G9 43A Service

Service Manual
Models G6-42A, G9-43A, G10-43A

31200151
Revised September 20, 2011
An Oshkosh Corporation Company
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.
31200151
G6-42A, G9-43A, G10-43A
EFFECTIVITY PAGE
-ii
G6-42A, G9-43A, G10-43A
31200151
SECTION CONTENTS
Section Subject Page
Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 1.2 1.3 1.4 1.5 1.6 1.7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2 1-2 1-2 1-2 1-2 1-3 1-4
Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 2.2 2.3 2.4 2.5 2.6 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2 2-3 2-11 2-15 2-18 2-21
Section 3 Boom
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10
...........................................................
Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2 3-3 3-3 3-3 3-7 3-12 3-13 3-14 3-15 3-16
Section 4 Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 4.2 4.3 4.4 4.5 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2 4-5 4-5 4-11 4-12
G6-42A, G9-43A, G10-43A
Section
Subject
Page
Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 5.2 5.3 5.4 5.5 5.6 5.7 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-2 5-3 5-3 5-10 5-11 5-12 5-12
Section 6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 6.2 6.3 6.4 6.5 6.6 6.7 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2 6-4 6-4 6-4 6-7 6-8 6-10
Section 7 Engine
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10
...........................................................
Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-2 7-4 7-6 7-8 7-10 7-10 7-12 7-13 7-14 7-17
Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-2 8-3 8-4 8-5 8-17 8-18 8-19 8-25
ii
G6-42A, G9-43A, G10-43A
Section
Subject
Page
Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . . 9.15 Hand Held Analyzer (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . . 9.16 Joystick Fault Codes (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . . 9.17 Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . . . . . .
9-1
9-3 9-5 9-5 9-5 9-10 9-38 9-45 9-46 9-47 9-48 9-49 9-55 9-56 9-58 9-60 9-62 9-67 9-68
G6-42A, G9-43A, G10-43A
iii
Section
Subject
Page
iv
G6-42A, G9-43A, G10-43A
Section 1 Safety Practices
Contents
PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 TITLE PAGE 1.2 1.2 1.2 1.2 1.2 1.2 1.3 1.3 1.3 1.3 1.4 1.4
1.7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
1-1
Safety Practices
1.1
INTRODUCTION
1.4
DO NOT OPERATE TAGS
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 operators 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.
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
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
1.2
DISCLAIMER
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.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
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
G6-42A, G9-43A, G10-43A
Safety Practices
1.6
SAFETY INSTRUCTIONS
1.6.3
General Hazards
Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding.
SOLVENTS: Only use approved solvents that are known to be safe for use. HOUSEKEEPING: Keep the work area and operators 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.
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.
G6-42A, G9-43A, G10-43A
1-3
Safety Practices 1.6.4 Operational Hazards

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.
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.
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
PARAGRAPH 2.1 2.2 TITLE PAGE 2-2 2-3 2-3 2-7 2-10 2-11 2-11 2-11 2-12 2-13 2-14 2-15 2-18 2-18 2-19 2-20 2-21 2-21 2-24
2.3
2.4 2.5
2.6
Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2 G9-43A / G10-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
2-1
General Information and Specifications
2.1
REPLACEMENT PARTS AND WARRANTY INFORMATION
DO NOT GO NEAR LEAKS

C
* 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.
10814B
MY0070
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
2.2.1
TORQUE CHARTS
SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Size TPI Bolt Dia Tensile Clamp Load Stress Area Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 LB 380 420 580 610 900 940 1120 1285 2020 2320 LB 3340 3700 4940 5600 6800 7550 9050 10700 11600 12950 14400 16300 21300 23800 29400 32400 38600 42200 42300 47500 53800 59600 64100 73000 78000 87700 Torque (Dry) IN-LB 8 9 16 18 30 31 43 49 96 120 FT-LB 17 19 30 35 50 55 75 90 110 120 150 170 260 300 430 470 640 700 800 880 1120 1240 1460 1680 1940 2200 [N.m] 0.9 1.0 1.8 2.0 3.4 3.5 4.8 5.5 10.8 13.5 [N.m] 23 26 41 47 68 75 102 122 149 163 203 230 353 407 583 637 868 949 1085 1193 1518 1681 1979 2278 2630 2983 Torque Lubricated IN-LB 6 7 12 13 22 23 32 36 75 86 FT-LB 13 14 23 25 35 40 55 65 80 90 110 130 200 220 320 350 480 530 600 660 840 920 1100 1260 1460 1640 [N.m] 0.7 0.8 1.4 1.5 2.5 2.6 3.5 4 9 10 [N.m] 18 19 31 34 47 54 75 88 108 122 149 176 271 298 434 475 651 719 813 895 1139 1247 1491 1708 1979 2224
Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 Torque Loctite 262 OR Vibra-TITE 131
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
IN-LB
[N.m]
IN-LB
[N.m]
105 135 FT-LB 19 21 35 40 55 60 85 100 120 135 165 190 285 330 475 520 675 735 840 925 1175 1300 1525 1750 2025 2300
12 15 [N.m] 26 29 48 54 75 82 116 136 163 184 224 258 388 449 646 707 918 1000 1142 1258 1598 1768 2074 2380 2754 3128 FT-LB 16 17 28 32 45 50 68 80 98 109 135 153 240 268 386 425 579 633 714 802 1009 1118 1322 1506 1755 1974 [N.m] 22 23 38 43 61 68 92 108 133 148 183 207 325 363 523 576 785 858 968 1087 1368 1516 1792 2042 2379 2676
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
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% 3. * ASSEMBLY USES HARDENED WASHER
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N

0100011 0100019 0100071
Loctite P/N
242TM 271TM 262TM
ND Industries P/N
Vibra-TITE TM 121 Vibra-TITE TM 140 Vibra-TITE TM 131
Description Medium Strength (Blue) High Strength (Red) Medium - High Strength (Red)
MY4650J
G6-42A, G9-43A, G10-43A
2-3
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Size TPI Bolt Dia Tensile Clamp Load Stress Area Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 LB Torque (Dry or Loctite 263) K= 0.20 IN-LB [N.m]
Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 K=.18

IN-LB [N.m]
Torque Loctite 262 OR Vibra-TITE 131 K=0.15

IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
1320 1580 1800 2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
43 60 68 143 164 FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
5 7 8 16 19 [N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
129 148 FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 770 895 1160 1300 1635 1810 2145 2435 2845 3200
15 17 [N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1045 1215 1580 1770 2225 2460 2915 3310 3870 4350 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
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% 3. * ASSEMBLY USES HARDENED WASHER MY4660J
2-4
G6-42A, G9-43A, G10-43A
SOCKET HEAD CAP SCREWS

Magni Coating*
Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17
Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 OR Precoat 85 K=0.16

IN-LB [N.m]
Torque Loctite 262 OR Vibra-TITE 131 K=0.15

IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB
IN-LB
[N.m]
2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
122 139 FT-LB 20 25 35 40 60 65 90 100 130 145 180 205 320 355 515 570 730 845 1095 1225 1545 1710 2025 2300 2690 3020
14 16 [N.m] 25 35 50 55 80 90 120 135 175 195 245 280 435 485 700 775 995 1150 1490 1665 2100 2325 2755 3130 3660 4105
114 131 FT-LB 20 20 35 40 55 60 85 95 125 135 170 190 300 335 485 535 685 795 1030 1155 1455 1610 1905 2165 2530 2845
13 15 [N.m] 25 25 50 55 75 80 115 130 170 185 230 260 410 455 660 730 930 1080 1400 1570 1980 2190 2590 2945 3440 3870 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m] 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
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% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 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. MY4670J
G6-42A, G9-43A, G10-43A
2-5
SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners*
Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .20 IN-LB [N.m] Torque (Loctite 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85 K=0.18 IN-LB [N.m] Torque (Loctite 262TM TM or Vibra-TITE 131) K=0.15 IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB
2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
143 164 FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
16 19 [N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
129 148 FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 775 895 1160 1300 1635 1810 2145 2435 2845 3200
15 17 [N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1055 1215 1580 1770 2225 2460 2915 3310 3870 4350 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m] 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
2-6
G6-42A, G9-43A, G10-43A
General Information and Specifications 2.2.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS
Torque Loctite Torque Loctite 262 242 or 271 OR OR Vibra-TITE 131 Vibra-TITE 111 or 140
[N.m] 1.2 1.9 2.8 5.6 9.4 16 23 45 79 126 197 271 383 523 663 970 1320 1790 2300 3680 [N.m] 1.4 2.3 3.4 6.8 12 19 28 55 97 154 241 331 469 639 811 1130 1530 2090 2690 4290
Size
PITCH
Tensile Stress Area
Clamp Load
Torque (Dry or Loctite 263TM)
Torque (Lub)
Sq mm 3 3.5 4 5 6 7 8 10 12 14 16 18 20 22 24 27 30 33 36 42 0.5 0.6 0.7 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5 4 4.5 5.03 6.78 8.78 14.20 20.10 28.90 36.60 58.00 84.30 115 157 192 245 303 353 459 561 694 817 1120
KN 2.19 2.95 3.82 6.18 8.74 12.6 15.9 25.2 36.7 50.0 68.3 83.5 106.5 132.0 153.5 199.5 244.0 302.0 355.5 487.0
[N.m] 1.3 2.1 3.1 6.2 11 18 26 50 88 140 219 301 426 581 737 1080 1460 1990 2560 4090
[N.m] 1.0 1.6 2.3 4.6 7.9 13 19 38 66 105 164 226 320 436 553 810 1100 1490 1920 3070
G6-42A, G9-43A, G10-43A
2-7
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque Lube OR Loctite 242 or 271 OR Vibra-TITE 111 or 140 K= 0.18
[N.m]
Size
PITCH
Tensile Stress Area
Clamp Load
Torque Dry or Loctite 263

K = 0.20
Torque Loctite 262 OR Vibra-TITE 131

K=0.15 [N.m]
Sq mm 3 3.5 4 5 6 7 8 10 12 14 16 18 20 22 24 27 30 33 36 42 0.5 0.6 0.7 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5 4 4.5 5.03 6.78 8.78 14.20 20.10 28.90 36.60 58.00 84.30 115 157 192 245 303 353 459 561 694 817 1120
KN 3.13 4.22 5.47 8.85 12.5 18.0 22.8 36.1 52.5 71.6 97.8 119.5 152.5 189.0 222.0 286.0 349.5 432.5 509.0 698.0
[N.m]
25.2 36.5 70 125 200 315 430 610 830 1065 1545 2095 2855 3665 5865
22.7 32.8 65 115 180 280 385 550 750 960 1390 1885 2570 3300 5275
18.9 27.4 55 95 150 235 325 460 625 800 1160 1575 2140 2750 4395
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% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 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, MY4700J ADDITIONAL TESTING IS REQUIRED.
2-8
G6-42A, G9-43A, G10-43A
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued)
Magni Coating*
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Torque Lube OR Loctite Torque Torque Dry 242 or 271 Loctite 262 or OR OR Loctite 263 Vibra-TITE Vibra-TITE 131 111 or 140 K = .17 K = .16 K = .15
[N.m] [N.m] [N.m]
Size
PITCH
Tensile Stress Area
Clamp Load See Note 4
Sq mm 3 3.5 4 5 6 7 8 10 12 14 16 18 20 22 24 27 30 33 36 42 0.5 0.6 0.7 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5 4 4.5 5.03 6.78 8.78 14.20 20.10 28.90 36.60 58.00 84.30 115 157 192 245 303 353 459 561 694 817 1120
kN
12.5 18.0 22.8 36.1 52.5 71.6 97.8 119.5 152.5 189.0 220.0 286.0 349.5 432.5 509.0 698.0
13 21 31 61 105 170 265 365 520 705 900 1315 1780 2425 3115 4985
12 20 29 58 100 160 250 345 490 665 845 1235 1680 2285 2930 4690
11 19 27 54 95 150 235 325 460 625 790 1160 1575 2140 2750 4395
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 4 6 8 10 12 16 20 24 32 ORFS 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) N/A JIC 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) 270 lb-ft (366 Nm) Flats Method 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 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 its 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.
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.
2-10
G6-42A, G9-43A, G10-43A
2.3
2.3.1
SPECIFICATIONS
Travel Speeds
G6-42A G9-43A & G10-43A 3.2 mph (5,1 km/h) 7.0 mph (11,2 km/h) 14.0 mph (22,5 km/h) 19.5 mph (31,4 km/h)
First Gear Second Gear Third Gear Fourth Gear
3.7 mph (5,6 km/h) 8.0 mph (12,9 km/h) 16.1 mph (25,9 km/h) 20.5 mph (32,9 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. Approximate Times (seconds) G6-42A 13.8 13.4 12.6 9.4 3.8 3.4 7.7 3.5 N/A N/A G9-43A & G10-43A 13.4 10.2 10.7 8.6 3.5 3.1 9.3 10.7 5.8 (G10-43A Only) 4.4 (G10-43A Only)
Function Boom Extend (Boom Level) Boom Retract Boom Lift Boom Lower Attachment Tilt Forward Attachment Tilt Rearward Frame Level - Full Right to Left Frame Level - Full Left to Right Outriggers Down (Boom Level- No Load) Outriggers Up (Boom Level- No Load)
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 Engine Make/Model Displacement Low Idle (with A/C) High Idle Horsepower Peak Torque Fuel Delivery Average Fuel Consumption (depending on load/duty) Air Cleaner G6-42A Naturally Aspirated John Deere PE 4045D150 276 in (4,5 liters) 825 to 875 rpm (950 to 1000 rpm) 2,675 to 2,750 rpm 80 HP (60 kW) @ 2500 rpm 215 lb-ft (292 Nm) @ 1200 rpm Fuel Injection 2.6 gal/hr (9,8 l/hr) Dry Type, Replaceable Primary and Safety Elements G6-42A - G9-43A Turbo John Deere PE 4045TF150 276 in (4,5 liters) 825 to 875 rpm (950 to 1000 rpm) 2,675 to 2,750 rpm 100 HP (75 kW) @ 2500 rpm 274 lb-ft (372 Nm) @ 1400 rpm Fuel Injection 3.0 gal/hr (11,4 l/hr) Dry Type, Replaceable Primary and Safety Elements
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 Engine Make/Model Displacement Low Idle (with A/C) High Idle Horsepower Peak Torque Fuel Delivery Average Fuel Consumption (depending on load/duty) Air Cleaner G6-42A, G9-43A & G10-43A John Deere PE 4045TF270 275 in (4,5 liters) 800 to 900rpm 2600 rpm 99 HP (74 kW) @ 2500 rpm 272 lb-ft (369 Nm) @ 1400 rpm Fuel Injection 3.2 gal/hr (12,1 l/hr) Dry Type, Replaceable Primary and Safety Elements
2-12
G6-42A, G9-43A, G10-43A
Description Engine Make/Model Displacement Low Idle High Idle Horsepower Peak Torque Fuel Delivery Average Fuel Consumption (depending on load/duty) Air Cleaner
G6-42A, G9-43A & G10-43A Perkins 1104-C 44T 268 in (4,4 liters) 800 to 850 rpm 2475 to 2525 rpm 99 HP (74 kW) @ 2500 rpm 372 lb-ft (504 Nm) @ 1400 rpm Fuel Injection Not Available 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 Engine Make/Model Displacement Low Idle High Idle Horsepower Peak Torque Fuel Delivery Average Fuel Consumption (depending on load/duty) Air Cleaner G6-42A, G9-43A & G10-43A Cummins QSB3.3 201 in (3,3 liters) 1000 rpm 2600 rpm 99 HP (74 kW) @ 2600 rpm 306 lb-ft (415 Nm) @ 1600 rpm Fuel Injection Not Available Dry Type, Replaceable Primary and Safety Elements
2.3.4
Battery:
Electrical System
Type, Rating Quantity Reserve Capacity Group/Series Alternator (with Optional A/C)
12 BCI, Negative (-) Ground, Maintenance Free 1 1000 Cold Cranking Amps @ 0 F (-18 C) Group 31 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 13.00 x 24 Tire Type G-2/L-2 Bias Ply Traction Minimum Ply/ Star Rating 12 Ply Fill Type Pneumatic Foam - Approx. 542 lb (246 kg) Pneumatic Foam - Approx. 542 lb (246 kg) Pneumatic Foam - Approx. 542 lb (246 kg) Pneumatic Foam - Approx. 600 lb (272 kg) Pneumatic Foam - Approx. 600 lb (272 kg) Pneumatic Foam - Approx. 600 lb (272 kg) Pneumatic Foam-Approx 464 lb (210 kg) Pressure 65 psi (4,5 bar) 60 psi (4,1 bar) 65 psi (4,5 bar) 65 psi (4,5 bar) 70 psi (4,8 bar) 70 psi (4,8 bar) 58 psi (4,0 bar) 58 psi (4,0 bar) 65 psi (4,5 bar) 65 psi (4,5 bar) 70 psi (4,8 bar) 70 psi (4,8 bar) 76 psi (5,2 bar) 73 psi (5,0 bar)
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
12 Ply
15.50 x 25
G-2/L-2 Radial
1 Star
370/75x28
DuraForce
14 Ply
a. G10-43A Size 14.00 x 24 Tire Type G-2/L-2 Bias Ply Traction Minimum Ply/ Star Rating 12 Ply Fill Type Pneumatic Foam - Approx. 720 lb (327 kg) Pneumatic Foam - Approx. 720 lb (327 kg) Pneumatic Foam-Approx 570 lb (2259 kg) Pressure 70 psi (4,8 bar) 62 psi (4,3 bar) 70 psi (4,8 bar) 62 psi (4,3 bar) 76 psi (5,2 bar) 73 psi (5,0 bar)
14.00 x 24
12 Ply
400/75-28
DuraForce
16 Ply
2-14
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 S/N 0160007869 thru 0160040674 Perkins G6-42A - S/N 0160040678 & After G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672 Cummins Oil Type 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Fuel Tank Capacity Type of Fuel 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Anti-gel Fluid -40 to 0 F (-40 to -20 C) Cooling System System Capacity G6-42A - Before S/N 0160040678 G6-42A - S/N 0160040678 & After G9-43A & G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672 G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672 Overflow Bottle Capacity G6-42A - S/N 0160040678 & After G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672 2.5 quart (2,4 liters) 15.2 quarts (14,4 liters) 18 quarts (17 liters) 22 quarts (20,8 liters) 18 quarts (17 liters) 16 ounce (0,5 liters) Low Sulfur Diesel #2 Low Sulfur Diesel #1 38 gallons (144 liters) 15W-40 CH 0W-40 CH 7.6 quarts (7,2 liters) 14.5 quarts (13,7 liters) 15.5 quarts (14,7 liters) 7 quarts (6,5 liters)
G6-42A, G9-43A, G10-43A
2-15
Type of Fluid 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Coolant Conditioner (refer engine manual) Transmission Capacity with Filter Change G6-42A G9-43A & G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672 G9-43A & G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672 Type of Fluid 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Transfer Case Capacity G6-42A - Before S/N 0160040678 G6-42A - S/N 0160040678 & After G9-43A & G10-43A Type of Fluid 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Axles G6-42A - Differential Housing Capacity Front Rear Wheel End Capacity G9-43A & G10-43A - Differential Housing Capacity Front & Rear Wheel End Capacity Type of Fluid 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) Mobilfluid LT (75W-80) Hydraulic Fluid 15 quarts (14,2 liters) 1.75 quarts (1,7 liters) 6.5 quarts (6,1 liters) 7.0 quarts (6,6 liters) 1.7 quarts (1,6 liters) Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) Mobilfluid LT (75W-80) Hydraulic Fluid 0.8 quarts (0,8 liters) 1.5 quarts (1,4 liters) Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) Mobilfluid LT (75W-80) Hydraulic Fluid 4.2 gallons (15,8 liters) 3.4 gallons (12,9 liters) 4.2 gallons (15,8 liters) 50/50 ethylene glycol & water 60/40 ethylene glycol & water 0.5 quarts (0,47 liters)
2-16
G6-42A, G9-43A, G10-43A
Hydraulic System System Capacity G6-42A G9-43A & G10-43A Reservoir Capacity G6-42A G9-43A & G10-43A Type of Fluid 0 to 104 F (-20 to 40 C) -40 to 0 F (-40 to -20 C) Air Conditioning System (if equipped) System Capacity 2.5 lb (1134 g) Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) Exxon Univis HVI All Season Hydraulic Fluid 20 gallons (75,7 liters) 23.3 gallons (88,2 liters) 43 gallons (163 liters) 40 gallons (151 liters)
G6-42A, G9-43A, G10-43A
2-17
2.5
SERVICE AND MAINTENANCE SCHEDULE

