-11

Boom

MY3880

MY3910

MY3880

20. Align the push beam bores with the second boom section bores and install the 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.

22. Install the previously removed wear pad and spacer (13) on the left or right side of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication,” for detailed information.

23. Install the previously removed wear pad and spacer (14) on the top of the third boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication,” for detailed information.

24. Install the previously removed wear pad and 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 3.11.2, “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

3.11.2, “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.

3-12

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

MY3840

MY3980

MY3990

MY3890

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.

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.

5. Install the 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

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

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

8. Install the previously removed wear pads, Spacers (4) P/N 298-1729 and shims at the top front of the first boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication,” for detailed information.

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

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

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

17. Install the previously removed wear pad and spacer (13) on the top of the second boom section. Snug mounting bolts. Shim as needed AFTER boom section is installed. Refer to Section 3.11.2, “Wear Pad Installation and Lubrication,” for detailed information.

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

3-13

Boom

MAL2660

G6-42A

G9-43A

G10-43A

MY0580

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

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

20. Apply CAT Thread Lubricant to the extend chain clevis rod threads (18).

21. Install the extend chain clevis rod (18) into the strong back (16).

22. Install the belleville washers (19) as previously removed (cupped washer facing strong back). Install the 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.

30. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid level in the 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 the Do Not Operate Tags from both the ignition key switch and the 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 the machine on a hard, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

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

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

4. Properly disconnect the battery.

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

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

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

3-14

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

Boom

MY1540

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

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 the push beam mounting pins from the rear of the second boom section.

12. Place the chain clevis rod to one side of the 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 the push beam. Center the chain clevis rod on the push beam to aid in removal.

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

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

3.6.2 Extend/Retract Chain Installation

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

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 the wire or rope secured to the extend chain.

5. Place the chain clevis rod to one side of the 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 the rear of the boom at the chain anchor bracket, install the cotter pin and pin from the extend chain clevis. Install the cotter pin and pin from the retract chain.

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

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

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

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

12. Install the adjustment and lock nuts on the 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 the Do Not Operate Tags from both the ignition key switch and the steering wheel.

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.

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

3-15

Boom

MAL1310

MAL2670

G6-42A

G9-43A

G10-43A

MAL2660

G6-42A

G9-43A

G10-43A

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).

The following section explains the removal of the push beam - extend/retract cylinder without removing or disassembling the boom assembly.

3.7.1 Push Beam - Extend/Retract Cylinder

Removal

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

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

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

7. Loosen and remove the lock nut, adjustment nut (3) and belleville washers (4) from the retract chain (5) at the bottom front of the first boom section.

Note: Note the position of the belleville washers for reassembly.

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

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).

3-16

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 the position of the belleville washer for reassembly.

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

Note: Disconnecting one or both extend/retract

MAL1290

MY3930

MAL1290

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.

Boom

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

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

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 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

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

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

Remove the strong back.

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

3-17

Boom

MAL1290

MY3930

20. Place a sling around the push beam - extend/retract cylinder assembly. Lift and slowly pull the push beam

- extend/retract cylinder assembly approximately half way out of the boom assembly. Lower the 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.

21. Relocate the sling or using two slings for better stability, balance the push beam - extend/retract cylinder assembly and slowly pull the push beam extend/retract cylinder assembly out of the boom assembly. Lower the push beam - extend/retract cylinder assembly onto suitable supports.

22. Remove the extend/retract cylinder as required.

3.7.2 Push Beam - Extend/Retract Cylinder

Installation

5. Install the strong back (1) with the previously removed hardware (2) and torque as required.

6. 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).

7. Install the anchor rod through the front of the boom assembly.

1. Clean and lubricate the bottom and sides of the third boom section where the 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 boom assembly. Lower the push beam onto a suitable support.

3. 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.

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

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

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

10. Properly connect the battery.

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

12. Properly disconnect the battery.

3-18

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

13. Install both push beam pins (10) being careful to

MAL1290

MAL2660

G6-42A

G9-43A

G10-43A

MAL2670

G6-42A

G9-43A

G10-43A

MAL1310

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.

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

Boom

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

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

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

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

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

Note: Note the position of the belleville washer for reassembly.

