JLG G6-42A Service Manual

4.3 (8)
An Oshkosh Corporation Company
Service Manual
Models
G6-42A, G9-43A
& G10-43A
G6-42A
Before S/N 0160048658
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
i
Section Subject Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 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
ii
G6-42A, G9-43A, G10-43A
Section Subject Page
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
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
iv
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
C
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.
1
1

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
TM
Vibra-TITETM121
Medium Strength (Blue)
0100019
271
TM
Vibra-TITETM140
High Strength (Red)
0100071
262
TM
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™
OR
Vibra-TITE™ 131
Torque
Loctite® 242™ or 271™
OR
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™
OR
Vibra-TITE™ 131
Torque
Loctite® 242™ or 271™
OR
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™
OR
Vibra-TITE™ 131
Torque
Loctite® 242™ or 271™
OR
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
TM
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
TM
or Vibra-
TITE
TM
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
TM
)
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™
OR
Vibra-TITE™ 131
Torque
Loctite®
242™ or 271™
OR
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™
OR
Vibra-TITE™ 131
Torque Dry
or
Loctite® 263™
Torque
Lube OR Loctite®
242™ or 271™
OR
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™
OR
Vibra-TITE™ 131
Torque
Lube OR Loctite®
242™ or 271™
OR
Vibra-TITE™
111 or 140
Torque Dry
or
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
4
6
8
10
12
16
20
24
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
1.5 to 1.75
1.0 to 1.5
0.75 to 1.0
0.75 to 1.0
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
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
10
EVERY
Check Tire
Condition &
Pressure
50
1
st
Check Wheel
Lug Nut
Torque
LB/FT (Nm)
50
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
Loading...
+ 216 hidden pages