10, 1st 50 & 50 Hour
2.5.1
EVERY
10
Check Fuel Level
Air Filter Restriction Indicator
Check Engine Oil Level
Check Hydraulic Oil Level
Check Tire Condition & Pressure
Check Hydraulic Return Check Transmission Filter Indicator (Before S/N 0160040675) Oil Level
50
LB/F T (N m)
1st
Check Wheel Lug Nut Torque
EVERY
50
Drain Fuel/ Water Separator
Check Engine Coolant Level
Check Battery
Check Washer Fluid Level (if equipped)
Lubrication Schedule
MY6040
2-18
G6-42A, G9-43A, G10-43A
General Information and Specifications 2.5.2 1st 250, 250 & 500 Hour
250
1st
Change Axle Oil
Change Wheel End Oil
Change Transmission Oil & Filter
Change Transfer Case Oil
EVERY
250
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
EVERY
500
LB/F T (N m)
Change Fuel Filters
Change Fuel Strainer (Before S/N 0160040675)
Check Wheel Lug Nut Torque

MY6050
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 2.5.3 1000, 1500 & 2000 Hour
EVERY
1000
Change Transmission Oil & Filter
Change Transfer Case Oil
Change Axle Oil
Change Wheel End Oil
Check Air Intake System
Check Boom Chains
EVERY
1500
Change Hydraulic Fluid & Filters
Change Hydraulic Tank Breather
Change Engine Coolant (Before S/N 0160040675)
EVERY
2000
Change Engine Engine Valve Coolant (S/N Lash Adjustment 0160040675 & After)
MY6060
2-20
G6-42A, G9-43A, G10-43A
2.6
2.6.1
LUBRICATION SCHEDULE
G6-42A
a. 50 Hour
EVERY
50
2 B
2 B B 2 B 2
B 2
2 B B 2 B 2
B 2
OY2270
G6-42A, G9-43A, G10-43A
2-21

b. 250 Hour
EVERY
250
2 B
2 B B 2
2 B
B 2
B 2
B 2
B 2
2 A
2 A
A 2
A 2
OY2280
2-22
G6-42A, G9-43A, G10-43A

c. 1000 Hour
EVERY
1000
OY2290
G6-42A, G9-43A, G10-43A
2-23
General Information and Specifications 2.6.2 G9-43A / G10-43A
a. 50 Hour
EVERY
50
G10-43A
2 B
2 B
B 2
B 2
B B 2 B 2 B 2
2 2 2 4 2 2
G10-43A
OY2550
2-24
G6-42A, G9-43A, G10-43A

b. 250 Hour
EVERY
250
2 B B B 2 2 B B 2 B 2 B
2 A
A A A A A
A 2
A 2
G10-43A
OY2560
G6-42A, G9-43A, G10-43A
2-25

c. 1000 Hour
EVERY
1000
G10-43A
OY2570
2-26
G6-42A, G9-43A, G10-43A
Section 3 Boom
Contents
PARAGRAPH 3.1 3.2 3.3 3.4 TITLE PAGE 3-2 3-3 3-3 3-3 3-3 3-4 3-4 3-5 3-6 3-6 3-7 3-7 3-8 3-10 3-10 3-10 3-11 3-12 3-13 3-13 3-13 3-14 3-14 3-14 3-14 3-14 3-15 3-15 3-15 3-16
3.5
3.6 3.7
3.8
3.9
3.10
Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Second & Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.5 Second & Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . 3.4.6 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.5 Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.6 Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Wear Pad Installation and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.4 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 Boom Head-Mounted Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
3-1
Boom
3.1
BOOM SYSTEM COMPONENT TERMINOLOGY
The following illustrations identify the components that are referred to throughout this section.
THIRD BOOM SECTION SECOND BOOM SECTION EXTEND CHAIN (INSIDE BOOM)
FIRST BOOM SECTION
TILT CYLINDER QUICK SWITCH
EXTEND/RETRACT CYLINDER (INSIDE BOOM) RETRACT CHAIN (INSIDE BOOM)
HOSE SHEAVE (INSIDE BOOM)

MY0110
3-2
G6-42A, G9-43A, G10-43A
Boom
3.2
SAFETY INFORMATION
3.4
BOOM ASSEMBLY MAINTENANCE
WARNING
DO NOT service the machine without following all safety precautions as outlined in Section 1, Safety Practices, of this manual.
These instructions must be completed in sequence. The second and third boom sections are removed from the first boom section.The third boom section is removed from the second boom section. 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. Note: These instructions are for the removal and installation of the optional auxiliary hydraulic boom. The instructions do not differ from the standard boom except for the extra auxiliary hydraulic hoses and sheave.
3.3
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 and third boom sections are 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 second and third boom sections 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.
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.
3.4.1
Boom Removal
1. Remove any attachment from the quick switch assembly. Note: If replacing the third section boom, remove the quick switch from the third section. Refer to Section 3.8.1, Quick Switch Removal. 2. 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. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the engine cover. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Using a suitable sling or hoist, support the boom. 7. 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. 8. Label and disconnect any electrical cables (if equipped) at the rear of the boom. 9. 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.
G6-42A, G9-43A, G10-43A
3-3
Boom
10. Remove the pin from the rod end of the lift/lower cylinder. Lower the cylinder onto the frame rails.
2
1
MY1520
MY0580
11. Confirm that the boom assembly is balanced with the sling and remove the boom assembly pivot pin (1). 12. Lift the boom assembly from the machine and lower onto suitable supports.
5. Remove the locknut and jam nut (2) from the extend chain at the rear of the boom. 6. Remove the extend/retract cylinder mounting pin, hose guards and strong back (3) from the rear of the boom. 7. Remove the strong back from the rear of the boom. 8. Reaching inside the rear of the boom at the chain anchor bracket, remove the cotter pin and pin from the retract chain clevis. Pull the chain out of the boom. 9. Place a suitable sling around the second boom section. Lift and slowly pull the second and third boom sections approximately half way out of the first boom section. Lower the second and third boom sections onto a suitable support. 10. 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 cables. Lower the second and third boom sections onto suitable supports.
3.4.2
Second & Third Boom Section Removal
1. Set the complete boom on level ground and by repositioning the slings, turn boom over on to the top side. Set the complete boom on suitable stands to begin tear down. Note: With the complete boom setting upside down, the removal and replacing of each boom section, hoses, extend and retract chains and hose carrier are made much easier. 2. Remove all wear pads, shims and backing plates from the front inside of the first boom section. Label and tag each set of wear pads being removed. 3. Loosen the hose brackets on the bottom front of the first boom section. Disconnect both tilt hoses and both auxiliary hoses (if equipped) inside the boom, below the take-up brackets. Plug the hose ends and cap the tube ends to prevent dirt & debris from entering the hydraulic system. 4. Loosen the locknut and jam nut on the retract chain at the front of the first boom section. Loosen and remove the bolts securing the retract chain adjusting block.
3.4.3
Third Boom Section Removal
1. Remove all wear pads and shims from the front inside of the second boom section. Label and tag each set of wear pads being removed. 2. Loosen and remove the tilt circuit hoses from the tilt cylinder at the front of the third boom section. Loosen and remove the auxiliary circuit hoses from the quick disconnect fittings at the front of the third boom section. Plug the hose ends and cap the fitting ends to prevent dirt & debris from entering the hydraulic system. 3. Remove the extend chain clevis from the third boom section bracket.
3-4
G6-42A, G9-43A, G10-43A
Boom
4. Connect the auxiliary hoses to the quick disconnects on the side of the boom head (if equipped). Connect the electrical cable to the plug mounted below the auxiliary quick disconnects (if equipped). 5. If necessary, install the extend/retract cylinder into the push beam. Torque nut to 155-195 lb-ft (210-264 Nm). Note: Be sure that the threaded end of the extend/ retract cylinder is flush with the back of the push beam plate before tightening the nut.
4
MY1520
4. At the rear of the boom, loosen and remove all retract chain sheave components (4) and the hydraulic hose rollers and components. 5. Loosen and remove all push beam pins. 6. Pull the push beam towards the front of the boom. Remove the chain retainer and guide bar. 7. Pull the push beam assembly along with the extend chain, through the front of the third boom section. As the push beam assembly and extend chain come out of the boom, secure them together with tie wraps. 8. If necessary, remove the nut, tab washer and washer from the extend/retract cylinder from the push beam assembly. Pull the extend/retract cylinder out through the rear of the push beam assembly. 9. Place the hydraulic hoses inside the third boom section. 10. Place a sling around the third boom section. Lift and slowly pull the third boom section approximately half way out of the second boom section. Lower the third boom section onto a suitable support. 11. Relocate the sling or using two slings for better stability, balance the third boom section and slowly pull the third boom section out of the second boom section. Lower the third boom section onto suitable supports.
6. Install the push beam assembly along with the still attached extend chain, through the front of the third boom section. Removing the tie wraps as they enter the boom. The end tie may remain fixed as it can be removed through the rear of the boom.
5
MY1530
7. Install the chain retainer (5) and guide bar (6). 8. Lubricate the inside of the second boom section on areas where the third boom section wear pads will slide. 9. Using a suitable sling, balance the third boom section and carefully slide 3-4 ft (90-120 cm) into the front of the second boom section. 10. Set the third boom section onto suitable supports and reset the sling under the boom head. Carefully slide the third boom section into the second boom section. Leave 6-8 in (10-15 cm) of the third boom section out to be able to install the wear pads in the front of the second boom section. 11. Install the push beam mounting pins and locking hardware to the second boom section. 12. With the sling still under the boom head, install the wear pads and spacers in the front of the second boom section.
3.4.4
Third Boom Section Installation
1. Install the wear pads and spacers on the bottom and both sides at the rear of the third boom section. For ease of installation, do not install the top wear pads at this time. 2. Install the hydraulic hoses, electrical cables and brackets inside protected areas. 3. Install the hose brackets in place at the front of the third boom section.
G6-42A, G9-43A, G10-43A
3-5
Boom 3.4.5 Second & Third Boom Section Installation

11. Place the extend chain rod through the strong back. Install the adjusting and jam nuts. Do not tighten at this time. 12. At the retract chain mounting block, tighten the retract chain adjusting nut until the front of the threaded end lines up with the front edge of the access hole.
9
1. Install the wear pads and spacers on the bottom and both sides at the rear of the second boom section. For ease of installation, do not install the top wear pads at this time. 2. Using a suitable sling, balance the second and third boom sections and carefully slide 3-4 ft (90-120 cm) into the front of the first boom section. 3. Set the second and third boom sections onto suitable supports and reset the sling under the boom head. Carefully slide the second and third boom sections into the first boom section. Leave 6-8 in (10-15 cm) of the second boom section out to be able to install the wear pads in the front of the first boom section.
MY0580
13. At the rear of the boom, tighten the extend chain adjusting nut (9) until the gaps in the belleville washer are less that 1/16 in (1,5 mm). Torque the chain jam nut to 100-110 lb-ft (135-149 Nm). 14. On the bottom side of the first boom section, install the tube clamps for the tilt and auxiliary (if equipped) circuits.
MY1540
4. Install the hose bracket assembly components (7) at the front of the first boom section. 5. Install the retract chain adjusting block (8). 6. Push the retract chain through the boom from the rear to the chain adjusting block. Do not tighten the adjusting and jam nut at this time. Thread the nut on the clevis enough to keep the chain in place. 7. Install the wear pad block to the front inside of the first boom section. Use Loctite 242 and torque the wear pad mounting block bolts to 76-86 lb-ft (103-116 Nm). 8. Shim all wear pads needed to obtain the minimum gap of 1/16 in (1,6 mm). Tighten all wear pad bolts to the correct values. Refer to Section 3.7, Boom Wear Pads. 9. Place the strong back in place at the rear of the boom and install the extend/retract cylinder mounting pin, spacers and retaining clips. 10. Install and torque the strong back mounting bolts to 240-265 lb-ft (325-359 Nm).
3.4.6
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. 3. With the sling still in place, install the compensation cylinder, pins and bolts. Apply Loctite 242 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.
3-6
G6-42A, G9-43A, G10-43A
Boom
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 3.6, Boom Section Separation Adjustment. 9. Properly connect the battery. 10. 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. 11. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine. 12. Close and secure the engine cover. 13. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
3.5
BOOM EXTEND AND RETRACT CHAINS

Boom Chain Inspection
3.5.1
WARNING
Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or machine instability. Under normal operating conditions the boom 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
3-7
Boom
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 chains 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.
MZ1463
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).
4 3
3.5.2
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:
MY1360
If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain.
3-8
G6-42A, G9-43A, G10-43A
Boom
Distorted or Battered Link Plates Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing. 8 5 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 chains endurance limit. Stress Corrosion Cracking - The 10 outside link plates are particularly susceptible to stress corrosion cracking (10).
MZ1466
9
MZ1467
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.
MZ1468
7 8
MZ1465
Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress. Other Modes of Failure Ultimate Strength Failure These types of failures are 1 caused by overloads far in excess of the design load. Either fractured plates (1) or 2 enlarged holes (2) can occur. If either of these failures occurs, the chain should be replaced immediately.
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.
MZ1469
MZ1470
Tight Joints - All joints in the chain should flex freely. Tight 3 MZ1471 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
3-9
Boom
3.5.3
Expose Chains for Inspection
3.5.4
Chain Lubrication
d. Extend Chains 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom until both extend chains are taut. Shut the engine OFF. The extend chains will be visible for inspection with the machine in this state. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevises be replaced at the same time. e. Retract Chains The three retract chains are only partially visible through the rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary. Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis be replaced at the same time. f. Removing Extend and Retract Chains
After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (LUBRIPLATE Chain & Cable Fluid, LPS3 or equivalent). 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.
3.5.5
Chain Removal
The following section explains the removal of the retract chains without removing the boom assemblies. 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, stating that the machine should not be operated. 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.
The four extend chains and the three retract chains can only be removed during a complete boom teardown. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevis be replaced at the same time.
3-10
G6-42A, G9-43A, G10-43A
Boom 3.5.6 Chain Installation
The following section explains the installation of the retract chains without removing the boom assemblies.
5
Inspect and lubricate chains thoroughly before installation.
6
MY0580
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. 8. Remove the extend chain locknut and jamnut from the strong back. 9. Remove the retract chain adjustment and jam nuts (6) 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 pin securing the chain clevis to the boom to free the extend chain. 15. Lower the push beam. Center the chain clevis rod on the push beam to aid in removal. 16. Pull the push beam forward. Remove the chain retainer and guide bar from the front of the push beam. Remove the push beam and chain through the access hole on the front of the boom. 17. Pull the retract chain from the first boom section.
MY1540
1. Push the retract chain through the boom from the rear to the chain adjusting block (6) on the first boom section. Do not tighten the adjusting and jam nut at this time. Thread the nut on the clevis enough to keep the chain in place. 2. With the extend chain clevis rod sitting on top of the push beam, secure the chain around the sheave to the rear of the push beam. Secure the chain to the push beam end with tie wraps. Note: If the chain is tied to the push beam at numerous points for assembly, remove the ties as the push beam enters the boom. Once the push beam is inside the boom, it is not possible to remove the ties. The end tie may be left in place as it can be removed through the rear of the boom. 3. Insert the push beam through the front of the boom. Once the push beam is inside the boom, install the chain retainer and guide bar. Place the push beam in its original orientation. 4. Lift the push beam assembly and remove any remaining ties for the chain. Secure the extend chain clevis to the third boom section. Install the pin and cotter pin of the retract chain to the clevis. 5. Lower the push beam assembly and install the push beam mounting pins to the second boom section. 6. Place the strong back in place at the rear of the first boom section and install the extend/retract cylinder mounting pin. 7. Install and torque the strong back mounting bolts to 240-265 lb-ft (325-359 Nm).
G6-42A, G9-43A, G10-43A
3-11
Boom
8. Place the extend chain rod through the strong back. Install the adjusting and jam nuts. Do not tighten at this time. 9. At the retract chain mounting block on the first boom section, tighten the retract chain adjusting nut until the front of the threaded end lines up with the front edge of the access hole. 10. At the rear of the boom, tighten the extend chain adjusting nut until the gaps in the belleville washer are less that 1/16 in (1,6 mm). Torque the chain jam nut to 100-110 lb-ft (135-149 Nm). 11. Uncap and connect the extend/retract cylinder hydraulic tubes to their appropriate locations. 12. Adjust the chain as needed. Refer to Section 3.6, Boom Section Separation Adjustment. 13. Install the cover on the rear of the boom. 14. Properly connect the battery. 15. Close and secure the engine cover. 16. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
8
Adjust the extend chain as follows: 1. Loosen the lock nut on the extend chain rod. 2. Tighten the adjusting nut on the extend chain rod until all washers are flat (no gap between any washers). 3. Torque the lock nut to 100 lb-ft (135 Nm). 4. After adjusting, check to see that the boom sections and access holes are aligned. If they are not, the retract chain will need to be adjusted as well. Adjust the retract chain as follows: 1. Fully retract the boom. 2. Measure the distance between the second boom section and the third boom section.
9
3.6
BOOM SECTION SEPARATION ADJUSTMENT
MY0880
1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch and level the boom. 2. Extend the boom 4 to 5 ft (1,2 to 1,5 m), then fully retract the boom.
The dimension (8) (should be 11.625 in 0.625 in (295,3 mm 16 mm) for the G6-42A measured from the back edge of the tilt cylinder pin and the second boom section. The dimension (9) should be 18.132 in 0.125 in (460,55 mm 3 mm) for the G9-43A and G10-43A measured from the center of the tilt cylinder pin and the second boom section. 3. Loosen the extend chain lock nut and adjusting nut as far as possible. 4. Tighten the retract chain adjusting nut until the proper distance is obtained and proper access hole alignment is obtained. 5. Torque the lock nut to 100 lb-ft (135 Nm). 6. Re-adjust the extend chain as needed.
3. Measure the gap (7) on the belleville washer on the extend chain rod. If the total of all gaps exceeds 0.12 in (3,04 mm), the boom chains will need to be adjusted. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevises be replaced at the same time. 3-12
G6-42A, G9-43A, G10-43A
Boom
3.7
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.
3.7.1
1
Wear Pad Inspection