Note: Note the position of the belleville washers for reassembly.

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

20. Install both hose retainer brackets (19).

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

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

23. Properly connect the battery.

3-19

Boom

MAL2561

MAL2601

MAL2611

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

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

26. Close and secure the engine cover.

27. 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.

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.

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

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

3-20

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.

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

3.8.2 Chain Tension Adjustment—G6-42A

MAL2571

MAL2551

MAL2561

MAL2571

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.

Boom

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).

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

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).

3-21

Boom

MAL2551

MAL2740

MAL2621

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.

3.8.3 Chain Tension Inspection— 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.

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).

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

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

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.

3-22

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

Boom

MAL2630

MAL2580

MAL2591

MAL2740

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.

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.

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).

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

3-23

Boom

MAL2580

MAL2591

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.

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).

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).

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.

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

3-24

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

Boom

MY5080

MY5090

3.9 QUICK SWITCH ASSEMBLY

3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin (2). Align the tilt

3.9.1 Quick Switch Removal

cylinder pin and screw in the locking bolt (1). Torque as required.

G6-42A - Before S/N 0160037722

G9-43A/G10-43A - Before S/N 0160037671

3.9.3 Quick Switch Removal

G6-42A - S/N 0160037722 & After

G9-43A/G10-43A - S/N 0160037671

& After

1. Remove the lock bolt (1) holding the tilt cylinder rod end pin (2) to the quick switch assembly (3). Remove the Tilt Cylinder pin.

2. Support the quick switch assembly (3).Remove the capscrew (4) and locknut (5) securing the head pin (6) to the boom head (7).

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.

3.9.2 Quick Switch Installation

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.

1. Assemble the quick switch assembly (3) to the boom head (7). 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 (6) with an anti-seize compound. Insert the quick switch head pin through the quick switch and boom head. Secure with the previous capscrew (4) and locknut (5).

3.9.4 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.

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

3-25

Boom

MAL0880

Ma2070

MAM1390

3.10 BOOM HEAD - MOUNTED WINCH

3.10.1 Boom Head-Mounted Winch Removal

1. Using a suitable lifting device, secure the winch assembly (15) with a nylon strap.

2. Disconnect the hydraulic hoses (16).

3. Loosen and remove the mounting bolts, washers and nuts (17).

4. Lower the winch assembly (15) onto a suitable skid or table.

3.11 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.

3.11.1 Wear Pad Inspection

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

3.11.2 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:

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

• Apply Loctite

242™ to all wear pad mounting bolts.

242™ and installing

3.10.2 Boom Head-Mounted Winch Installation

1. Using a suitable lifting device, secure the winch assembly (4) with a nylon strap.

2. Raise the winch assembly (4) into position behind the boom head.

3. Apply to the previously removed mounting bolts.

4. Install the mounting bolts, washers and nuts (6)(not shown). Torque to 200 lb-ft (271 Nm).

5. Connect the hydraulic hoses (5).

3-26

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

• A shim (3) must be inserted between the spacer (2)

and wear pad support plate, block or boom section (4).

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

• The bottom wear pads must be shimmed equally on

each side.

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

Boom

MY5510

MY3620

3.12 BOOM EXTEND AND RETRACT CHAINS

3.12.1 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.

• Maintain a total boom section clearance (5) of

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

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

• The thickness of each threaded wear pad insert is

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

• 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).

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

• 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.

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

• 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)

• Torque wear pad bolts after shimming is completed.

• Lubricate the face and pockets of each wear pad

after being installed.

Boom Section Wear Pad Pathway Lubrication:

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

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

Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains 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.

• 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.

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

3-27

Boom

MZ1463

MY1360

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.

3.12.2 Inspection Guidelines

1. Park the machine on a firm, level surface, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

2. Fully extend the boom until the extend chain is taut. Shut the engine off.

3. The extend chains will be visible for inspection with the vehicle in this state.

4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

5. Inspect the retract chains every 1000 hours of operation.

6. Inspect the chains for the following conditions:

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

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

3-28

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

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

Boom

MZ1466

MZ1465

MZ1467

MZ1468

MZ1469

MZ1470

MZ1471

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.

Cracked Plates

Inspect the 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

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

• 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.

•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.