1
MY5510
Ma2070
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.
Maintain a total boom section clearance (5) of 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and vertical directions.
A
3.7.2
Wear Pad Installation and Lubrication

MY3620
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 242 and installing mounting bolts. Apply Loctite 242 to all wear pad mounting bolts.
4
3 2
MAM1390
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.
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. 7. Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.
G6-42A, G9-43A, G10-43A
3-13
Boom
3.8
3.8.1
QUICK SWITCH ASSEMBLY

Quick Switch Removal
3.8.3
Quick Switch Removal
G6-42A - S/N 0160037722 & After G9-43A/G10-43A - S/N 0160037671 & After
14
G6-42A - Before S/N 0160037722 G9-43A/G10-43A - Before S/N 0160037671

7 9 13
2 6 1
11 12 10 4 3 5
MY5080 MY5090
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.
1. Remove the lock bolt (8) holding the tilt cylinder rod end pin (9) to the quick switch assembly (10). Remove the Tilt Cylinder pin. 2. Support the quick switch assembly (10).Remove the capscrew (11) and locknut (12) securing the head pin (13) to the boom head (14). 3. Inspect the above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired the pin must be replaced.
3.8.4
Quick Switch Installation
3.8.2
Quick Switch Installation
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. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin (2). Align the tilt cylinder pin and screw in the locking bolt (1). Torque as required.
1. Assemble the quick switch assembly (10) to the boom head (14). Line up the quick switch between the mounts on the boom head. The quick switch should be centered in the boom head. 2. Coat the quick switch head pin (13) with an antiseize compound. Insert the quick switch head pin through the quick switch and boom head. Secure with the previous capscrew (11) and locknut (12). 3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin (9). Align the tilt cylinder pin and screw in the locking bolt (8). Torque as required.
3-14
G6-42A, G9-43A, G10-43A
Boom
3.9
3.9.1
BOOM HEAD - MOUNTED WINCH

Boom Head-Mounted Winch Removal
3.9.2
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).
5 4
MAL0880
1. Using a suitable lifting device, secure the winch assembly (4) with a nylon strap. 2. Disconnect the hydraulic hoses (5). 3. Loosen and remove the mounting bolts, washers and nuts (6). 4. Lower the winch assembly (4) onto a suitable skid or table.
G6-42A, G9-43A, G10-43A
3-15
Boom
3.10
TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that occur during operation of the boom.
Problem
1. Boom will not extend or retract.
Cause
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.
Remedy
1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8, Hydraulic System. 3. Repair cylinder. Refer to Section 8.8, Hydraulic Cylinders. 1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.7, Boom Wear Pads. 1. Lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedule. Replace worn pins as needed. 2. Replace bearing(s) and lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedule. 1. Lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedule. Replace worn pins as needed. 2. Replace bushing(s) and lubricate at regular intervals.
2. Boom shifts to right or left when extending.
1. Boom side wear pads improperly shimmed or worn.
3. Excessive boom pivot pin noise and/or wear.
1. Insufficient lubrication.
2. Worn bearing(s).
4. Excessive Compensation cylinder pivot pin noise and/ or wear.
1. Insufficient lubrication.
2. Worn bushing(s).
3-16
G6-42A, G9-43A, G10-43A
Boom
Problem
5. Drooping chain, or jerky boom extend or retract functions.
Cause
1. Chain(s) tension not properly adjusted. 2. Chain(s) stretched or binding.
Remedy
1. Adjust chain(s).
2. Replace chains as needed. Refer to Section 3.6, Boom Section Separation Adjustment. 3. Replace wear pad. Refer to Section 3.7, 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. 6. Replace the damaged boom section. Refer to Section 3.4, Boom Assembly Maintenance. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8.4, Hydraulic Circuits. 3. Repair cylinder. Refer to Section 8.8.1, General Cylinder Removal Instructions. 4. Replace bearing. 1. Lubricate at regular intervals. Refer to Section 2.5, Service and Maintenance Schedule. Replace worn pins as needed. Refer to Section 8.8.1, General Cylinder Removal Instructions. 2. Replace bushing(s) and lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedule.
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. Boom will not raise or lower.
1. Broken hydraulic hoses or tubes and/or connection leaks. 2. Lift/lower hydraulic system not operating properly. 3. Faulty lift/lower cylinder.
4. Seized boom pivot pin bearing. 7. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 1. Insufficient lubrication.
2. Worn self-aligning bushing(s).
G6-42A, G9-43A, G10-43A
3-17
Boom
Problem
8. Rapid boom pad wear.
Cause
1. Incorrect wear pad gap.
Remedy
1. Check wear pad gaps and correct as needed. Refer to Section 3.7, Boom Wear Pads. 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. 1. Adjust to correct tension. Refer to Section 3.6, Boom Section Separation Adjustment.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. 4. Lubricate at regular intervals. Refer to Section 2.5, Service and Maintenance Schedule. Replace chains as needed.
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. Auxiliary hydraulic system not operating properly. 1. Improper chain adjustment.
2. Chain sheave(s) not properly lubricated. 3. Chain sheave(s) not rotating freely.
4. Improper chain lubrication.
3-18
G6-42A, G9-43A, G10-43A
Section 4 Cab and Covers
Contents
PARAGRAPH 4.1 TITLE PAGE
4.2
4.3
4.4 4.5
Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . 4-2 4.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.1.2 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 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 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
G6-42A, G9-43A, G10-43A
4-1
Cab and Covers
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
FRAME LEVEL INDICATOR STEERING WHEEL BOOM CONTROL JOYSTICK INSTRUMENT PANEL FRAME LEVEL AND ATTACHMENT TILT CONTROLLER
TRANSMISSION CONTROL LEVER
OUTRIGGER CONTROLS (IF EQUIPPED) HEATER AND A/C CONTROLS (IF EQUIPPED) AUXILIARY HYDRAULICS CONTROLLER
IGNITION SWITCH
SERVICE BRAKE PEDAL ACCELERATOR PEDAL
MAL0200
4-2
G6-42A,G9-43A, G10-43A
Cab and Covers

b. G6-42A - S/N 0160040678 & After
ACCESSORY CONTROL LEVER STEERING WHEEL
FRAME LEVEL INDICATOR
HEATER AND A/C CONTROLS (IF EQUIPPED) BOOM CONTROL JOYSTICK FRAME LEVEL JOYSTICK
INSTRUMENT PANEL
AUXILIARY HYDRAULIC JOYSTIVCK (IF EQUIPPED)
IGNITION SWITCH
SERVICE BRAKE PEDAL ACCELERATOR PEDAL
MY6450
4.1.2
General Overview
4-3
G6-42A, G9-43A, G10-43A
Cab and Covers

c. G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672
ACCESSORY CONTROL LEVER STEERING WHEEL FRAME LEVEL INDICATOR HEATER AND A/C CONTROLS (IF EQUIPPED) BOOM CONTROL JOYSTICK
INSTRUMENT PANEL FRAME LEVEL AND ATTACHMENT TILT (IF EQUIPPED) JOYSTICK
AUXILIARY HYDRAULIC JOYSTICK
G9-43A
IGNITION SWITCH
SERVICE BRAKE PEDAL
ACCELERATOR PEDAL ACCESSORY CONTROL LEVER STEERING WHEEL
MY6460
FRAME LEVEL INDICATOR
HEATER AND A/C CONTROLS (IF EQUIPPED) BOOM CONTROL JOYSTICK
INSTRUMENT PANEL FRAME LEVEL JOYSTICK
TRANSMISSION CONTROL LEVER OUTRIGGER JOYSTICKs
G10-43A
IGNITION SWITCH
SERVICE BRAKE PEDAL
ACCELERATOR PEDAL
MY6470
4-4
G6-42A,G9-43A, G10-43A
Cab and Covers
WARNING
4.3
4.3.1
CAB COMPONENTS
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, stating that the machine should not be operated. 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.
2
4.2
4.2.1
OPERATOR CAB
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.
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.
3
4.2.2
Serial Number Decal

4
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.
MY0120
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

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. 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.
2
MY0141
4.3.2
Service Brake Pedal
a. Brake Valve Removal Refer to Section 8.7.2, Service Brake Valve, for removal information. b. Brake Valve Installation Refer to Section 8.7.2, Service Brake Valve, for installation information. c. Service Brake Pedal Removal 1. Park 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 steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
1 3
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.
4-6
G6-42A,G9-43A, G10-43A
Cab and Covers

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. 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 2.3.4, Engine Performance Specifications. G6-42A - S/N 0160040678 & After
5 7
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 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 steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery.
G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 016040672 a. Throttle Pedal Removal
6
MAL0990
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.
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 steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery.
G6-42A, G9-43A, G10-43A
4-7
Cab and Covers
(If Equipped)
(If Equipped)
10 11 9 8 11
MY6480
4. Lift the joysticks rubber sleeve (11), remove the bolts securing the boom joystick to the cab.
MAL1000
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.
(If Equipped) (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 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 steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery.
14 12 13
MY6480
4-8
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. Install the joystick knob. 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.
4.3.5
Frame Level, Attachment Tilt, Auxiliary Hydraulics and Outriggers (G10-43A) Joysticks
a. Joystick 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 steering wheel, stating that the machine should not be operated. 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.
G6-42A, G9-43A, G10-43A
4-9
Cab and Covers 4.3.7 Heater/Air Conditioning System (if equipped)

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.
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, stating that the machine should not be operated. 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.
13
MY0200
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.
12
8. Properly connect the battery. Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing. 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
11
MY0190
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
Cab and Covers
4.4
CAB REMOVAL
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. 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

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.
16
MY0610
14
15
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.
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.
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.
14 15
17
17 16
MY0610
MY4170
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.
18
18
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
G6-42A,G9-43A, G10-43A
Cab and Covers

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. 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.
17 17
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.
MY4170
18
18
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
Cab and Covers
This Page Intentionally Left Blank
4-14
G6-42A,G9-43A, G10-43A
Section 5 Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH 5.1 5.2 5.3 TITLE PAGE 5-2 5-3 5-3 5-3 5-3 5-3 5-3 5-4 5-5 5-7 5-10 5-10 5-10 5-10 5-10 5-10 5-11 5-11 5-12 5-12 5-12 5-12 5-13
5.4
5.5
5.6 5.7
Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing a Disabled machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
5-1
Axles, Drive Shafts, Wheels and Tires
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.
REAR STEERING CYLINDER
TRANSMISSION DROP BOX REAR AXLE ASSEMBLY
FRONT STEERING CYLINDER
REAR DRIVE SHAFT
REAR AXLE WHEEL HUBS (2)
FRONT DRIVE SHAFT
FRONT AXLE ASSEMBLY
FRONT AXLE WHEEL HUBS (2)
MY0570
5-2
G6-42A, G9-43A, G10-43A
5.2
GENERAL INFORMATION
5.3
5.3.1
AXLE ASSEMBLIES
Axle Serial Number Plate
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.
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)
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.
G6-42A, G9-43A, G10-43A
5-3

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.
MY4180
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. 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.
5.3.5
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. 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, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
5-4
G6-42A, G9-43A, G10-43A

14. Remove the axles from the machine using the jack, 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
4 1 4
MY0230
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.
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.
MT0220
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

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
1. Excessive axle noise while driving.
Cause
1. Oil level too low.
Remedy
1. Fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 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. 5. Replace bearings as needed. 6. Replace gears as needed. 7. Drain axle and/or wheel end housings and fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 8. Replace damaged parts. 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.
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. 6. Worn or broken gear teeth. 7. Contamination in the axle.
8. Axle housing damaged. 2. Intermittent noise when traveling. 1. Universal joint(s) worn or damaged. 2. Differential ring and/or pinion gears damaged. 3. Vibration or intermittent noise when traveling. 1. Drive shaft universal joint assembly(ies) incorrectly tightened. 2. Drive shaft universal joint(s) worn or damaged. 3. Drive shaft(s) damaged/ unbalanced.
G6-42A, G9-43A, G10-43A
5-7
Problem
4. Oil leaking from axle (differential housing and/or axle housings).
Cause
1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 2. Hose fittings loose. 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.
Remedy
1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Tighten fittings. 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. 1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Replace o-ring.
5. Oil leaking from wheel end housing (planet carrier).
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. 5. Housing (planet carrier) damaged.
3. Replace seal and/or fork joint shaft. 4. Tighten housing capscrews to 41 lb-ft (55 Nm). 5. Replace housing (planet carrier). 1. Tighten fittings. 2. Replace o-rings and seals. 3. Replace piston rod seal. 4. Replace cylinder tube.
6. Oil leaking from steering cylinder.
1. Hose fittings loose. 2. Steering cylinder o-rings and/or seals worn or damaged. 3. Piston rod seal worn or damaged. 4. Cylinder tube damaged.
5-8
G6-42A, G9-43A, G10-43A
Problem
7. Axle overheating.
Cause
1. Oil level too high.
Remedy
1. Fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain axle and fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 3. Adjust park brake cable as 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. 1. Check brake discs for wear. Refer to Section 5.6, Brakes. 2. Replace brake discs. 1. Refer to Section 8.7.3, Brake Test. 2. Replace o-rings and seals. 1. Check brake discs for wear. Refer to Section 5.6, Brakes. 2. Refer to Section 8.7.3, Brake Test. 3. Replace o-rings and seals.
2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low. 3. Dragging park brake. 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. 2. Brake discs damaged. 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. 1. Brake discs worn. 2. Brake (hydraulic) system not operating properly. 3. Brake piston o-rings and seals damaged (leaking).
G6-42A, G9-43A, G10-43A
5-9
5.4
5.4.1
DRIVE SHAFTS
TO TRANSMISSION
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.
TO AXLE
3 4
MT0351
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.
5.4.2
Drive Shaft Maintenance
Refer to Section 2.4, Fluid and Lubricant Capacities, for information regarding the lubrication of the drive shafts.
5.4.4
Drive Shaft Cleaning and Drying
5.4.3
Drive Shaft Removal
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.
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, stating that the machine should not be operated. 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.
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 243 to all mounting bolts. 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.
5-10
G6-42A, G9-43A, G10-43A
5.5
WHEELS AND TIRES

5
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: 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.
MY4190
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 5.5.2 Installing Wheel and Tire Assembly onto Machine
5.6
BRAKES
Note: The wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel.
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.
TREAD ARROWS MUST POINT FORWARD
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 machines park brake AND service brakes are inoperable.
5.7.1
INSTALL TIRES ONTO WHEELS TO ROTATE IN PROPER DIRECTION
Manually Releasing the Park Brake
a. Before S/N 0160000847

6
MAH0460
1. Position wheel onto studs on wheel end of axle. 2. Install wheel lug washers. 3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.
1 8
MY0260
1. On one side of the axle, remove the three plugs from the differential housing.
9 10
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.
MY4200
4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 350-400 lb-ft (475-542 Nm). 5. Remove machine from supports. 5-12
G6-42A, G9-43A, G10-43A

Note: After the machine has been towed to a secure location, reactivate the parking brake. Carefully follow the procedures from start to finish. Consult your local JLG distributor or the JLG Service Department if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation. b. S/N 0160000847 & After
7 7
5.7.2
Manually Resetting the Park Brake
Note: Block the wheels of the machine BEFORE attempting to reset the machines park brake. Once the park brake is released the machines park brake AND service brakes are inoperable. a. Before S/N 0160000847 1. Loosen each release screw, only 1/4 turn at a time, in sequence, until each screw has lost contact with the guide pin. 2. Back out each screw until it bottoms out against the stop. 3. Install the previously used plugs over each release screw. 4. Repeat steps 1 thru 3 for the other side of the differential.
7
MZ1020
1. Loosen the nuts of the screws (7) for the manual release of the braking units. Draw the nuts back approximately 0.25 in (6 mm). 2. Tighten the screws until they are gently seated on the driving plate 3. Carefully tighten each release screw a 1/4 turn at a time in sequence until all have been turned on full turn 360. 4. Repeat steps 1 thru 3 for the other side of the differential. Note: After the machine has been towed to a secure location, reactivate the parking brake. Carefully follow the procedures from start to finish. Consult your local JLG distributor or the JLG Service Department if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation.
5. After repairs to the machine have been made, start the machine and check the park brake and service brakes for proper function. b. S/N 0160000847 & After 1. Loosen each release screw, only 1/4 turn at a time, in sequence, until each screw has lost contact with the guide pin. 2. Remove the screws along with the nuts and seals. Replace the seals, lubricate the screws with a silicone-based grease and re-install the screws along with the nuts. 3. Adjust the nut of the screw heads in relation to the arm by 1.26 in (32 mm). 4. Repeat steps 1 thru 3 for the other side of the differential. 5. After repairs to the machine have been made, start the machine and check the park brake and service brakes for proper function.
G6-42A, G9-43A, G10-43A
5-13
5-14
G6-42A, G9-43A, G10-43A
Section 6 Transmission
Contents
PARAGRAPH 6.1 6.2 6.3 6.4 TITLE PAGE
6.5
6.6
6.7
Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . 6-4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5 6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.4.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-6 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5.1 G6-42A - Before S/N 0160040678 G9-43A/G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5.2 G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.6.1 Thermal Bypass Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.6.2 Thermal Bypass Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6.7.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
G6-42A, G9-43A, G10-43A
6-1
Transmission
6.1
TRANSMISSION ASSEMBLY 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 transmission. The following illustration identifies the components that are referred to throughout this section.
6.1.1
General Overview
FLEX PLATE ASSEMBLY
SHIFT SOLENOIDS
TRANSMISSION FILTER
TRANSMISSION BREATHER
TRANSMISSION FILL TUBE AND DIPSTICK
TRANSFER CASE BREATHER OIL FILL PLUG
OIL LEVEL SIGHT GAUGE MAGNETIC DRAIN PLUG

MY0270
OIL DRAIN PLUG
6-2
G6-42A, G9-43A, G10-43A
Transmission
b. G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672
TRANSFER CASE BREATHER
TRANSMISSION FILL TUBE AND DIPSTICK
OIL DRAIN PLUG
OIL FILL PLUG
TRANSMISSION FILTER SHIFT SOLENOIDS SHIFT SOLENOIDS
OAL0010
OIL DRAIN PLUG
G6-42A, G9-43A, G10-43A
6-3
Transmission
WARNING
WARNING
NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling with a minimum lifting capacity of 1000 lb (454 kg).
6.2
TRANSMISSION SERIAL NUMBER

6.4.1 Transmission 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, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Remove engine cover to allow easier access to the transmission. 5. Drain the hydraulic oil reservoir. Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining. 6. Disconnect the (+) positive and (-) negative battery cables and remove the battery. 7. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding.
DANA TRANSMISSION ZF TRANSMISSION
The transmission serial number plate is located on the front of the transmission case below the converter housing. Information specified on the serial number plate includes the transmission model number, the transmission serial number and other data.
6.3
TRANSMISSION SPECIFICATIONS AND MAINTENANCE INFORMATION
For transmission, oil specifications and maintenance information, refer to Section 2, General Information and Specifications. Detailed transmission service instructions are provided in the following publications: Parts Manual - G6-42A (P/N 91474001) - G9-43A/G10-43A (91514001) G6-42A - Before S/N 0160040678 G9-43A/G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672 Dana Spicer Repair Manual - (P/N 31200163) G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672 ZF Repair Manual - (P/N 31200241)
6.4
TRANSMISSION REPLACEMENT
MY6070
Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. Note: Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components.
8. Place a suitable receptacle under the transmission drain plug (1). Remove the transmission drain plug, and allow the transmission oil to drain into the receptacle. Repeat drain procedure with the drop box (2). 9. Transfer the used transmission oil into a suitable, covered container, and label the container as Used Oil. Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug. 10. Remove the transmission-to-axle drive shafts. Refer to Section 5.4.3, Drive Shaft Removal.
6-4
G6-42A, G9-43A, G10-43A
Transmission
11. Remove air cleaner unit and intake tubes. 12. Remove the hydraulic pump. Refer to Section 8.6.1, Implement Pump Replacement. 13. Label and disconnect the transmission temperature switch connector and shift solenoid wiring harness connectors. 14. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission. The transmission oil cooler outlet hose, routed to the lower radiator fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper radiator fitting, is located on top of the transmission. 15. Remove the access plug from the engine bell housing. This will allow access to remove the bolts holding the flex plate to the engine flywheel. 16. Turn the engine over slowly by hand and align each of the flex plate bolts to be accessed. Remove them one at a time. 17. Wipe up any spilled hydraulic and transmission oil. 18. Connect a lifting strap or chain to the lifting eye at the top of the transmission, and to a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain, but DO NOT raise the transmission at this time. 19. Place blocks under rear of engine for support BEFORE transmission mounts are removed. 20. Place blocks under the transmission to help support it during removal. 21. Remove both rear transmission mount bolts and lockwashers securing the transmission mount to the frame. 22. Remove the bolts and washers holding the transmission to the engine. 23. Remove the capscrews and lockwashers securing each rear transmission mount to the transmission. 24. Remove the transmission mounts from the machine. 25. Inspect the rubber mounts. Replace the mounts if damaged. 26. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts. 27. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it will not move or fall. 28. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings. 29. Remove the transmission oil filter and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount. 30. If transmission oil is suspect to contamination or torque converter is damaged, remove the converter and flex plate from the transmission. 31. Remove the bolt and washers holding the converter to the flex plate.
6.4.2
Transmission Inspection and Internal Repair
If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are included with a new transmission.
6.4.3
Transmission Installation
1. Install both rear transmission mounts on the transmission. Torque capscrews to 66 lb-ft (89 Nm). 2. Install two guide studs near the top of the bell housing holes. 3. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis. 4. Align the torque converter, align the transmission bolt holes with the two studs in the bell housing. Install the eight bolts and washers and torque to 53 lb-ft (72 Nm). Remove the two alignment studs and install and torque the last two transmission mounting bolts. 5. Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers. Apply Loctite 242 to the transmission mount bolts and torque to 220 lb-ft (298 Nm). 6. Turn the engine over slowly by hand and align each flex plate bolts to be accessed. Install them one at a time. Torque to 26-29 lb-ft (35-39 Nm). Replace access plug. 7. Remove the hoist or overhead crane and sling. 8. Connect the transmission temperature switch connector and shift solenoid wiring harness connectors. 9. Secure the wiring harness to the transmission housing.
G6-42A, G9-43A, G10-43A
6-5
Transmission
10. Connect the transmission oil cooler inlet and outlet hoses at the transmission. 11. Install the hydraulic pump. Refer to Section 8.6.1, Implement Pump Replacement. 12. Install the transmission-to-axle drive shafts. Refer to Section 5.4.5, Drive Shaft Installation. 13. Install the air cleaner and tubing. 14. Clean the transmission oil filter mounting surface. 15. Apply a thin film of clean oil to the new transmission filter gasket. Install the new filter and torque to 20-25 lb-ft (27-34 Nm). 16. Transmission oil may be added through the dipstick tube. Remove the dipstick and add clean, fresh oil. Refer to Section 2.4, Fluid and Lubricant Capacities. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished. 17. Transmission transfer case oil may be added through the fill plug. Refer to Section 2.4, Fluid and Lubricant Capacities, for proper capacities. Reinstall the fill plug and tighten. 18. Install the engine cover. 19. Install the battery. Connect the (+) positive and (-) negative battery cables. 20. Close and secure the engine cover. 21. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6.4.4
In general:
After Transmission Service or Replacement
1. Check the transmission oil level and add oil as required. 2. Drain and flush the entire transmission cooling system. 3. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements. 4. Reassemble all components and fill the transmission with clean, fresh oil through the dipstick tube opening. Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished. 5. Run the engine for two minutes at idle to help prime the torque converter and the transmission oil lines. 6. Recheck the level of the fluid in the transmission with the engine running at idle. 7. Add hydraulic oil as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 180-200 F (83-94 C). 8. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.
6-6
G6-42A, G9-43A, G10-43A
Transmission
6.5
6.5.1
ENGINE DRIVE PLATE

G6-42A - Before S/N 0160040678 G9-43A/G10-43A - Before S/N 0160040675 excluding 0160040468 & 0160040672
6.5.2
G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040675 & After including 0160040468 & 0160040672
a. Drive Plate 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 shut the engine OFF. Note: In order to remove the engine drive plates, the engine and transmission must be separated. 2. Refer to Section 6.4.1, Transmission Removal, or Section 7.9.1, Engine Removal.
3 2 4
a. Drive Plate 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 shut the engine OFF. Note: In order to remove the engine drive plates, the engine and transmission must be separated. 2. Refer to Section 6.4.1, Transmission Removal, or Section 7.9.1, Engine Removal.
1
MZ0580
3. Remove the four bolts holding the drive plates to the flywheel. 4. With the drive plates and torque converter removed, loosen and remove the four bolts (2) and eight lock washers holding the two drive plates (3) to the torque converter (4). 5. Replace both drive plates if damaged. b. Drive Plate Installation 1. Install the two new drive plates on the torque converter and install the four bolts with lock washers. 2. Mount the drive plates/converter assembly to the transmission. Refer to Section 6.4.3, Transmission Installation, or Section 7.9.2, Engine Installation. for the remainder of the installation.
3. Remove the eight bolts holding the drive plates (1) to the flywheel. 4. With the drive plates and torque converter removed, loosen and remove the six bolts and six lock washers holding the three drive plates to the torque converter. 5. Replace all three drive plates if damaged. b. Drive Plate Installation 1. Install the three new drive plates on the torque converter and torque the six bolts with lock washers to 26-29 lb-ft (35-39 Nm). 2. Mount the drive plate/converter assembly to the transmission. 3. Refer to Section 6.4.3, Transmission Installation,or Section 7.9.2, Engine Installation. for the remainder of the installation.
G6-42A, G9-43A, G10-43A
6-7
Transmission
6.6
TRANSMISSION COOLER THERMAL BYPASS VALVE

6
6.6.1
Thermal Bypass 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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect and remove the battery.
3
MAL1410
NOTE: ITEMS REMOVED FROM ILLUSTRATION FOR CLARITY
7. Remove the transmission oil filter (3) and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount.
1
MY0980
8. Place a suitable container beneath the transmission cooler fittings on the hydraulic cooler. Transfer any transmission oil into a properly labeled container. Dispose of properly. 9. Label, disconnect and cap both transmission cooler hoses at the radiator. Cap all fittings and openings to prevent dirt and debris from entering. 10. Label, disconnect and cap the hoses (4) at the thermal bypass valve (5). Cap all fittings and openings to prevent dirt and debris from entering. 11. Loosen and remove the two bolts (6) securing the thermal bypass valve. 12. Remove the thermal bypass valve.
5. Place a suitable container under the transmission drain plug (1). Remove the transmission drain plug, and allow the transmission oil to drain into the receptacle. Repeat drain procedure with the drop box (2). 6. Transfer the used transmission oil into a suitable, covered container, and label the container as Used Oil. Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission and drop box drain plugs.
6-8
G6-42A, G9-43A, G10-43A
Transmission 6.6.2 Thermal Bypass Valve Installation
1. Place the new thermal bypass valve (5) in the engine compartment and secure using the previously used bolts (6). 2. Uncap and connect the previously labeled hydraulic oil cooler hoses (4) to the thermal bypass valve. 3. Uncap and connect the previously labeled transmission oil cooler hoses to the transmission oil cooler. 4. Clean the transmission oil filter mounting surface. 5. Apply a thin film of clean hydraulic oil to the new transmission filter gasket. Install the new filter and torque to 20-25 lb-ft (27-34 Nm). 6. Transmission oil may be added through the dipstick tube. Remove the dipstick and add transmission oil. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Maintenance Manual. DO NOT overfill. Reinstall the dipstick when finished. 7. Remove drop box fill/level plug and fill with transmission fluid. Reinstall plug. 8. Install and properly connect the battery. 9. Run the engine for two minutes at idle. 10. Recheck the level of the fluid in the transmission with the engine running at idle. 11. Add transmission oil as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 180-200 F (83-94 C). 12. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary. 13. Close and secure the engine cover. 14. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
G6-42A, G9-43A, G10-43A
6-9
Transmission
6.7
TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.
6.7.1
Transmission Troubleshooting
Problem
1. Transmission will not engage or will not shift properly.
Cause
1. Oil level too high or low.
Remedy
1. Fill transmission oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Refer to Section 9.5, Electrical System Schematics.
2. Transmission control lever not functioning properly and/or a fault in the wiring harness.Transmission control lever not functioning properly and/or a fault in the wiring harness. 3. Transmission valve body solenoids not functioning properly. 4. Pilot-operated shift valves not operating properly. 5. Pump output pressure low.
3. Refer to Section 9.5, Electrical System Schematics. 4. Clean the valve spool and housing. Replace return spring as needed. 5. Refer to Section 6.7.1, Transmission Troubleshooting, Problem 2. Low or no pump flow or pressure. 6. Replace o-rings. 7. Replace clutch discs. 8. Replace couplings.
6. Clutch piston o-rings damaged. 7. Clutch discs worn or damaged. 8. Coupling shafts or gear teeth damaged.
6-10
G6-42A, G9-43A, G10-43A
Transmission
Problem
2. Low or no pump flow or pressure.
Cause
1. Low oil level.
Remedy
1. Fill transmission oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain transmission and fill oil to correct level. (Refer to Section 2.4, Fluid and Lubricant Capacities.) 3. Clean, repair and/or replace suction pipe. 4. Replace central shaft. 5. Repair or replace pump assembly. 1. Fill transmission oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Clean the valve spool and housing. 3. Replace coupling and/or o-rings. 4. Clean the valve spool and housing. 1. Refer to Section 8.4, Hydraulic Circuits. 2. Adjust the engine rpm to specifications. Refer to Engine Service Manual. 3. Refer to Section 6.7.1, Transmission Troubleshooting, Problem 2. Low or no pump flow or pressure. 4. Replace clutch discs. 5. Refer to Section 6.7.1, Transmission Troubleshooting, Problem 5. Transmission overheating (oil above 248 F (120 C)).
2. Transmission filled with incorrect oil, or oil contaminated.
3. Pump suction pipe screen clogged. 4. Central shaft damaged. 5. Pump worn or damaged. 3. Low clutch pressure. 1. Incorrect oil level.
2. Main pressure valve stuck open. 3. Broken or worn coupling shaft or piston o-rings. 4. Pressure reducing valve stuck open. 4. Lack of power. 1. Park or service brake dragging. 2. Low engine rpm causes converter stall. 3. Pump output pressure is low.
4. Clutch discs worn or damaged. 5. Transmission overheating.
G6-42A, G9-43A, G10-43A
6-11
Transmission
Problem
5. Transmission overheating (oil above 248 F (120 C)).
Cause
1. Low oil level.
Remedy
1. Fill transmission oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Remove debris from the radiator. 3. Drain transmission and fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 4. Stop and idle the engine. 5. Replace cooler hoses. 6. Repair or replace pump assembly. 7. Replace engine thermostat. Refer to Section 7.4.2, Thermostat Replacement. 8. Replace thermal by-pass valve. Refer to Section 6.6, Transmission Cooler Thermal Bypass Valve. 1. Fill transmission oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain transmission and fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 3. Refer to Section 9.11.3, Transmission Solenoid Valves. 4. Repair or replace parts as needed. 5. Replace drive plates. Refer to Section 6.5, Engine Drive Plate. 6. Tighten capscrews.
2. Clogged radiator. 3. Transmission filled with incorrect oil, or oil contaminated.
4. Excessive roading. 5. Restriction in oil cooler hoses. 6. Pump worn or damaged. 7. Engine thermostat stuck.
8. Thermal by-pass valve damaged or flow restricted.
6. Grinding or clunking noise from transmission.
1. Oil level too low.
2. Transmission filled with incorrect oil.
3. Incorrect clutch engagement. 4. Internal damage. 5. Broken drive plate.
6. Loose drive plate mounting capscrews.
6-12
G6-42A, G9-43A, G10-43A
Transmission
Problem
7. Oil leaking from transmission.
Cause
1. Oil leaking from vent (high oil level).
Remedy
1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm). 3. Tighten fittings. 4. Replace gaskets and/or tighten capscrews to 7 lb-ft (9,5 Nm).
2. Drain plug loose and/or o-rings damaged or missing. 3. Hose fittings loose. 4. Oil leaking at valve bodies (possible valve body gaskets damaged or missing and/or mounting capscrews not tight). 5. Housing capscrews loose. 6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight). 7. Oil leaking at converter bell (possible converter leak and/or input shaft seal damage). 8. Oil leaking at output shaft (output shaft seal damaged). 9. Housing damaged.
5. Tighten capscrews to 34 lb-ft (46 Nm). 6. Replace o-rings and/or tighten capscrews to 85 lb-ft (115 Nm).
7. Replace converter and/or input shaft seal. 8. Replace output shaft seal. 9. Replace housing as needed.
G6-42A, G9-43A, G10-43A
6-13
Transmission
6-14
G6-42A, G9-43A, G10-43A
Section 7
Engine
Contents
PARAGRAPH 7.1 TITLE PAGE 7-2 7-2 7-2 7-2 7-3 7-4 7-4 7-4 7-4 7-5 7-6 7-6 7-6 7-6 7-7 7-8 7-8 7-8 7-9 7-10 7-10 7-10 7-11 7-12 7-12 7-12 7-13 7-13 7-13 7-13 7-13 7-14 7-14 7-14 7-15 7-17
7.2
7.3
7.4
7.5 7.6
7.7
7.8
7.9
7.10
Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.1.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.2.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.3.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.3 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8.1 Air Cleaner Assembly Removal (John Deere & Perkins) . . . . . . . . . . . . . 7.8.2 Air Cleaner Assembly Installation (John Deere & Perkins) . . . . . . . . . . . . 7.8.3 Air Cleaner Assembly Removal (Cummins) . . . . . . . . . . . . . . . . . . . . . . . 7.8.4 Air Cleaner Assembly Installation (Cummins). . . . . . . . . . . . . . . . . . . . . . Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
7-1
Engine
7.1
7.1.1
INTRODUCTION - JOHN DEERE

Disclaimer and Scope
7.1.2
Engine Serial Number
These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Engine Distributor and the applicable Engine Service Manual for assistance with comprehensive engine diagnosis, repair and component replacement. A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F (60 C). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.
The John Deere 4045D150 & 4045TF270 serial number Is stamped on a plate which is secured to the engine block, near the fuel injector pump. Information contained in the serial number is required in correspondence with the engine manufacturer.
7.1.3
Specifications and Maintenance Information
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, General Information and Specifications. Detailed John Deere engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate John Deere engine service manual. For engine electrical related issues, refer to the John Deere Engine Troubleshooting Manual (P/N 31200371).
7-2
G6-42A, G9-43A, G10-43A
Engine 7.1.4 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 engine components. The following illustration identifies the components that are referred to throughout this section.
THERMOSTAT
TURBOCHARGER
FUEL INJECTOR PUMP
ENGINE CONTROL MODULE (ECM)

MY1011
ALTERNATOR
STARTER
IN LINE FUEL FILTER
OIL FILTER
MY4500
G6-42A, G9-43A, G10-43A
7-3
Engine
7.2
7.2.1
INTRODUCTION - PERKINS
7.2.2
The Perkins 1104C-44T serial number Is stamped on top of the engine. Information contained in the serial number is required in correspondence with the engine manufacturer.
7.2.3
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, General Information and Specifications. Detailed Perkins engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate Perkins engine service manual.
7-4
G6-42A, G9-43A, G10-43A
THERMOSTAT
FUEL FILTER
FUEL INJECTOR PUMP
STARTER
OIL FILTER
MAL0260
ALTERNATOR
TURBOCHARGER
MAL0270
G6-42A, G9-43A, G10-43A
7-5
Engine
7.3
7.3.1
INTRODUCTION - CUMMINS
7.3.2
The Cummins serial number Is stamped on top of the engine. Information contained in the serial number is required in correspondence with the engine manufacturer.
7.3.3
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, General Information and Specifications. Detailed Cummins engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate Cummins engine service manual.
7-6
G6-42A, G9-43A, G10-43A
FUEL FILTER (SECONDARY)
FUEL INJECTOR PUMP OIL FILTER
FUEL FILTER (PRIMARY)
TURBOCHARGER THERMOSTAT ALTERNATOR
STARTER
MY5530
G6-42A, G9-43A, G10-43A
7-7
Engine
7.4
7.4.1
ENGINE COOLING SYSTEM