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

3-29

Boom

MH6460

3.12.3 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated with Mystik Tetrimoly Grease.

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 JLG Distributor or the vehicle distributor be consulted for guidance.

3.13 FORKS

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

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 the local Caterpillar dealer with the fork part number to find the manufactured dimensions of the fork blade.

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

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

6. Compare fork tips (11) when mounted on a carriage.

3-30

Maximum difference in height of fork tips is 3 percent of the length of the blade (10).

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

Boom

3.14 EMERGENCY BOOM LOWERING PROCEDURE

WARNING

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

3.14.1 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.

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/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.

3.14.2 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.

• 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

WARNING

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

3-31

Boom

MY8630

MY8620

G6-42A

G9-43A

G10-43A

7. If access is required, loosen and remove any clamps

8. Disconnect the extend/retract cylinder tubes from

securing the lift/lower cylinder (1 & 2) and extend/ retract cylinder tubes (3 & 4) to the frame.

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.

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.

3-32

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

3.15 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during operation of the boom.

Problem Cause Remedy

Boom

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 3.11, “Boom Wear Pads.”

Refer to Section 2.6, “Lubrication Schedule.” Replace worn pins as needed.

lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedule.”

Refer to Section 2.6, “Lubrication Schedule.” Replace worn pins as needed.

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

2. Worn bushing(s). 2. Replace bushing(s) and lubricate at regular intervals.

3-33

Boom

Problem Cause Remedy

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 3.11, “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 2.5, “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 2.6, “Lubrication Schedule.”

3-34

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

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 3.11, “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 2.5, “Service and Maintenance Schedule.”

3. Lubricate chain sheave. Refer to Section 2.5, “Service and Maintenance Schedule.” Repair or replace chain sheave(s) as needed.

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

4. Improper chain lubrication. 4. Lubricate at regular intervals. Refer to Section 2.5, “Service and Maintenance Schedule.” Replace chains as needed.

3-35

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

Boom

3.16 PUSH BEAM TEMPORARY BRACKETS

Note: The drawings below are only suggested and can be subject to individual interpretation.

3-36

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.2 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.1 Steering Column and Orbitrol Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.3 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3.4 Boom Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and Outriggers (G10-43A)

Joysticks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3.7 Heater/Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . 4-10

4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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

4-1

Cab and Covers

MAL0200

TRANSMISSION

CONTROL LEVER

INSTRUMENT PANEL

STEERING WHEEL

FRAME LEVEL

INDICATOR

BOOM CONTROL

JOYSTICK

FRAME LEVEL AND

ATTACHMENT TILT

CONTROLLER

HEATER AND A/C

CONTROLS

(IF EQUIPPED)

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

IGNITION

SWITCH

AUXILIARY

HYDRAULICS

CONTROLLER

OUTRIGGER CONTROLS

(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

a. G6-42A - Before S/N 0160040678

G9-43A/G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672

4-2

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

b. G6-42A - S/N 0160040678 & After

MY6450

TRANSMISSION

CONTROL LEVER

INSTRUMENT PANEL

STEERING WHEEL

FRAME LEVEL

INDICATOR

BOOM CONTROL

JOYSTICK

FRAME LEVEL

JOYSTICK

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

IGNITION

SWITCH

ACCESSORY

CONTROL

LEVER

AUXILIARY HYDRAULIC

JOYSTIVCK

(IF EQUIPPED)

HEATER AND A/C

CONTROLS

(IF EQUIPPED)

Cab and Covers

4.1.2 General Overview

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

4-3

Cab and Covers

MY6460

MY6470

TRANSMISSION

CONTROL LEVER

INSTRUMENT PANEL

STEERING WHEEL

FRAME LEVEL

INDICATOR

BOOM CONTROL

JOYSTICK

FRAME LEVEL

AND ATTACHMENT TILT

(IF EQUIPPED) JOYSTICK

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

IGNITION

SWITCH

ACCESSORY

CONTROL

LEVER

AUXILIARY HYDRAULIC

JOYSTICK

HEATER AND A/C

CONTROLS

(IF EQUIPPED)

G9-43A

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

HEATER AND A/C

CONTROLS

(IF EQUIPPED)

G10-43A

FRAME LEVEL

JOYSTICK

c. G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672

4-4

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

WARNING

MY0120

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.

Cab and Covers

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

a. Orbitrol Valve Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the 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 the 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, “Analog 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 the left side of the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

5. Label, disconnect and cap the four hoses from the side of the steering valve (1). Cap the fittings on the steering valve. Label, disconnect and plug the load sense hose at the front of the steering valve. Cap the fitting on the steering valve.

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

4-5

Cab and Covers

MY0141

6. Remove the steering wheel (2), disconnect and remove the travel select lever (3), disconnect the instrument panel harness connector (4).

7. Remove the steering assembly through the dash panel opening.

8. Support the steering valve, and remove the four hexhead capscrews and four lockwashers.

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 the steering valve to the steering column with four hex-flange capscrews and four lockwashers.

2. Install the steering column through the dash panel opening. Position steering valve to its original orientation in the cab.

3. Install the 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

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

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

4. Properly disconnect the battery.

Note: If necessary, install the main dash panel. Refer to Section 9.12.1, “Analog Gauges.”

7. Properly connect the battery.

8. Carefully examine all connections one last time before engine start-up. Rectify any faulty conditions.

9. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

10. Close and secure the engine cover.

11. Remove the Do Not Operate Tags from both the ignition key switch and the 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.”

4-6

5. Remove the bolt and lockwasher (1) securing the service brake pedal pivot pin (2).

6. Pull the pivot pin from the service brake pedal bracket (3).

7. Remove the service brake pedal from the cab.

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.

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

Cab and Covers

MAL0990

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 Throttle Pedal

G6-42A - Before S/N 0160040678

G9-43A/G10-43A - Before S/N 0160040675 excluding

0160040468 & 016040672

a. Throttle Pedal Removal

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

3. Properly disconnect the battery.

b. Throttle Pedal Installation

1. Position the throttle pedal in its mounting location within the cab.

2. Secure the throttle pedal into position with the pivot pin.

3. Install the throttle pedal ball joint to the throttle pedal.

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.

c. Throttle Adjustment

1. From within the cab, lightly depress the accelerator pedal to the full-throttle position. As needed, adjust the limit-stop screw (7) until it touches the pedal. Tighten the locknut.

Note: During the full throttle check:

• DO NOT operate any hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in (N) NEUTRAL.

2. Check the engine rpm at full throttle. If the rpm is not within the specified range, readjust the throttle limit screw at the throttle pedal within the cab. Refer to Section 2.3.5, “Engine Performance Specifications.”

4. Remove the ball joint (4) connected to the throttle pedal.

5. Remove the bolt and lockwasher (5) securing the throttle pedal pivot pin (6).

6. Remove the throttle pedal assembly from the cab.

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

G6-42A - S/N 0160040678 & After

G9-43A/G10-43A - S/N 0160040675 & After including

0160040468 & 016040672

a. Throttle Pedal Removal

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

3. Properly disconnect the battery.

4-7

Cab and Covers

MAL1000

MY6480

(If Equipped)

MY6480

(If Equipped)

4. Disconnect the electrical harness connector (8).

5. Remove the bolts (9) securing the throttle pedal to the throttle pedal bracket (10).

6. Remove the throttle pedal assembly from the cab.

b. Throttle Pedal Installation

1. Position the throttle pedal in its mounting location within the cab.

2. Secure the throttle pedal into position with the pivot pin.

3. Install the throttle pedal ball joint to the throttle pedal.

4. Properly connect the battery.

5. Verify proper throttle 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.

4.3.4 Boom Joystick Assembly

a. Joystick Removal

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

3. Properly disconnect the battery.

4. Lift the joystick’s rubber sleeve (11), remove the bolts securing the boom joystick to the cab.

5. Lift the joystick from its mounting position.

6. Label, disconnect and cap the hydraulic hoses attached to the boom joystick.

7. Disconnect the electrical connectors.

8. 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 joystick functions:

a. Move the joystick handle rearward, activating the

boom lift function. The boom should RISE.

b. Move the joystick handle forward, activating the

boom lower function. The boom should LOWER.

c. Move the joystick handle to the right, activating

the boom extend function. The boom should EXTEND.

d. Move the joystick handle to the left, activating the

boom retract function. The boom should RETRACT.