Radiator Pressure Cap
a. Thermostat 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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. 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 plug and slowly remove to allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Replace the radiator drain plug.
TYPICAL THERMOSTAT
John Deere/Perkins: For a 210 F (99 C) system, use a 13 psi (90 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. Cummins: For a 210 F (99 C) system, use a 16 psi (110 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.
7.4.2
Thermostat Replacement
Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator. If the engine seems to take a long time to warm up, the thermostat may be stuck in the open position and requires replacement. If the engine runs hot, check the temperature of the upper radiator hose. If the hose is not hot, the thermostat may be stuck in the closed position. If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.
1 2
MY4520
7. Disconnect the engine water temperature sender (1) if connected to the thermostat housing. 8. Remove the two capscrews (2) securing the thermostat housing (3) to the engine. 9. Remove the thermostat housing, old gasket and thermostat. Clean all gasket surfaces. DO NOT let any debris into the thermostat opening. Note: ALWAYS use the correct thermostat and install a new gasket. NEVER operate the engine without a thermostat, or engine damage will result.
7-8
G6-42A, G9-43A, G10-43A
Engine
b. Thermostat Installation 1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews and torque as required. 2. Connect the engine water temperature sender if connected to the thermostat housing. 3. Properly connect the battery. 4. Open the radiator cap, and fill the radiator completely with coolant. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system. 5. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary. 6. Close and secure the engine cover. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
5
5. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap. 6. Place a suitable container beneath the radiator drain. 7. Place a funnel at the base of the radiator to channel the drained coolant into a container. Loosen the drain cock and slowly remove to allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Tighten the radiator drain cock. 8. If equipped, label, disconnect and cap the hoses attached to the coolant recovery tank. Remove the coolant recovery tank.
CUMMINS RADIATOR ASSSEMBLY
7.4.3
Radiator/Oil Cooler and Replacement

5 4 6 7
MY4530
Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator. If the engine runs hot, check the temperature of the upper radiator hose. If the hose is not hot, the thermostat may be stuck in the closed position. If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage. a. Radiator/Oil Cooler 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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
G6-42A, G9-43A, G10-43A
9. Loosen the clamps on the hoses/tubes (4) attached to the intercooler. Work the hoses off the intercooler. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect the hoses, and replace if necessary. 10. Loosen the clamps on the hoses (5) attached to the radiator. Work the hoses off the radiator. Position the hoses out of the way to allow radiator removal, or remove the hoses/tubes from the engine. Inspect the hoses, and replace if necessary. 11. Loosen and remove the hoses (6) attached to the oil cooler. Plug and/or cap the hoses to prevent dirt and debris from entering the hydraulic system. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect the hoses, and replace if necessary.
7-9
Engine
12. Loosen and remove the hoses (7) attached to the transmission cooler. Plug and/or cap the hoses to prevent dirt and debris from entering the transmission system. Position the hoses out of the way to allow radiator removal, or remove the hoses from the engine. Inspect the hoses, and replace if necessary. 13. Remove the radiator fan guard. 14. Remove the nuts and washers the radiator fan shroud and pull the shroud back over the fan. 15. Remove the nuts and washers from the radiator and oil cooler mounts. 16. Carefully lift the radiator and oil cooler out of the engine compartment. Note: If more clearance is needed to remove the radiator, the engine fan may be removed for easier access. b. Radiator/Oil Cooler Installation 1. Install the isolator mounts to the bottom of the radiator and oil cooler. Place the radiator and oil cooler in the engine compartment at their original orientations. Secure with the previously used hardware. Note: Be sure there is adequate clearance between the radiator and the engine fan. 2. If necessary, install the engine fan. 3. Install the radiator fan shroud. 4. Uncap and connect the previously labeled hoses to the radiator, oil cooler and/or transmission cooler. 5. Connect both intercooler hoses. 6. If equipped, install the coolant recovery tank. Uncap and connect the previously removed hose. 7. Open the radiator cap and fill the radiator completely with coolant. Replace and tighten the radiator cap. Refer to Section 2.4, Fluid and Lubricant Capacities, for proper capacities. 8. Properly connect the battery. 9. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary. 10. Close and secure the engine cover. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7.5
ENGINE ELECTRICAL SYSTEM
The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9.5, Electrical System Schematics.
7.6
7.6.1
FUEL SYSTEM
Diesel Fuel
Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair. Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance. Note: Due to the precise tolerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles. Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking. Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 32 F (0 C). When temperatures are below 32 F (0 C), a blend of #1 diesel and #2 diesel fuels (known as winterized #2 diesel) may be used. Note: #1 diesel fuel may be used, however, fuel economy will be reduced. Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10 below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistrokes to provide adequate fuel system lubrication.
7-10
G6-42A, G9-43A, G10-43A
Engine 7.6.2 Fuel Tank

9. Remove screws securing fuel sender (5) to the tank. Remove fuel sender from tank. 10. Remove the bolts on the fuel tank hold down bar (13). 11. Lift the empty fuel tank from the rear of the cab. b. Disassembly The fuel tank is a one-piece unit and cannot be disassembled. The fuel level indicator can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal. c. Cleaning and Drying If contaminated fuel or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the fuel tank, contact JLG Service Department. To clean the fuel tank: 1. Have a dry chemical (Class B) fire extinguisher near the work area. 2. Remove the fuel or oil tank drain plug, and safely drain any fuel into a suitable container. Dispose of fuel properly. 3. Clean the fuel tank with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly. 4. Add a diesel fuel emulsifying agent to the tank. Refer to the manufacturers instructions for the correct emulsifying agent-to-water mixture ratio. Refill the tank with water, and agitate the mixture for 10 minutes. Drain the tank completely. Dispose of contaminated water properly. 5. Refill the fuel tank with water until it overflows. Completely flush the tank with water. Empty the fuel tank, and allow it to dry completely. d. Assembly
MY4230
Note: The fuel tank is a one piece unit. It is located on the rear of the cab. If it is determined that the fuel tank must be removed, the fuel must be drained before tank removal. Always dispose of fuel properly. a. Fuel Tank 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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. Note: If replacing the tank, remove all internal and external components from the old tank, and retain for use on the replacement tank. Note: Have a dry chemical (Class B) fire extinguisher near the work area.
6 5
1 2 3 4
5. Remove fuel tank drain plug (1), and drain fuel into an approved and suitable container. Dispose of fuel properly. 6. Label, disconnect and cap the supply fuel line (2) from the bottom of the fuel tank. 7. Label, disconnect and cap the return fuel line (3) from the bottom of the fuel tank. 8. Disconnect the fuel gauge harness (4).
G6-42A, G9-43A, G10-43A
The fuel level indicator can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal regulations. e. Inspection Note: If a leak is suspected in the fuel tank, contact a JLG Service Department.
7-11
Engine
1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage. 2. With the fuel tank removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 1-1.5 psi (7-10 kPa) of air pressure through the elbow. Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area. f. Fuel Tank Installation
7.7
7.7.1
ENGINE EXHAUST SYSTEM

Exhaust System 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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids and the exhaust system to cool. 4. Properly disconnect the battery.
9
1. Set fuel tank in its original orientation at the rear of the cab. 2. Install the fuel tank hold down bar. 3. Install the fuel sender with new gasket into the fuel tank and secure with screws. DO NOT overtighten. 4. Connect the previously labeled fuel hoses to their appropriate locations. Secure with clamps. 5. Connect the fuel gauge harness. 6. Fill the fuel tank according to specifications.Refer to Section 2.4, Fluid and Lubricant Capacities. 7. Check fuel tank for leaks. 8. Properly connect the battery. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
10
7.6.3
After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated. 2. Vent air from the fuel system in accordance with the instructions found in the appropriate Operation & Safety Manual. 3. Fill the fuel tank with fresh, clean diesel fuel as required.
1 3 2 6
MY4240
5. Remove the muffler heat shield (1) 6. Remove the exhaust heat shield (2). 7. Loosen and remove both clamps (3) securing the muffler (4) to the frame mounted brackets. Remove the muffler. 8. Loosen and remove the clamp (5) securing the exhaust pipe (6) to the frame at the bottom rear corner of the engine pod. Remove the exhaust pipe. Note: Removal of the turbo charger heat shields may be required to access exhaust pipe bolts. 9. Disconnect and remove the three bolts (7) securing the exhaust pipe/flex pipe (8) to the turbo charger. Remove the exhaust pipe/flex pipe from under machine.
7-12
G6-42A, G9-43A, G10-43A
Engine 7.7.2 Exhaust System Installation

4. Properly disconnect the battery.
13
Note: Keep all clamps loosened until entire exhaust system is in place. 1. Install the exhaust pipe/flex pipe (8) with a new seal (9) to the turbo charger. 2. Install the exhaust pipe/flex pipe clamp (5) at the bottom rear corner of the engine pod. 3. Install the exhaust pipe (6) to the exhaust/flex pipe (8). 4. Install the muffler (4) to the exhaust pipe (6). 5. Install the tail pipe (10) to the muffler (4). 6. Install the clamps (3) securing the tail pipe/muffler/ exhaust pipe to the frame mounted brackets. 7. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps. 8. Install the exhaust heat shield (2). 9. Install the muffler heat shield (1). 10. Properly connect the battery. 11. Start engine and check for exhaust leaks at all exhaust connections. Adjust as needed. 12. Close and secure the engine cover. 13. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
12 11
14
MY4250
5. Remove the clamp (11) securing the air intake elbow (12) to the air cleaner assembly (13). Pull the air intake elbow off the air cleaner. 6. Remove the capscrews and nuts securing the air cleaner mounting bracket (14) to the air cleaner mounting plate. Remove the air cleaner assembly.
7.8.2
7.8
AIR CLEANER ASSEMBLY
Air Cleaner Assembly Installation (John Deere & Perkins)
WARNING
NEVER run the engine with only the inner safety element installed. Note: Refer to the appropriate Operation & Safety Manual for your machine for the correct element change procedure.
Note: Apply Loctite 242 the capscrew threads to before installation. 1. Install the air cleaner assembly (13) to the cab mounting plate with the previously removed hardware (14). 2. Place the loosened clamp (11) over the air outlet elbow (12) and install elbow on the air cleaner assembly. 3. Adjust and tighten the clamp. 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.
7.8.1
Air Cleaner Assembly Removal (John Deere & Perkins)
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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool.
G6-42A, G9-43A, G10-43A
7.8.3
Air Cleaner Assembly Removal (Cummins)
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 shut the engine OFF. 7-13
Engine
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
15 16 17
7.9
7.9.1
ENGINE REPLACEMENT
Engine Removal
Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section 7.4, Engine Cooling System. Several additional components must be removed before engine removal. They will be addressed in the following procedures. 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 shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect and remove the battery. Properly disconnect and remove the second battery if equipped. 5. Remove the engine cover. Mark the position of the cover to help with cover adjustment when being reinstalled. 6. Remove the oil pan cover underneath the engine compartment. 7. Drain and remove the radiator assembly. Refer to Section 7.4.3, Radiator/Oil Cooler and Replacement. 8. Remove the heater hoses attached to the engine (if equipped). Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at various places on the engine. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that the engine clears the harness during removal. 9. Label and disconnect all electrical wire connections on the engine. 10. Label and disconnect all electrical wire connections on the Power Distribution bracket. 11. Remove the Power Distribution bracket. 12. Disconnect and cap the fuel inlet line. 13. Disconnect and cap the fuel return line. 14. Remove the exhaust pipe from the exhaust manifold. Refer to Section 7.7.1, Exhaust System Removal.
18
MY5070
5. Loosen the clamp (15) securing the air intake elbow (16) engine. 6. Loosen the capscrews securing the air cleaner mounting bracket (17) to the engine fire wall. 7. Remove the air cleaner assembly (17 & 18). 8. Remove the air cleaner mounting bracket (17) from the air cleaner (18).
7.8.4
Air Cleaner Assembly Installation (Cummins)
Note: Apply Loctite 242 the capscrew threads to before installation. 1. Install the air cleaner (18) to the air cleaner mounting bracket (17). 2. Install the air cleaner assembly (17 & 18) to the engine fire wall. 3. Tighten the previously loosened capscrews. 4. Install the air intake elbow (16) onto the engine. 5. Adjust and tighten the clamp (15). 6. Properly connect the battery. 7. Close and secure the engine cover. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7-14
G6-42A, G9-43A, G10-43A
Engine
15. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe. 16. Remove the air cleaner tube assembly. Refer to Section 7.8.1, Air Cleaner Assembly Removal (John Deere & Perkins), or Section 7.8.3, Air Cleaner Assembly Removal (Cummins). 17. Remove the access plug from bottom of the engine bell housing. This will allow access to remove the bolts holding the torque convertor diaphragm to the engine flywheel. 18. Turn the engine over slowly by hand and align each of the drive plate bolts to be accessed. Remove them one at a time.
1
7.9.2
Engine Installation
1. Secure the engine with a lifting strap or chain from the appropriate lifting points (1). Use a suitable hoist or overhead crane. to Note: Apply Loctite 242 the engine mount bracket capscrew threads before installation. 2. Install two guide studs in the bell housing holes. 3. Lift the engine and slowly push and lower into the engine bay. Have an assistant ensure that the engine clears the frame, hose and harness components during engine installation. Position engine brackets over the front frame mounts. 4. Push the engine towards the transmission aligning the guide studs and the torque convertor shaft with the corresponding holes. 5. Push the engine against the transmission and install eight of the ten bolts and washers. Remove both guide studs and replace with the remaining two bolts and washers. Torque bolts to 53-58 lb-ft (72-79 Nm). 6. Remove the support from under the transmission and lower the engine the remainder of the way onto the frame. Align the motor mount holes and install the bolts. Apply Loctite 242 to the motor mount bolts and torque to 125-140 lb-ft (169-190 Nm).
MY4270
19. Secure the engine with a lifting strap or chain from the appropriate lifting points (1). Use a suitable hoist or overhead crane. 20. Place a support or jack under the transmission to hold the transmission in place while engine is being removed. 21. Remove the bolts and washer securing the engine mounts. 22. Remove the ten bolts holding the transmission to the engine. Slightly lift and pull the engine out of the machine. Have an assistant ensure that the engine clears all frame components during removal. 23. Place engine on a flat, level surface.
7. Turn the engine over slowly by hand and align each of the drive plate bolts through the access plug in the bell housing. Install them one at a time. DO NOT fully tighten until all of the capscrews and locknuts are in place. Torque to 26-39 lb-ft (35-59 Nm). Replace access plug. 8. Install the exhaust pipe. Refer to Section 7.7.2, Exhaust System Installation. 9. Install the complete air cleaner assembly. Refer to Section 7.8.2, Air Cleaner Assembly Installation (John Deere & Perkins), or Section 7.8.4, Air Cleaner Assembly Installation (Cummins). 10. Connect the fuel inlet line. 11. Connect the fuel return line. 12. Install the Power Distribution bracket. 13. Connect all the previously labeled electrical wire connections on the Power Distribution bracket. 14. Connect all the previously labeled electrical wire connections on the engine. 15. Install both heater hoses to the engine and tighten clamps (if equipped). 16. Install the complete radiator assembly. Refer to Section 7.4.3, Radiator/Oil Cooler and Replacement.
G6-42A, G9-43A, G10-43A
7-15
Engine
17. Install the engine cover and adjust. 18. Install and properly connect the battery. Install and properly connect the second battery if equipped. 19. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and connected tightly. 20. From within the cab, lightly depress the throttle pedal to full-throttle position. As needed, adjust the limitstop screw until it touches the pedal bracket. Note: Have an assistant stand by with a Class B fire extinguisher. 21. Start the engine and run to normal operating temperature then shut off the engine. While the engine is cooling, check for leaks. 22. Allow the engine to cool. Check the radiator coolant level and add coolant if required. Replace the radiator cap. 23. Check for leaks from the engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill as required. 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. 24. Obtain and connect an appropriate engine analyzer or tachometer. Check the engine rpm at full throttle. 25. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level. 26. Check for proper operation of all components. 27. Turn the engine OFF. 28. Install the oil pan cover underneath the engine compartment. 29. Close and secure the engine cover. 30. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
7-16
G6-42A, G9-43A, G10-43A
Engine
7.10
TROUBLESHOOTING Possible Causes (see key, below)