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

Cab and Covers

e. Push the roller switch (13) down to activate the

tilt up function. The attachment should TILT UP.

f. Push the roller switch (13) up to activate the tilt

down function. The attachment should TILT DOWN.

g. Squeeze and release trigger (14)

(back side of joystick) once to deactivate the Clutch Lock and have the transmission disengage while depressing the service brake. Quickly squeeze and release the trigger twice to activate the Clutch Lock and keep transmission engaged while depressing the service brake.

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 ignition key switch and the steering wheel.

4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and Outriggers (G10-43A) Joysticks

a. Joystick Removal

5. Properly connect the battery.

6. Test the joystick for proper functions.

Auxiliary Hydraulic Joystick

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.

4.3.6 Windshield Wiper Assembly

Refer to Section 9.9, “Window Wiper/Washer Windshield Wiper Motor,” for removal and installation information.

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

3. Properly disconnect the battery.

4. Remove the knob on the end of the joystick (9).

5. Remove the screws (10) securing the dash panel to the cab. Remove the dash panel.

6. Remove any hardware securing the joystick to the cab.

7. Label, disconnect and cap the hydraulic fittings attached to the joystick.

8. Remove the joystick from the cab.

b. Joystick Installation

1. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations.

2. Install the bolts securing the joystick to the cab.

3. Install the dash panel to its original position with the previously used hardware.

4. Install the joystick knob.

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

4-9

Cab and Covers

MY0190

MY0200

4.3.7 Heater/Air Conditioning System (if equipped)

a. Heater Assembly Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF.

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

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

4. Properly disconnect the battery.

5. Place a suitable container beneath the radiator. Slowly turn the radiator cap to the first stop, and allow any pressure to escape. Remove the radiator cap.

6. 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.

7. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.

8. Tighten the radiator drain petcock.

9. Remove the bolts that secure the seat to the cab. Remove the seat.

12. Loosen the hose clamps, label and disconnect the heater hoses (13). Cap or plug the hoses to prevent debris from entering the heater system.

13. Label and disconnect any electrical connections.

14. Remove the bolts securing the heater assembly to the cab. Remove the heater assembly.

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 2.4, “Fluid and Lubricant Capacities.”

8. Properly connect the battery.

10. Remove the bolts securing the front plate (11) to the seat riser weldment (12).

11. Remove the bolts securing the seat riser weldment to the cab. Remove the riser weldment.

4-10

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.

9. Wait for the engine to cool and check the coolant level. Add coolant as required to bring the coolant to the proper level.

10. Close and secure the engine cover.

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

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

Cab and Covers

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 the machine on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the 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 the engine cover. Allow the system fluids to cool.

4. Properly disconnect the 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 the cab heater hoses. Refer to Section

4.3.7, “Heater/Air Conditioning System (if equipped).”

9. Remove the necessary dash panels to gain access to the electrical wiring connections. Label and disconnect the harnesses. Push the harness connectors through the opening in the cab.

10. Remove the boom joystick from is mounting position. Refer to Section 4.3.4, “Boom Joystick Assembly.” Label, disconnect and cap all hydraulic hoses attached to the boom joystick. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

11. Remove the frame level and attachment tilt and auxiliary control joystick. Refer to Section 4.3.5, “Frame Level, Attachment Tilt, Auxiliary Hydraulics and Outriggers (G10-43A) Joysticks.” Label, disconnect and cap all hydraulic hoses attached to the joystick. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

12. Label, disconnect and cap all hydraulic hoses attached to the steering orbital valve. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

13. Label, disconnect and cap all hydraulic hoses attached to the steering orbital valve. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

14. 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.

15. Push all the hydraulic hoses through the opening in the cab.

16. Disconnect the throttle cable from the throttle assembly. Refer to Section 4.3.3, “Throttle Pedal.”

17. Disconnect the engine air filter and hydraulic oil reservoir breather from their brackets at the top of the cab. Move the air filter and breather clear from the cab so they do not become damaged during cab removal.

18. Remove the fuel tank from the cab. Refer to Section

7.6.2, “Fuel Tank.”

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

4-11

Cab and Covers

MY0610

MY4170

MY0610

19. 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).