1, 2, 3, 4 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62 4, 36, 37, 38, 39, 40, 42, 43, 44, 58 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49 4, 38, 41 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57 25, 31, 33, 34, 45, 55, 60 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59 10, 11, 12 Key to Possible Causes
Trouble
Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfiring Excessive Fuel Consumption Black Exhaust Blue/White Exhaust Low Oil Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Battery charge low Bad electrical connection Faulty starter motor Incorrect grade of lubricating oil Low cranking speed Fuel tank empty Faulty stop control operation Fuel inlet restricted Faulty fuel lift pump Clogged fuel filter Restricted air cleaner Air in fuel system Faulty fuel injection pump Faulty fuel injectors or incorrect type Incorrect use of cold start equipment Faulty cold start equipment Broken fuel injection pump drive Incorrect fuel pump timing Incorrect valve timing Poor compression
21. Blocked fuel tank vent 22. Incorrect grade of fuel 23. Sticking throttle or restricted movement 24. Exhaust pipe restriction 25. Leaking cylinder head gasket 26. Overheating 27. Cold running 28. Incorrect tappet adjustment 29. Sticking valves 30. Incorrect high pressure pipes 31. Worn cylinder bores 32. Pitted valves and seats 33. Broken, worn or sticking piston ring(s) 34. Worn valve stems and guides 35. Restricted air cleaner 36. Worn or damaged bearings 37. Insufficient oil in sump 38. Inaccurate gauge 39. Oil pump worn 40. Pressure relief valve sticking open 41. Pressure relief valve sticking closed 42. Broken relief valve spring
43. 44. 45. 46. 47. 48. 49.
50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63.
Faulty suction pipe Restricted oil filter Piston seizure/pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors (if fitted) Coolant level too low Blocked sump strainer Broken valve spring Exhauster or vacuum pipe leak Turbo impeller damaged or dirty Turbo lubricating oil seal leak Induction system leaks 7-17
G6-42A, G9-43A, G10-43A
Engine
7-18
G6-42A, G9-43A, G10-43A
Section 8 Hydraulic System
Contents
PARAGRAPH 8.1 8.2 8.3 8.4 TITLE PAGE 8-2 8-3 8-4 8-4 8-5 8-5 8-6 8-7 8-9 8-12 8-17 8-17 8-17 8-17 8-18 8-18 8-19 8-19 8-22 8-22 8-23 8-23 8-24 8-25 8-25 8-27 8-27 8-28 8-29
8.5
8.6 8.7
8.8
Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Pressure Specifications - G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3 Pressure Specifications - G9-43A & G10-43A . . . . . . . . . . . . . . . . . . . . . 8.4.4 Hydraulic Schematic - G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.5 Hydraulic Schematic - G9-43A & G10-43A . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.5 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.6 Outrigger Valve (G10-43A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.4 Cylinder Torque Specifications - G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.5 Cylinder Torque Specifications - G9-43A & G10-43A . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
8-1
Hydraulic System
8.1
HYDRAULIC COMPONENT TERMINOLOGY
To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
OUTRIGGER CONTROL VALVE (G10-43A)
EXTEND/RETRACT CYLINDER (INSIDE BOOM)
HYDRAULIC FLUID RESERVOIR
LIFT/LOWER CYLINDER
COMPENSATION CYLINDER
TILT CYLINDER
MY0601
OUTRIGGER CYLINDER (G10-43A)
FRAME LEVEL CYLINDER (BEHIND TIRE)
MAIN CONTROL VALVE
PRIORITY VALVE
8-2
G6-42A, G9-43A, G10-43A
Hydraulic System
8.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all safety precautions as outlined in Section 1, Safety Practices, of this manual. Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present. Hydraulic fluid has a flash point that ranges from 300-600 F (150-318 C) and an auto-ignition temperature of 500-750 F (262-402 C). Accordingly, periodically inspect all hydraulic system components, hoses, tubes, lines, fittings, etc. Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard. If in doubt, replace the component. Operate the hydraulic controls after the engine has stopped to relieve trapped pressure. Note: Residual pressure may remain in hydraulic cylinders, hoses, valve bodies, components, etc. If the hydraulic lines going to or coming from a component are taut, slowly and cautiously relieve (bleed off) pressure.
Whenever you disconnect a hydraulic line, coupler, fitting or other component, slowly and cautiously loosen the part involved. A hissing sound or slow seepage of hydraulic fluid may occur in most cases. After the hissing sound has ceased, continue removing the part. Any escaping oil should be directed into an appropriate container. Cap or otherwise block off the part to prevent further fluid seepage. Hydraulic system maintenance will, at times, require that the engine be operated. Always follow safety precautions. A major cause of hydraulic component failure is contamination. Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs. Sand, grit and other contaminants can damage the finely machined surfaces within hydraulic components. If operating in an exceptionally dirty environment, change filters and inspect the fluid more often. When servicing the system, cap or plug hydraulic fittings, hoses and tube assemblies. Plug all cylinder ports, valves and the hydraulic reservoir, and pump openings until installation occurs. Protect threads from contamination and damage. Some hydraulic functions are actuated by interfacing with electrical system components (switches, solenoids and sensors). When the hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also. Refer to Section 9.5, Electrical System Schematics, in this manual.
G6-42A, G9-43A, G10-43A
8-3
Hydraulic System
8.3
HYDRAULIC PRESSURE DIAGNOSIS
8.3.1
Pressure Checks and Adjustments
JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting: the JLG Pressure Test Kit. The kit is contained in a durable polyethylene carrying case for demanding field service conditions. Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system. The kit includes: Gauges for testing high and low pressure circuits Fittings, couplers and hoses Durable carrying case
When diagnosing trouble in the hydraulic system, use the hydraulic testing information in Section 8.4.1, Hydraulic Pressures. In general, follow the steps below whenever conducting pressure checks and performing adjustments: 1. Park the machine on a firm, level surface. Engage the park brake, place the travel select lever in (N) NEUTRAL, level the boom and turn the engine OFF. 2. The test port is located at the top right corner of the main control valve. Install a pressure gauge capable of measuring at least 10% more pressure than that which the circuit being checked operates under. 3. Start the engine. Operate machine functions several times to allow hydraulic oil to reach operating temperature. The hydraulic oil temperature should be between 100-120F (38-49 C). If a temperature gauge or thermometer is unavailable, the hydraulic oil reservoir should be warm to the touch. 4. Refer to Section 8.4.1, Hydraulic Pressures, for testing procedures. 5. Fully depress the accelerator pedal if required. Place and hold the joystick in the position needed to operate the particular machine function being checked. Continue holding the joystick in position until pressure readings are taken. 6. Check the pressure gauge reading. It should read as specified in the Pressure Readings column of the charts found in Section 8.4.1, Hydraulic Pressures. If the reading is not as specified, turn the engine OFF and check other components in the system. Verify that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly. 7. Adjust the relief valve by turning the adjustment screw clockwise will increase the pressure; turning the screw counterclockwise will decrease the pressure. 8. Start the engine and check the pressure again. Turn the engine OFF. If there is pressure reading in the gauge, bleed it off then disconnect or remove the pressure gauge from the machine.
MZ1460
Contact your local authorized distributor for ordering information.

Part Number Description Approximate Weight 10 lbs. 7 lbs. Price and Availability Consult Factory Consult Factory
70000652 Hydraulic Pressure Test Kit 70000101 Digital Hydraulic Pressure Test Kit
8-4
G6-42A, G9-43A, G10-43A
Hydraulic System
8.4
HYDRAULIC CIRCUITS
8.4.1
Hydraulic Pressures
This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those pressures and a hydraulic schematic. Electrical and hydraulic functions are often related. Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit. Always check the following before beginning to troubleshoot a circuit that is not functioning correctly. 1. Check the hydraulic oil level in the reservoir. Oil level should be to the middle of the sight glass with all cylinders retracted. 2. Check hoses, tubes, fittings and other hydraulic components for leaks, bends, kinks, interference, etc. 3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder operation are signs of air in the hydraulic system. If air in the hydraulic system is suspected, you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid. Loose fittings, faulty o-rings or seals, trapped oil, leaks, system opened for service, etc., can cause air in the system. Determine what is causing air to enter the system and correct it. Bleed air from the system.
a. Checking Pressures 1. Start the machine and warm the hydraulic system to operating temperature. 2. Shut off the machine and install a digital or a 5000 psi (345 bar) gauge to the appropriate test port on the priority valve. 3. Start the machine, run the engine and follow the procedures in Section 8.4.2, 8.4.2. Pressure Specifications - G6-42A, or Section 8.4.3, 8.4.3. Pressure Specifications - G9-43A & G10-43A. b. Adjusting Hydraulic Pressure 1. Shut the machine off. Remove the cap on the relief (if necessary). 2. Start the machine and loosen the jam nut on the relief. Turn the relief clockwise to increase pressure or counter-clockwise to decrease pressure. Set to the correct pressure. 3. Tighten the jam nut and recheck the pressure at full throttle. If the reading is within specification, shut the machine off, install the safety cap and remove the gauge from the test port. 4. If the proper pressure cannot be set, use the accompanying hydraulic schematic and/or the electrical schematic to help troubleshoot and correct the problem.
G6-42A, G9-43A, G10-43A
8-5
Hydraulic System 8.4.2 Pressure Specifications - G6-42A

Test Port TP (A) P1 (B) CF1 (C) Procedure Connect gauge to TP port, run engine at low idle. Connect gauge to P1 port, run engine at low idle. Connect gauge to CF1 port, run engine at high idle, bottom out function. Hold over relief and check pressure. Connect gauge to EF1 port, run engine at high idle, bottom out function. Hold over relief and check pressure. Connect gauge to EF1 port, run engine at high idle, bottom out function. Hold over relief and check pressure. Connect gauge to EF1 port, run engine at high idle, bottom out function. Hold over relief and check pressure. Connect gauge to EF1 port, run engine at high idle, bottom out function. Hold over relief and check pressure. Connect gauge to EF1 port, run engine at high idle, bottom out function. Hold over relief and check pressure. Adjustment Location 1 2 Consult Factory 3 Pressure Range 450 - 550 psi (31,0 - 37,9 Bar) 550 - 650 psi (37,9 - 44,8 Bar) 2500 - 2700 psi (172,3 - 186,1 Bar) 3800 - 4200 psi (262,0 - 289,5 Bar) 3800 - 4200 psi (262,0 - 289,5 Bar) 3800 50 psi (262,0 3,4 Bar) 4100 - 4500 psi (282,6 - 310,2 Bar) 3800 - 4200 psi (262,0 - 289,5 Bar)
Hydraulic Circuit Service/Park Brake Stand By Steering
Boom Lift
EF1 (D)
Boom Retract
EF1 (D)
Boom Extend
EF1 (D)
Fork Tilt
EF1 (D)
Frame Level
EF1 (D)
A B C
MY0320
1
MY6010
8-6
G6-42A, G9-43A, G10-43A
Hydraulic System 8.4.3 Pressure Specifications - G9-43A & G10-43A
a. Before S/N 0160040675 excluding 0160040468 & 0160040672 Hydraulic Circuit Pilot Steering Test Port TP (A) Primary (B) Function Used to Test Connect gauge to P1 port, run engine at high idle. No Function Connect gauge to Primary port, run engine at high idle, bottom out steering. Hold over relief and check pressure. Connect gauge to P1 port, run engine at high idle, bottom out steering. Hold over relief and check pressure. Connect gauge to Secondary port, run engine at high idle, bottom boom extend. Hold over relief and check pressure. Adjustment Location 1 2 Pressure Range 450 - 550 psi (31,0 - 38,0 Bar) 2350 - 2550 psi (162,0 - 175,8 Bar) 1090 - 1110 psi (75,1 - 76,5 Bar) 3750 - 3850 psi (258,5 - 265,4 Bar)
Service Brake
P1 (C)
Boom Lift, Extend/Retract, Frame Level
Secondary (D)
1 A C B 2 3
MY0320
D
MY6150
G6-42A, G9-43A, G10-43A
8-7
Hydraulic System
b. S/N 0160040675 & After including 0160040468 & 0160040672 Hydraulic Circuit Stand By Priority Load Sense (Steering) Pilot Test Port P1 (A) GLS (B) Function Used to Test Connect gauge to P1 port, run engine at high idle. No Function Connect gauge to GLS port, run engine at high idle, bottom out steering. Hold over relief and check pressure. Connect gauge to P1 port, run engine at high idle, bottom out steering. Hold over relief and check pressure. Connect gauge to BV1 port, run engine at high idle, bottom out steering. Hold over relief and check pressure. Connect gauge to P1 port, run engine at high idle, bottom boom retract. Hold over relief and check pressure. Connect gauge to GLS port, run engine at high idle, bottom boom extend. Hold over relief and check pressure. Connect gauge to GLS port, run engine at high idle, bottom boom retract. Hold over relief and check pressure. Connect gauge to GLS port, run engine at high idle, bottom boom lift. Hold over relief and check pressure. Connect gauge to GLS port, run engine at high idle, bottom function. Hold over relief and check pressure. Adjustment Location 1 2 Pressure Range 250 - 265 psi (17,2 - 18,2 Bar) 2400 - 2500 psi (165,4 - 172,3 Bar) 500 - 550 psi (34,5 - 37,9Bar) 1050 - 1150 psi (72,3 - 79,2 Bar) 3800 - 3900 psi (262,0 - 269,0 Bar) 3800 - 3900 psi (262,0 - 269,0 Bar) 3800 - 3900 psi (262,0 - 269,0 Bar) 3800 - 3900 psi (262,0 - 269,0 Bar) 2633 - 2733 psi (181,5 - 188,4 Bar)
JS1 (C)
Service Brake
BV1 (D)
Main
P1(A)
Boom Extend
GLS(B)
N/A
Boom Retract
GLS(B)
N/A
Boom Lift
GLS(B)
N/A
Auxiliary Hydraulics
GLS(B)
N/A
5 2
MY6100 MY6080
8-8
G6-42A, G9-43A, G10-43A
8.4.4
PT
STEERING ORBITROL
RED
PURPLE YELLOW
LP
LS
TANK
SERVICE BRAKE
GREEN
.120 SV BV TP
PRIORITY/BRAKE VALVE
500 PSI
PB
25 PSI
G6-42A, G9-43A, G10-43A

B1 A1 A2 B2
a. Before S/N 0160040678
STEER SELECT VALVE LIFT CYLINDER SERVICE BRAKE VALVE CROWD CYLINDER JOYSTICK
5000 PSI
REAR SERVICE BRAKES
TILT CYLINDER
OUTLET T INLET 1 2 3 4
5000 PSI 5000 PSI
COMPENSATING CYLINDER
SWAY CYLINDER
Hydraulic Schematic - G6-42A
OUTLET
.040
.050
PARK BRAKE
4000 PSI
T
3800 PSI
4300 PSI 4300 PSI
B A
B A
B A
B A
MAIN CONTROL VALVE
LIFT
CROWD
TILT
SWAY
EF1 JS
EF
CF
CF1
LS
COM
2600 PSI
HYDRAULIC OIL COOLER
RV T PR CV
RETURN FILTER B8=75
OR
10 MICRON BREATHER
P1
Hydraulic System
MY0911
IMPLEMENT PUMP 1.97 CU.IN./REV
8-9
P T
STEERING ORBITROL
RED
PURPLE YELLOW
LP
LS
TANK
SERVICE BRAKE
GREEN
.120 SV BV TP
PRIORITY/BRAKE VALVE
450 PSI
PB
10 MICRON BREATHER
P1
G6-42A, G9-43A, G10-43A
IMPLEMENT PUMP 1.97 CU.IN./REV
25 PSI
8-10
PT B1 A1 A2 B2
b. S/N 0160040678 & After
STEER SELECT VALVE

LIFT CYLINDER
Hydraulic System
SERVICE BRAKE VALVE

TE TEST PORT
CROWD CYLINDER JOYSTICK TILT CYLINDER
REAR SERVICE BRAKES

5000 PSI
P OUTLET T 1 2 3 4 INLET
5000 PSI
SWAY CYLINDER
OUTLET
.040
.050
T
4000 PSI
3800 PSI
PARK BRAKE
4300 PSI
4300 PSI
B A
B A
B A
B A
MAIN CONTROL VALVE
LIFT
CROWD
TILT
SWAY
EF1 JS
EF
CF
CF1
LS
COM
2600 PSI
RV1 550 PSI PR CV RV2

RETURN FILTER B8 =75
OR
MY6120
25 PSI
G6-42A, G9-43A, G10-43A

AUXILIARY HYDRAULICS PORTS
4100 PSI 4100 PSI 3000 PSI 3000 PSI
MY0921
SOLENOID VALVE
MAIN CONTROL VALVE
3800 PSI
4100 PSI
4100 PSI
TILT CYLINDER
P
B A A A
B B B
P
5000 PSI
LIFT
CROWD
TILT
SWAY
AUX.
AUXILIARY HYDRAULICS (IF EQUIPPED)
T
4300 PSI 3800 PSI 4300 PSI
4000 PSI
P
A A A
MAIN CONTROL VALVE
LIFT
CROWD
TILT
SWAY
EF1 EF CF CF1 LS
JS
4300 PSI 4300 PSI
C2
.03
600 PSI T

1000
B A
STABILIZER CYLINDER
STABILIZER VALVE BLOCK

.03
500 PSI P1
C1 T
PB P BV TP
PRIORITY/BRAKE BLOCK
CROWD
MAIN CONTROL VALVE
Hydraulic System
RESERVOIR
REAR AXLE STABILIZER (IF EQUIPPED)
8-11
CYLINDER FRONT STEERING
P STEER SELECT VALVE

5000 PSI
STEERING ORBITROL
YELLOW
GREEN
RED
OUTLET
LP LOAD SENSE PARK BRAKES TANK FRONT SERVICE BRAKES
LS
BLUE
VALVE BLOCK
REAR SEC 3.19 CU IN/REV @2750 RPM

100 MESH
25 PSI
8-12
PT B1 A1 LIFT CYLINDER A2 B2
8.4.5
Hydraulic System
Hydraulic Schematic - G9-43A & G10-43A
a. Before S/N 0160040675 excluding 0160040468 & 0160040672
MY0651
CROWD CYLINDER SERVICE BRAKE VALVE REAR SERVICE BRAKES JOYSTICK
5000 PSI
TILT CYLINDER
P OUTLET INLET T 1 2 4 3
5000 PSI
SWAY CYLINDER
.040
.050
T
3800 PSI
4100 PSI 4100 PSI
4100 PSI 4100 PSI
B A
B A
B A
B A
MAIN CONTROL VALVE
LIFT
CROWD
TILT
SWAY
GAUGE PORT SECONDARY
P1
SV
BV
PB
PRIMARY GAUGE PORT

PR CV
PRIMARY PORT
SECONDARY PORT
.030
LOAD SENSING SIGNAL PORT

500 PSI
P P
JS
TP
2450 PSI
1100 PSI RV1
PUMP
FRONT SEC .75 CU IN/ REV @2750 RPM
G6-42A, G9-43A, G10-43A
10 MICRON BREATHER
25 PSI
G6-42A, G9-43A, G10-43A

4100 PSI 4100 PSI 4100 PSI 3000 PSI 3000 PSI
MY0661
TILT CYLINDER MAIN CONTROL VALVE
5000 PSI
3800 PSI
4100 PSI
P
B A A A A
B B B
LIFT COMPENSATING CYLINDER
CROWD
TILT
SWAY
AUX.
AUXILIARY HYDRAULICS (IF EQUIPPED)

TO JOYSTICK
B
.030
A .030
P1
BV
SV
PB
T
4100 PSI 4100 PSI 4100 PSI
4100 PSI
CV PR .030
3800 PSI
4100 PSI
4100 PSI
JS
P
A A A
MAIN CONTROL VALVE
TP
T
LIFT
CROWD
TILT
SWAY
T
T
RV
PUMP
VALVE BLOCK

1000
C2
.03
STABILIZER CYLINDER
STABILIZER VALVE BLOCK
TILT ON JOYSTICK (IF EQUIPPED)

.03
C1 T
MAIN CONTROL VALVE
Hydraulic System
RESERVOIR
REAR AXLE STABILIZER (IF EQUIPPED)
8-13
YELLOW
GREEN
RED
BLUE
25 PSI
8-14
LEFT OUTRIGGER CYLINDER RIGHT OUTRIGGER CYLINDER
5000 PSI 5000 PSI
Hydraulic System
MY3200
TO HYDRAULIC OIL COOLER
LOD ROD
PUMP
TANK LOU ROU
B B
TANK
4100 PSI
3800 PSI
4100 PSI
3000 PSI
PUMP
4100 PSI 3000 PSI
OUTRIGGER VALVE
POWER BEYOND
LIFT CROWD TILT
4100 PSI
SWAY
AUX
A
MAIN CONTROL VALVE (W/ POWER BEYOND)
JOYSTICK
P T 1 2 3 4
T P
LEFT AND RIGHT OUTRIGGER JOYSTICK
JS
1 LOD
2 LOU
1 ROD
ROU
VALVE BLOCK
RETURN FILTER B8=75
10 MICRON BREATHER
G6-42A, G9-43A, G10-43A

OUTRIGGERS (G10-43A)
100 MESH
PT
B1 A1 A2
STEERING ORBITROL
YELLOW
GREEN
RED
OUTLET
LP LOAD SENSE PARK BRAKES FRONT SERVICE BRAKES
LS
BLUE
25 PSI
G6-42A, G9-43A, G10-43A

FRONT STEERING CYLINDER P STEER SELECT VALVE TILT CYLINDER T SERVICE BRAKE VALVE JOYSTICK
5000 PSI
L REAR SERVICE BRAKES P LIFT CYLINDER 1 2 4 .040 INLET

5000 PSI 5000 PSI
B2
CROWD CYLINDER
SWAY CYLINDER
T OUTLET 3 COMPENSATING CYLINDER
.050
LEFT DWN QA EXTD.
RIGHT, UP, QA RET.