20. Enclosed Cab: Install two lifting eye bolts (14) in the threaded holes on the roof of the cab above the B pillars (16). Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) through the lifting eye bolts.

24. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

25. 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.

26. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is being removed from the machine.

27. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

28. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

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.

21. Remove the two cab side-mount bolts in the cab (17).

22. Remove the four cab-to-frame bolts, flat washers and nuts (18).

23. Remove the mirrors and all other cab components as needed, if not previously removed.

4-12

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 the threaded holes on the roof of the cab above the B pillars (16). Route a sling with a minimum lifting capacity of 1000 lbs (453 kg) through the lifting eye bolts.

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

Cab and Covers

MY4170

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. Readjust the position of the sling as needed to help balance the cab during installation.

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 2.4, “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.

5. Install the four cab-to-frame mount bolts, washers and nuts (18). Torque to 280-305 lb-ft (379-414 Nm).

6. Install the two cab side mount bolts washers and nuts (17). Torque to 680-720 lb-ft (922-976 Nm).

7. Install the engine air filter and hydraulic oil reservoir breather to their brackets at the top of the cab.

8. Install the throttle cable to the throttle pedal assembly. Refer to Section 4.3.3, “Throttle Pedal.”

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.”

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

4-13

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This Page Intentionally Left Blank

4-14

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

Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGR APH TITLE PAGE

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

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-7

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.5.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . 5-11

5.5.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . 5-12

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7 Towing a Disabled machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

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

5-1

Axles, Drive Shafts, Wheels and Tires

MY0570

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.

5-2

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

Axles, Drive Shafts, Wheels and Tires

5.2 GENERAL INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the 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.

Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace elastic locknuts and any damaged, worn, cracked, seized or otherwise improper parts that could affect the safe and proper functioning of the machine, axles and drive shafts.

5.3 AXLE ASSEMBLIES

5.3.1 Axle Serial Number Plate

The front and rear axle serial number plate is located on a mounting pad on the front side of the center section of each axle. Information on the serial number plate is required in correspondence regarding the axle.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.3.2 Axle Specifications

General axle specifications are found in Section 2.4, “Fluid and Lubricant Capacities.”

5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the following manuals:

G6-42A - Before S/N 0160000847

• Carraro (front) - CA357152 (JLG P/N 31200236)

• Carraro (rear) - CA357153 (JLG P/N 31200237)

G6-42A - S/N 0160000847 & After

• Dana - MO212S20 (JLG P/N 31200162)

G9-43A & G10-43A

• Dana - MO223S10 (JLG P/N 31200239)

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

5.3.4 Axle Maintenance

CLEANING: Clean parts with machined or ground

surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces.

DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemical to help protect them from corrosion. If storing components for a prolonged period, wrap them in wax paper.

5-3

Axles, Drive Shafts, Wheels and Tires

MY4180

PERIODIC OPERATION REQUIREMENT: Every two

weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity.

SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary.

Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly. If replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set.

5.3.5 Axle Removal

The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly.

Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machine. Avoid spraying water or cleaning solution on the stabilizer solenoids and other 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.

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

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

4. Properly disconnect the battery.

5. If the axle will be disassembled after removal, place a suitable receptacle under the axle (1) and wheel hubs drain plugs (2). Remove the drain plugs and allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

Note: Rotate the wheel hubs until the drain plugs are facing down.

6. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.

7. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding.

8. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal.

9. 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.

10. Remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.5.1, “Removing Wheel and Tire Assembly from Machine.”)

Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern “arrows” facing in the direction of forward travel.

11. Remove the drive shaft assembly. Refer to Section

5.4.3, “Drive Shaft Removal.”

12. 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.

13. Remove the bolts and locknuts securing the axle to the frame.

5-4

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

14. Remove the axles from the machine using the jack,

MY0230

MT0220

hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axle. Balance the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand.

5.3.6 Axle Installation

1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine.

2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure.

4. Position the axle under the frame, and align the axle housings with the holes in the frame.

5. Install the four axle bolts and nuts. Tighten and torque to 340-365 lb-ft (460-495 Nm) on the G6-42A. Torque bolts to 530-560 lb-ft (718-759 Nm) on the G9-43A and G10-43A.