SECONDARY GAUGE PORT

RV2
P1
BV
PB
B
500 PSI
SV
PRIMARY GAUGE PORT

4100 PSI
PRIMARY PORT
SECONDARY PORT
3800 PSI
PR
CV
.030
TP
4100 PSI
b. S/N 0160040675 & After including 0160040468 & 0160040672
LOAD SENSING SIGNAL PORT
3000 PSI
450 PSI
PUMP
JS
1100 PSI
4100 PSI
3000 PSI
TANK
2450 PSI
RV1
PUMP
LIFT
CROWD
4100 PSI
TILT
SWAY
AUX
VALVE BLOCK
REAR SEC 3.19 CU IN/REV @2750 RPM
FRONT SEC .75 CU IN/ REV @2750 RPM
MAIN CONTROL VALVE (W/O POWER BEYOND)
RETURN FILTER B8=75
10 MICRON BREATHER
Hydraulic System
MY6130D
100 MESH
8-15
YELLOW
GREEN
RED
SEE SHT #1
JS
BLUE
25 PSI
8-16
LEFT OUTRIGGER CYLINDER
RIGHT OUTRIGGER CYLINDER
5000 PSI
5000 PSI
Hydraulic System
OPTIONAL REMOTE HYDRAULIC QUICK ATTACH

TO HYDRAULIC OIL COOLER SHT1
LOD ROD
PUMP TANK
B B B B B
LOU ROU TANK
QA CYLINDER
C2 C3
3800 PSI
4100 PSI
AUXILIARY HYD. PORTS

4100 PSI
3000 PSI
OUTRIGGER VALVE
POWER BEYOND
C1 C4
PUMP
4100 PSI
3000 PSI
4100 PSI CROWD
LIFT TILT
SWAY
AUX
A A A A A
P1 P2
MAIN CONTROL VALVE (W/ POWER BEYOND)
JOYSTICK
P T 1 2 3 4
T P
LEFT AND RIGHT OUTRIGGER JOYSTICK
LEFT DWN QA EXTD.
RIGHT, UP, QA RET.

AUXILIARY HYD. PORTS @ BOOM NOSE
1 LOD 2 LOU
1 ROD
2 ROU
VALVE BLOCK
RETURN FILTER B8=75
OUTRIGGER OPTION
100 MESH
MY6140D
G6-42A, G9-43A, G10-43A
10 MICRON BREATHER
Hydraulic System
8.5
HYDRAULIC RESERVOIR
1
8.5.2
Hydraulic Oil Reservoir Filling
BEFORE S/N 0160040675 EXCLUDING 0160040468 & 0160040672
1. Be sure the reservoir is clean and free of all debris. 2. Install a new hydraulic oil filter. 3. Fill the reservoir according to specifications. Refer to Section 2.4, Fluid and Lubricant Capacities. 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.
MY1150
8.5.3
Hydraulic Oil Reservoir Removal/ Installation
S/N 0160040675 & AFTER INCLUDING 0160040468 & 0160040672
If it is determined that the hydraulic oil reservoir must be removed, the hydraulic oil must be drained before the reservoir is removed. Always dispose of hydraulic oil properly. a. Reservoir 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Drain the hydraulic oil reservoir. Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining. 6. Label, disconnect and cap all hydraulic hoses attached to the hydraulic oil reservoir. Cap all fittings and openings to keep dirt & debris from entering the hydraulic system. 7. Remove the bolts securing the hydraulic oil reservoir to the frame. 8. Remove the hydraulic oil reservoir. b. Disassembly The hydraulic oil reservoir is a one-piece unit and cannot be disassembled. The hydraulic oil level sight- glass and hydraulic oil filler cap can be removed and reused on the new replacement reservoir. Dispose of the old reservoir according to local regulations concerning hazardous materials disposal.
MY5300
The hydraulic reservoir (1) is located on the frame between the engine compartment and the cab.
8.5.1
Hydraulic Oil Reservoir Draining
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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Open the filler cap on the hydraulic oil reservoir. Remove the drain plug on the side of the hydraulic oil reservoir. 6. Transfer the used hydraulic oil into a suitable covered container, and label as "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
G6-42A, G9-43A, G10-43A
8-17
Hydraulic System
c. Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the hydraulic oil reservoir, contact JLG Service Department. To clean the hydraulic oil reservoir: 1. Have a dry chemical (Class B) fire extinguisher near the work area. 2. Remove the hydraulic oil reservoir drain plug, and safely drain any hydraulic oil into a suitable container. Dispose of hydraulic oil properly. 3. Clean the hydraulic oil reservoir with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly. d. Inspection Note: If a leak is suspected in the fuel or hydraulic oil tank, contact JLG Service Department. 1. Inspect the hydraulic oil reservoir thoroughly for any cracks, slices, leaks or other damage. 2. With the hydraulic oil reservoir removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 1-1.5 psi (7-10 kPa) of air pressure through the elbow. Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area. e. Reservoir Installation 1. Place the hydraulic oil reservoir into its original orientation. 2. Secure the hydraulic oil reservoir to the frame with the previous mounting hardware. 3. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 4. Install the hydraulic fluid level sight-glass using special designed and drilled capscrews and gaskets. 5. Install hydraulic filter bracket and hydraulic filter. 6. Fill the hydraulic oil reservoir according to specifications. Refer to Section 2.4, Fluid and Lubricant Capacities. 7. Check the hydraulic oil reservoir for leaks. 8. Properly connect the battery. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8-18
G6-42A, G9-43A, G10-43A
MY1550
8.6
IMPLEMENT PUMP
For internal service instructions contact your local JLG distributor.
8.6.1
Implement Pump Replacement
a. Pump 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Drain the hydraulic reservoir. Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining. 6. Thoroughly clean the pump and surrounding area, including all hoses and fittings before proceeding. Note: Cap all hoses as you remove them to prevent unnecessary fluid spillage. 7. Label, disconnect and cap the hydraulic hoses attached to the pump.
2
8. Remove the bolts and lockwashers securing the pump (2) to the transmission. Remove the o-ring located between the transmission and the pump. Wipe up any hydraulic oil spillage.
Hydraulic System
Note: DO NOT disassemble the operating pump. The pump is pre-set from the manufacturer. Any adjustments or repairs performed by anyone other than an authorized dealer could void the warranty. b. Pump Installation 1. Place the pump and a new, oiled o-ring into position on the transmission. Align the pump shaft with the internal transmission gear, so that the machined teeth mesh together. 2. Align the bolt holes with the pump mount holes. 3. Apply Loctite 242 previously removed bolts 4. Secure the pump to the transmission with the previously removed bolts and washers. Torque as required. 5. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 6. Fill the hydraulic reservoir. Refer to Section 8.5.2, Hydraulic Oil Reservoir Filling. 7. Prime the pump by filling the case drain port with fresh, filtered hydraulic oil from a clean container before installing the case drain connector and hose. 8. Check all routing of hoses and tubing for sharp bends or interference with any rotating members. All tube and hose clamps must be tight. 9. Properly connect the battery. 10. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions. 11. Inspect for leaks and check all fluid levels. The hydraulic reservoir oil level must be to the middle of the sight gauge. 12. Close and secure the engine cover. 13. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. c. Pump Test Refer to Section 8.3.1, Pressure Checks and Adjustments.
8.7
8.7.1
CONTROL VALVES
Main Control Valve
The main control valve is mounted on the frame behind the cab underneath a protective cover. The main control valve assembly consists of four working sections with their own valve assemblies, each providing a specific hydraulic function. Note: The optional main control valve for auxiliary hydraulics contains a fifth valve section next to the frame level section. a. Main Control Valve 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the main control valve protective cover. 6. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding. 7. Drain the hydraulic fluid reservoir. Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining. 8. Place a suitable container to catch hydraulic fluid drainage beneath the frame. Note: Slowly remove the hydraulic hoses attached to the main control valve to relieve any possible trapped pressure in the hydraulic line. 9. Label, disconnect and cap all the hydraulic hoses, tubes and wires at the main control valve. 10. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area. 11. Remove the three bolts, washer and nuts (3) securing the main control valve to the frame.
G6-42A, G9-43A, G10-43A
8-19
Hydraulic System
b. Main Control Valve Disassembly
G6-42A
G9-43A & G10-43A
MY0340
8-20
G6-42A, G9-43A, G10-43A
Hydraulic System
1. To disassemble the individual sections of the main control valve, remove the nuts from one end of the tie rods (4). Pull the tie rods out through the sections. 2. Disassemble each section assembly as required. Some sections include a pre-adjusted relief valve that regulates pressure in a specific circuit. Note: DO NOT adjust any of the relief valve assemblies! Tampering with a relief valve will irrevocably alter pressure in the affected circuit, requiring recalibration or a new relief valve. Disassemble each Valve Section 1. Carefully separate the load sense outlet section from the lift/lower section. 2. Remove the o-rings from between the two sections. 3. Carefully separate each remaining sections, being careful not to lose the load sense shuttle ball. 4. Remove both end caps from each end of the valve sections then remove each control spool. 5. Remove any check valves, compensator valves, anti-cavitation valves or shock valves from individual valve section if equipped. 6. Keep all parts being removed from individual valve sections tagged and kept together. c. Main Control Valve Parts Cleaning Clean all components with a suitable cleaner, such as triclorethylene, before continuing. Blow dry. d. Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear, damage, etc. If inner surfaces of any component DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals, damage to the polished surfaces within the component, and wear of and/or harm to other parts. e. Main Control Valve Assembly Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Assemble each Valve Section 1. Reassemble any check valves, compensator valves, anti-cavitation valves or shock valves from each individual valve sections if equipped.
G6-42A, G9-43A, G10-43A
2. Install the control spool being careful not to nick or scratch the valve section bore or the control spool. 3. Install the end caps on each end of the valve section. Assemble the Main Control Valve. 1. Place all three tie rods with the washers and nuts through the end main control valve section. 2. Stand the end main control valve section on end. 3. Install the proper o-rings and load sense shuttle on the inner face of the end main control valve section. Align the next valve section over the three tie rods and slide onto the end main control valve section. 4. Using the proper o-rings and load sense shuttle, repeat step three for the remaining valve sections and lastly the inlet end valve section. 5. Install the three washers and nuts on the tie rods. Torque to 32 lb-ft (43 Nm) for the G6-42A and to 42 lb-ft (57 Nm) for the G9-43A and G10-43A. f. Main Control Valve Installation
1. Install the main control valve onto the frame, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts. 2. Prime the main control valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses. 3. Use new oiled o-rings as required. Uncap and connect all previously labeled hoses, clamps, etc. to the main control valve. 4. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 5. Fill the hydraulic fluid reservoir. Refer to Section 8.5.2, Hydraulic Oil Reservoir Filling. 6. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions. 7. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8-21
Hydraulic System
9. Install the main control valve protective cover. 10. Close and secure the engine cover. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. g. Main Control Valve Test Conduct a pressure check of the hydraulic system in its entirety. Adjust pressure(s) as required. Refer to Section 8.3.1, Pressure Checks and Adjustments. b. Service Brake Valve Installation 1. Install the service brake valve with the four capscrews, four lockwashers and four nuts onto the service brake bracket. 2. Install the service brake pedal. Refer to Section 4.3.2, Service Brake Pedal. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 3. Use new oiled o-rings as required. Uncap and connect the previously labeled hoses to the service brake valve. 4. Check the routing of all hoses, and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 5. Properly connect the battery. 6. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic functions. 7. Inspect the service brake valve and connections for leaks, and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF.
1
8.7.2
Service Brake Valve
a. Service Brake Valve 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
Note: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
8.7.3
MY0140
Brake Test
5. Label, disconnect and cap all hose attached to the service brake valve (1). 6. Remove the service brake pedal. Refer to Section 4.3.2, Service Brake Pedal. 7. Remove the four capscrews, four nuts and four lockwashers mounting the service brake valve to the service brake bracket. Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective. 8-22
Carefully bleed the brake lines as soon as the brake valve is installed in the machine. Air in the system will not allow the brakes to apply properly. There are four brake bleeder locations on the axles. Work with an assistant to perform this procedure. 1. Place the travel select lever in (N) NEUTRAL, engage the park brake, and start the engine.
G6-42A, G9-43A, G10-43A
Hydraulic System 8.7.5 Steer Select Valve
MY0151
2. Remove the plastic cap from the brake bleeder (2). Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil. The end of the tubing must be below the oil level in the container. 3. DO NOT open the brake bleeder without holding the tubing firmly on the bleeder. There is pressure at the brakes. Carefully open the bleeder with a 12mm wrench. Have the assistant depress the brake pedal. Close the brake bleeder when air bubbles no longer appear in the oil. Release the brake pedal. Remove the tubing from the brake bleeder. 4. Repeat Steps 2 and 3 for the remaining brake bleeders. 5. Install a vacuum pump on the brake reservoir and remove the remainder of the trapped air from the brake system. 6. Check brake fluid level and add fluid if necessary. 7. Conduct a pressure and function check of the service brake. Refer to Section 8.4.1, Hydraulic Pressures.
4
MY0350
The machine can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve (4) controls the direction of hydraulic fluid flow to the steering cylinder mounted on each axle. The steer select valve is attached to a mounting plate inside the frame near the left front corner of the cab. Verify the correct operation of the steer select valve solenoids before considering replacement of the valve. Refer to Section 9.5, Electrical System Schematics, and Section 9.12, Display Monitor and Gauges. The housing of the steer select valve is not serviceable and must be replaced if defective. a. Steer Select Manifold and Valve 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 the steering wheel, stating that the machine should not be operated.
8.7.4
Steering Orbitrol Valve
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Label, disconnect and cap the hydraulic hoses and the electrical plugs connected to the steering select valve. 6. Remove the bolts holding the steer select valve to the mounting plate on the frame. 7. Remove the steer select manifold with the attached steer select valve from the machine. Wipe up any hydraulic fluid spillage in, on, near and around the machine. 8-23
MZ0370
The steering orbitrol valve (3) is located at the base of the steering wheel shaft, concealed by the lower dash cover. The valve is not serviceable and must be replaced in its entirety if defective. For detailed information refer to Section 4.3.1, Steering Column and Orbitrol Valve.
G6-42A, G9-43A, G10-43A
Hydraulic System
b. Steer Select Manifold and Valve Disassembly, Cleaning, Inspection and Assembly 1. Place the steer select assembly on a suitable work surface. 2. Separate the steer select valve from the manifold by removing the four socket head capscrews. Discard the four o-rings. 3. Remove the solenoid valves and cartridges from the steer select housing. 4. Clean all components with a suitable cleaner before inspection. 5. Inspect the solenoid cartridges for proper operation. Check by shifting the spool to ensure that it is functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination. 6. Inspect internal passageways of the steer select manifold and valve for wear, damage, etc. If inner surfaces of the manifold DO NOT display an ultrasmooth, polished finish, or components are damaged in any way, replace the manifold or appropriate part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 7. Install the solenoid valves and cartridges in the steer select housing. 8. Attach the steer select valve to the manifold using four new, oiled o-rings and the four socket head capscrews. c. Steer Select Valve and Manifold Installation 1. Install the steer select valve to the mounting plate under the left front side of the frame using the two bolts. 2. Connect all the hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the steer select valve 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 4. Properly connect the battery. 5. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions.
OAL0070
6. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8. Close and secure the engine cover. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. d. Steering Test Refer to Section 8.4.1, Hydraulic Pressures. 1. Conduct a pressure check of the steering hydraulic circuit. 2. Check each steering mode for proper function.
8.7.6
Outrigger Valve (G10-43A)
a. Outrigger Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise 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, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the cover over the outrigger valve.
8-24
G6-42A, G9-43A, G10-43A
Hydraulic System
6. Label, disconnect and cap the hydraulic hoses connected to the outrigger control valve (5). Cap all fittings to keep dirt & debris from entering the hydraulic system. 7. Remove the bolts holding the outrigger control valve to the frame. b. Outrigger Valve Installation 1. Install the outrigger valve onto the machine frame. 2. Uncap and connect the previously labeled hydraulic hoses to the outrigger valve. 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 4. Properly connect the battery. 5. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions. 6. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8. Close and secure the engine cover. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
8.8
8.8.1
HYDRAULIC CYLINDERS
General Cylinder Removal Instructions
1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retract the boom. Allow sufficient work space around the hydraulic cylinder being removed. Support the boom if the lift/lower cylinder is being removed. Place the travel select lever in (N) NEUTRAL, engage the park brake, shut the engine OFF and chock wheels. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Label, disconnect and cap or plug hydraulic hoses in relation to the cylinder. 5. Attach a suitable sling to an appropriate lifting device and to the cylinder. Make sure the device used can actually support the cylinder. 6. Remove the lock bolt and/or any retaining clips securing the cylinder pins. Remove the cylinder pins. 7. Remove the cylinder. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. a. General Cylinder Disassembly
MZ0400
1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder. 2. Clamp the barrel end of the cylinder in a soft-jawed vise or other acceptable holding equipment if possible.
G6-42A, G9-43A, G10-43A
8-25
Hydraulic System
white, powdery residue on threads and other parts, which must be removed by brushing with a soft brass wire brush prior to reassembly. 9. Remove the piston head from the rod and carefully slide the head gland off the end of the rod. 10. Remove all seals, back-up rings and o-rings from the piston head and all seals, back-up rings and o-rings from the head gland. Note: The head gland bearing will need to be inspected to determine if replacement is necessary. DO NOT attempt to salvage cylinder seals, sealing rings or o-rings. ALWAYS use a new, complete seal kit when rebuilding hydraulic components. Consult the parts catalog for ordering information. b. Cylinder Cleaning Instructions 1. Discard all seals, back-up rings and o-rings. Replace with new items from seal kit to ensure proper cylinder function. 2. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, grooves, threads, etc. Note: If a white powdery residue is present on threads or parts, it can be removed by using a soft brass wire brush. Wipe clean with Loctite Cleaner prior to reassembly. c. Cylinder Inspection 1. Inspect internal surfaces and all parts for wear, damage, etc. If the inner surface of the cylinder barrel does not display a smooth finish, or is scored or damaged in any way, replace the barrel. 2. Remove light scratches on the piston, head gland, rod or inner surface of the cylinder barrel with a 400600 grit emery cloth. Use the emery cloth in a rotary motion to polish out and blend the scratch(es) into the surrounding surface. 3. Check the piston rod assembly for run-out. If the rod is bent, it must be replaced. d. General Cylinder Assembly Instructions 1. Use the proper tools for specific installation tasks. Clean tools are required for installation. 2. Install new seals, back-up rings and o-rings on the piston and new seals, back-up rings, o-rings and bearing on the head gland.
WARNING
Significant pressure may be trapped inside the cylinder. Exercise caution when removing a counterbalance valve or a pilot-operated check valve from a cylinder. Note: Avoid using excessive force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely. Excessive force can damage the cylinder tube. 3. If applicable, remove the counterbalance valve from the side of the cylinder barrel. Note: DO NOT tamper with or attempt to adjust the counterbalance valve cartridge. If adjustment or replacement is necessary, replace the counterbalance valve with a new part. 4. Extend the rod as required to allow access to the base of the cylinder. Note: Protect the finish of the rod at all times. Damage to the surface of the rod can cause seal failure. 5. Using a pin spanner wrench, unscrew the head gland from the tube. A considerable amount of force will be needed to remove the head gland. Carefully slide the head gland down along the rod toward the rod eye, away from the cylinder barrel. Note: When sliding the rod and piston assembly out of the barrel, prevent the threaded end of the barrel from damaging the piston. Keep the rod centered within the barrel to help prevent binding. 6. Carefully pull the rod assembly along with the head gland out of the cylinder barrel. 7. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. 8. Remove the set screw from the piston head. Note: It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed. Some cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these parts, remove any accessible seals from the area of the bonded parts. Wipe off any hydraulic oil, then heat the part(s) uniformly to break the bond. A temperature of 300-400 F (149-204 C) will destroy the bond. Avoid overheating, or the parts may become distorted or damaged. Apply sufficient torque for removal while the parts are still hot. The sealant often leaves a 8-26
G6-42A, G9-43A, G10-43A
Hydraulic System
Note: The extend/retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head. 3. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. Note: Protect the finish on the cylinder rod at all times. Damage to the surface of the rod can cause seal failure. 4. Lubricate and slide the head gland over the cylinder rod. Install the piston head on to the end of the cylinder rod. Loctite 242 and install the set screw in the piston head. Refer to Section 8.8.4, Cylinder Torque Specifications - G6-42A or Section 8.8.5, Cylinder Torque Specifications - G9-43A & G1043A for torque specifications for the piston head and the set screw. Note: Avoid using excess force when clamping the cylinder barrel in a vise. Apply only enough force to hold the cylinder barrel securely. Excessive force can damage the cylinder barrel. 5. Place the cylinder barrel in a soft-jawed vise or other acceptable holding devise. Note: When sliding the rod and piston assembly into the cylinder barrel, prevent the threaded end of the cylinder barrel from damaging the piston head. Keep the cylinder rod centered within the barrel to prevent binding. 6. Carefully insert the cylinder rod assembly into the cylinder barrel. 7. Screw the head gland into the cylinder barrel and tighten with a spanner wrench. Refer to Section 8.8.4, Cylinder Torque Specifications - G6-42A or Section 8.8.5, Cylinder Torque Specifications - G943A & G10-43A for torque specifications for the head gland. 8. If applicable, install new counter balance valve into block on the cylinder barrel. e. General Cylinder Installation 1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the cylinder into its mounting position. 2. Align cylinder bushing and install pin, lock bolt or retaining clip. 3. Connect the hydraulic hoses in relation to the labels or markings made during removal. 4. Before starting the machine, check level of hydraulic fluid in reservoir. Add hydraulic fluid if needed. Refer to Section 8.5.2, Hydraulic Oil Reservoir Filling.
G6-42A, G9-43A, G10-43A
AXLE CENTER SECTION
5. Start the machine and run at low idle for about one minute. Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil. 6. Inspect for leaks and check level of hydraulic fluid in reservoir. Add hydraulic fluid if needed. Shut the engine OFF. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8. Close and secure the engine cover.
8.8.2
Cylinder Pressure Checking
Attach a 5000 psi (345 bar) gauge to the test port on the P1 port on the priority valve to check the system pressure. Note: If a hydraulic cylinder pressure is greater than the main control valve pressure, increase the main control valve pressure by adjusting the main relief. Generally, one half turn clockwise will be adequate to check an individual circuit. Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn. Re-check the main relief setting and adjust if necessary.
8.8.3
Steering Cylinders
STEERING CYLINDER
The steer cylinder is attached to each axle center housing.The steer cylinder assembly can be found in Section 5.3, Axle Assemblies. The steer cylinder is covered in the appropriate manufacturers axle literature.
8-27
Hydraulic System 8.8.4 Cylinder Torque Specifications - G6-42A
a. Lift/Lower Cylinder Head Before S/N 0160010497 S/N 0160010497 & After 100 lb-ft (135 Nm) 100 lb-ft (135 Nm) Nut N/A 2025-2075 lb-ft (2745-2813 Nm) Bolt Plate 95 lb-ft (129 Nm) N/A Valve 44 lb-ft (60 Nm) 44 lb-ft (60 Nm) Valve Screw 10-12 lb-ft (14-16 Nm) 10-12 lb-ft (14-16 Nm) Set Screw 11 lb-ft (15 Nm) N/A
Note: The capscrews for the bolt plate need to be torqued in sequence in an alternating pattern starting at 35 lb-ft to 75 lb-ft to 95 lb-ft. Check the final torque in a circular pattern a minimum of two times. b. Extend/Retract Cylinder Head 100 lb-ft (135 Nm) Nut 600-650 lb-ft (813-881 Nm) Valve 40-45 lb-ft (54-61 Nm) Set Screw 11 lb-ft (15 Nm)
c. Tilt Cylinder Head 200 lb-ft (271 Nm) Nut 1250-1300 lb-ft (1694-1762 Nm) Valve 40-45 lb-ft (54-61 Nm) Set Screw 11 lb-ft (15 Nm)
d. Compensation Cylinder Head Before S/N 0160008059 S/N 0160008059 & After e. Frame Level Cylinder Head Before S/N 0160000022 S/N 0160000022 & After f. Stabilizer Cylinder (if equipped) Head 100 lb-ft (165 Nm) Nut 650-700 lb-ft (881-949 Nm) N/A 100 lb-ft (165 Nm) Nut 400 lb-ft (542 Nm) 550-600 lb-ft (745-813 Nm) 200 lb-ft (271 Nm) N/A Nut 1250-1300 lb-ft (1694-1762 Nm) 1100 lb-ft (1491 Nm)
8-28
G6-42A, G9-43A, G10-43A
Hydraulic System 8.8.5 Cylinder Torque Specifications - G9-43A & G10-43A
a. Lift/Lower Cylinder Piston 460 lb-ft (623 Nm) Valve 44 lb-ft (60 Nm)
Note: The capscrews for the piston need to be torqued in sequence in an alternating pattern starting at 150 lb-ft to 300 lb-ft to the final 460 lb-ft. Check the final torque in a circular pattern a minimum of two times. b. Extend/Retract Cylinder Head 100 lb-ft (135 Nm) c. Tilt Cylinder Head Before S/N 0160007142 S/N 0160007142 & After 200 lb-ft (271 Nm) 550-600 lb-ft (745-813 Nm) Nut 1250-1300 lb-ft (1694-1762 Nm) 2025-2075 lb-ft (2745-2813 Nm) Valve 45-50 lb-ft (61-67 Nm) N/A Valve Plug N/A 10-15 lb-ft (14-20 Nm) Nut 1000 lb-ft (1355 Nm) Valve 44 lb-ft (60 Nm) Set Screw 11 lb-ft (15 Nm)
d. Compensation Cylinder Head Before S/N 0160007176 S/N 0160007176 & After e. Frame Level Cylinder Head 100 lb-ft (165 Nm) f. Stabilizer Cylinder (if equipped) Head 300-325 lb-ft (407-441 Nm) g. Outrigger Cylinder (G10-43A) Head N/A Nut 1100 lb-ft (1491 Nm) Nut 650-700 lb-ft (881-949 Nm) Nut 900 lb-ft (1220 Nm) 200 lb-ft (271 Nm) 550-600 lb-ft (745-813 Nm) Nut 1250-1300 lb-ft (1694-1762 Nm) 2025-2075 lb-ft (2745-2813 Nm)
G6-42A, G9-43A, G10-43A
8-29
Hydraulic System
8-30
G6-42A, G9-43A, G10-43A
Section 9 Electrical System
Contents
PARAGRAPH 9.1 9.2 9.3 9.4 TITLE PAGE 9-3 9-3 9-5 9-5 9-5 9-5 9-5 9-10 9-38 9-38 9-40 9-43 9-45 9-45 9-46 9-46 9-47 9-48 9-48 9-48 9-49 9-49 9-50 9-52 9-52 9-53 9-54 9-54 9-55 9-55 9-55 9-56 9-56 9-57
9.5 9.6
9.7 9.8 9.9 9.10 9.11
9.12 9.13
Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.1 Constant Power Circuit from Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.2 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.3 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.2 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.3 Transmission Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.4 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.5 Engine Coolant Temperature Sender / Switch . . . . . . . . . . . . . . . . . . . . . 9.11.6 Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.7 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.8 Front and Rear Axle Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G6-42A, G9-43A, G10-43A
9-1
Electrical System
9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58 9.14.1 Pump Displacement Analyzer Software Version A . . . . . . . . . . . . . . . . . . 9-58 9.14.2 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59 Hand Held Analyzer (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60 9.15.1 Analyzer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60 9.15.2 Analyzer Software - Version A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61 Joystick Fault Codes (G9-43A/G10-43A S/N 0160040675 and After including 0160040468 & 016040672). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62 Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67 SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . 9-68
9.15
9.16 9.17 9.18
9-2
G6-42A, G9-43A, G10-43A
Electrical System
9.1
ELECTRICAL COMPONENT TERMINOLOGY
To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
9.1.1
General Overview