6. Move the cylinder into position on the axle cylinder anchor. Insert a cylinder-mount pin through the cylinder and cylinder anchor. Secure the cylindermount 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

5.4.5, “Drive Shaft Installation.”)

9. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission.

Axles, Drive Shafts, Wheels and Tires

10. Tighten the axle oil drain plugs (1), loosen and remove the axle oil fill plug (3) and sight plugs (4). (Refer to Section 2.4, “Fluid and Lubricant Capacities,” for proper oil and capacities.

11. Rotate wheel hubs 90 degrees so the drain plug becomes the fill plug (2). Refer to Section 2.4, “Fluid and Lubricant Capacities,” for proper oil and capacities.

12. Install the wheel and tire assemblies. Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto Machine.”

13. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.

14. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.

15. Remove the blocks from the front and rear of both tires on the 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. Properly connect the battery.

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

5-5

Axles, Drive Shafts, Wheels and Tires

20. Start the engine. Turn the 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.

Note: The service brake circuit will need bled after axle installation. Refer to Section 8.7.3, “Brake Test.”

21. Close and secure the engine cover.

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

5-6

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

Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “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

8. Axle housing damaged. 8. Replace damaged parts.

2. Drain axle and/or wheel end housings and fill oil to correct level. Refer to Section 2.4, “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.

housings and fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

1. Universal joint(s) worn or damaged.

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.

1. Repair or replace universal joints as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

2. Repair or replace universal joints as needed.

3. Replace drive shaft(s) as needed.

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

5-7

Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

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. 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 o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm).

7. Replace housing(s) as needed.

5. Oil leaking from wheel end housing (planet carrier).

6. Oil leaking from steering cylinder.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

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.

4. Cylinder tube damaged. 4. Replace cylinder tube.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

41 lb-ft (55 Nm).

2. Replace o-rings and seals.

3. Replace piston rod seal.

5-8

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

Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to

Section 2.4, “Fluid and Lubricant Capacities.”

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

8. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

3. Worn or damaged swivel bearings.

9. Slow steering response. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

10. Excessive noise when brakes are engaged.

1. Brake discs worn. 1. Check brake discs for wear.

2. Brake discs damaged. 2. Replace brake discs.

2. Drain axle and fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.”

needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Correct bearing preload by adding or removing shims as needed.

3. Replace swivel bearings as needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Repair or replace steering cylinder as needed.

Refer to Section 5.6, “Brakes.”

11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.

2. Brake piston o-rings and seals damaged (leaking).

12. Brakes will not hold the machine or braking power reduced.

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

1. Brake discs worn. 1. Check brake discs for wear.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

1. Refer to Section 8.7.3, “Brake Te st.”

2. Replace o-rings and seals.

Refer to Section 5.6, “Brakes.”

2. Refer to Section 8.7.3, “Brake Te st.”

3. Replace o-rings and seals.

5-9

Axles, Drive Shafts, Wheels and Tires

MT0351

TO AXLE

TRANSMISSION

5.4 DRIVE SHAFTS

5.4.1 Drive Shaft Inspection and Service

Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later.

Inspect areas where the drive shaft flange yokes and slip yokes mount to the 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: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.

5.4.2 Drive Shaft Maintenance

Refer to Section 2.4, “Fluid and Lubricant Capacities,” for information regarding the lubrication of the drive shafts.

7. Remove the four bolts (1) and two straps (2) securing the bearing cross to the transmission output shaft flange.

8. Remove the four bolts (3) and two straps (4) securing the bearing crosses to the axle.

9. Remove the front drive shaft assembly.

10. Repeat the above procedure on the rear drive shaft.

5.4.4 Drive Shaft Cleaning and Drying

5.4.3 Drive Shaft Removal

1. Park the machine on a firm, level surface, level the machine, 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 a Do Not Operate Tag on both the ignition key switch and steering wheel.

3. Open the 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 the yoke and axle, transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.

2. Remove any burrs or rough spots from all machined surfaces. Re-clean and dry as required.

5.4.5 Drive Shaft Installation

1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal.

2. Apply Loctite

3. Install the two straps (1) and four new bolts (2) securing the bearing crosses to the transmission. Torque bolts to 55-60 lb-ft (75-81 Nm).

4. Install the two straps (3) and four new bolts (4) securing the bearing crosses to the axle. Torque bolts to 55-60 lb-ft (75-81 Nm).

5. Repeat the above procedure on the rear drive shaft.

6. Properly connect the battery.

7. Close and secure the engine cover.

8. Unblock the wheels.

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

243™ to all mounting bolts.

5-10

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

5.5 WHEELS AND TIRES

MY4190

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.

JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using a JLG approved replacement tire, JLG recommends that replacement tires have the following characteristics:

Axles, Drive Shafts, Wheels and Tires

• 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. JLG does not recommend the use of hydrofill as a tire-fill substance 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.

The wheel and tire assemblies must be installed with the directional tread pattern “arrows” (5) facing in the direction of forward travel.

5.5.1 Removing Wheel and Tire Assembly from Machine

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, stating that the machine should not be operated.

3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the 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 the wheel and tire assembly from the machine.

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

5-11

Axles, Drive Shafts, Wheels and Tires

MAH0460

TREAD “ARROWS” MUST

POINT FORWARD

INSTALL TIRES ONTO

WHEELS TO ROTATE IN

PROPER DIRECTION

MY4200

MY0260

5.5.2 Installing Wheel and Tire Assembly onto Machine

Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

5.6 BRAKES

Check the brake disks for wear every 1,000 hours of operation or yearly.

For more information on brake disk inspection, refer to the appropriate axle repair manual.

5.7 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.

5.7.1 Manually Releasing the Park Brake

a. Before S/N 0160000847

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

4. Tighten lug nuts in an alternating pattern as

5. Remove machine from supports.

5-12

NOT use a lubricant on threads or nuts.

indicated in figure. Torque to 350-400 lb-ft (475-542 Nm).

1. On one side of the axle, remove the three plugs from the differential housing.

2. Tighten each release screw (6) revealed by the plugs, lightly until it just makes contact with the guide pin.

3. Carefully tighten each release screw a 1/4 turn at a time in sequence until all three have been turned one full turn 360°.

Note: Larger turns could cause components to bind and cause brake failure. DO NOT over tighten.

4. Repeat steps 1 thru 3 for the other side of the differential.

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 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

2.2.2 Metric Fastener Torque Chart

2.2.3 Hydraulic Hose Torque Chart

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

2.3.2 Hydraulic Cylinder Performance

2.3.3 Engine Performance Specifications

2.3.4 Electrical System

2.3.5 Tires

2.4 FLUID AND LUBRICANT CAPACITIES

2.5 SERVICE AND MAINTENANCE SCHEDULE

2.5.1 10, 1st 50 & 50 Hour

2.5.2 1st 250, 250 & 500 Hour

2.5.3 1000, 1500 & 2000 Hour

2.6 LUBRICATION SCHEDULE

2.6.1 G6-42A

2.6.2 G9-43A / G10-43A

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

3.5.2 Third Boom Section Removal

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

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

3.8.3 Chain Tension Inspection— G9-43A/G10-43A

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

3.9 QUICK SWITCH ASSEMBLY

3.9.1 Quick Switch Removal

3.9.3 Quick Switch Removal

3.9.2 Quick Switch Installation

3.9.4 Quick Switch Installation

3.10 BOOM HEAD - MOUNTED WINCH

3.10.1 Boom Head-Mounted Winch Removal

3.11 BOOM WEAR PADS

3.11.1 Wear Pad Inspection

3.11.2 Wear Pad Installation and Lubrication

3.10.2 Boom Head-Mounted Winch Installation

3.12 BOOM EXTEND AND RETRACT CHAINS

3.12.1 Boom Chain Inspection

3.12.2 Inspection Guidelines

3.12.3 Chain Lubrication

3.13 FORKS

3.14 EMERGENCY BOOM LOWERING PROCEDURE

3.14.1 Equipment and Supplies Required

3.14.2 Lowering Procedure

3.15 TROUBLESHOOTING

3.16 PUSH BEAM TEMPORARY BRACKETS

4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY

4.1.1 General Overview

4.1.2 General Overview

4.2 OPERATOR CAB

4.2.1 Cab Safety

4.3 CAB COMPONENTS