IGNITION & DASH SWITCHES
POWER CONTROL BOARD (UNDER DASH PANEL)
TILT SPEED CONTROL
HEATER CONTROLS (IF EQUIPPED)
MY0410
COOLANT TEMPERATURE SENDER
JOHN DEERE
ALTERNATOR COOLANT TEMPERATURE SENDER
PERKINS
ALTERNATOR STARTER (NOT SHOWN)
FUEL SHUT-OFF SOLENOID

MY0450
STARTER OIL PRESSURE SENDER

MY1600
OIL PRESSURE SENDER
G6-42A, G9-43A, G10-43A
9-3
Electrical System
3 IN 1 GAUGE
DASH SWITCHES
OPTIONAL POWER DISTRIBUTION UNIT (behind dash panel)
OPTIONAL HEATER/AC CONTROLS

MY4350
IGNITION SWITCH
COOLANT TEMPERATURE SENDER ENGINE CONTROL MODULE (ECM)
ALTERNATOR
STARTER
MY6160
9-4
G6-42A, G9-43A, G10-43A
Electrical System
9.2
SPECIFICATIONS
9.4.2
Cab
Electrical system specifications are listed in Section 2, General Information and Specifications.
9.3
SAFETY INFORMATION
WARNING
TILT SPEED CONTROL
9.4
9.4.1
FUSES AND RELAYS

Engine Compartment

JOHN DEERE PERKINS
MY0410
For access to the fuse and relay panel, remove the screws securing the load chart panel (3) to the dash. The fuses and sealed 12-volt relays are mounted under the panel. b. S/N 0160040675 & After including 0160040468 & 0160040672
MY1510

CUMMINS
MY6500
MY4550
The starter relay (1) is located on the engine (John Deere), on the frame directly above the engine (Perkins) and beside the air cleaner assembly (Cummins). The power distribution unit (2) is mounted beside the air cleaner assembly.
G6-42A, G9-43A, G10-43A
9-5
Electrical System
9.4.3
Power Control Board
X1 F1 F2 F3
X2
X3 F8 F9
X4 F10
F4 F5 F6 F7
X5 X8
X6 X9
X7 X10 R1 R2 R3 R4 X11 X12 X13
F11 F12 F13 R5 R6 R7 R8 R9
X14 X15
X16
X17 X18 X19 X20 X21

MY0392
Connector Legend No. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 R1 R2 R3 R4 R5 R6 9-6 Function Optional Power Horn Key Spare Battery Steer Gauges Relays Lights W/W Fan/Heater Option3 Option2 Option1 ACC Lights W/W Fan/Heater Opt Aux Elec2
G6-42A, G9-43A, G10-43A
Amp Rating 30 10 15 25 10 10 10 25 25 25 15 15 10
Electrical System
Connector Legend R7 R8 R9 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X20 X21 Aux Elec1 Warn Lt Ck Rev Alarm Spare Bat SL SWA WL SWA W/W SW Gnd 3 Gnd 2 Gnd 1 Opt 3 Opt 2 Opt 1 Fan SW Heater SW WL 2 SL SWB WL SWB Spare Coil Gnd 85 SW1-87A SW2-86 SW2-87A Sw1-86
G6-42A, G9-43A, G10-43A
9-7
Electrical System 9.4.4 VEC Module - S/N 0160040675 & After including 0160040468 & 0160040672
F8 F15 F16 F9 F10 F11 F12 F14 F7
F3 F4 F13
IGN1 F1 IGN3 F2 ACCY2
ACCY1 F5 F6
MY4610
Connector Legend No. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 IGN1 IGN 2 ACCY1 ACCY2 Function Trans/Park Brake Power Alternator Excite Engine ECU Ignition Power Gauge Power Spare Accessory Power Auxiliary Electric Power Horn Power Spare Battery Power Engine ECU Battery Power Steer/Sway Power Rear Axle Stabilizer/Tilt Power Key Battery Power Options Power 3 Options Power 4 Options Power 1 Options Power 2 Ignition 1 Ignition 2 Accessory 1 Accessory 2 Amp Rating 15 5 10 10 15 10 15 25 25 10 10 15 20 20 20 20
9-8
G6-42A, G9-43A, G10-43A
Electrical System 9.4.5 VEC Module - Options S/N 0160040675 & After including 0160040468 & 0160040672
F1 R1 F2 F3 R2 F4 R6 R5
R3
F5 F6
R7
R4
F7 F8
R8
MY6240
Connector Legend No. F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 R5 R6 R7 R8 Function Wiper Option (Roof Wiper) Option Option Heater Lights Beacon Dash Fan Wiper Heater Blower Aux Elec 1 Aux Elec 2 Option Option Lights Beacon/Fan 15 25 Amp Rating 20 5 15 25 20 30 10 10
G6-42A, G9-43A, G10-43A
9-9
9.5
PB LT GND HOUR METER DATCON P/N 56458-10 DIODE
DEUTSCH P/N HD-36-24-18-PN
DEUTSCH P/N HD-34-24-18-SN
CLT TMP
TEMP
DIODE
ST RLY
SHFT PWR 1
SP-3 SP-2 SP-1
ST RLY PWR
STEER LIGHT
BRK SW
HORN LIGHT
SEALED ENDS
STRT
PS IGN
KEY PWR KEY STRT
HORN HRN PWR
KEY ACC
STR CRB STR PWR STR AW
TR LT
TRANSMISSION
GND-E GND-D GND-C GND-A GND-B GND-1
GND-2
GND-7 GND-8 GND-6
OPT-1
OPT-2
F WARN LT CK AUX ELEC1 G
85 30 REV
ALARM
AUX ELEC2 OPT
OPT-3
BACK LT
STOP LT
WORK LT
SEALED ENDS
1 2 3 4 5 6 7 8
SHFT PWR 1 SHIFT-A SHIFT-B SHIFT STRT SHIFT-C TRANS-E TRANS-D SHFT PWR 2
M (25A) FAN/HTR (25A) LIGHTS (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (10A) RELAYS (30A) OPT_PWR (25A) W/W
2-FRONT
N D10 MOTOROLA MR 752 OR EQUIV (25A) SPARE BAT
GND AA BATT WL_SWA SL_SWA SPARE_BAT W/W_SW
OIL GAG
CLT TMP
9-10
9.5.1
Electrical System
Before S/N 0160011059
ELECTRICAL SYSTEM SCHEMATICS
DEUTSCH P/N DT06-8S LOCKING WEDGE W8S

H I J K L Y W X
DEUTSCH P/N DT04-8P LOCKING WEDGE W8P
MY0670
DASH PANEL
C
GAG PWR
PARK BRAKE LIGHT
OIL GAG
OIL
FUEL
12 UDC
STR CRB
FUL GAG HMTR GND HR MTR

GND 12V
B+
PARK BRAKE CARLING SWITCH P/N VDD1B6ABARC00-000
GND-7
A B
STR CRB GND-7
2W
STEER SELECT VALVE

4W
INST GND
GND
BR SW PWR 2
STR AW
STR AW GND-8
B
REV AL TRANS-E TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 REV AL TRANS-E TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1
GND-8
4 IN 1 GAGE BEEDE
CAB FIREWALL
30
86
ST RLY
GND-6 87 85
STARTER RELAY
IGNITION SWITCH POLLACK P/N 31-610
STEER SELECT CARLING SWITCH P/N VJD1S00BAZC00-000
HORN CARLING SWITCH P/N V2D1S00BAZC00-000
BAT
STRT SOL
ACC
TR LT SW BRK SOL CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT
STARTER MOTOR
BAT-2 BAT-1 SNSR ALT BAT
BACK LT GND-1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BACK LT GND-1
IGN
HORN
GROUND BATTERY 12VDC GROUND (AT ENGINE POD)
HORN
TRANS TEMP WARN LIGHT
TRANSMISSION TEMPERATURE SWITCH

TR LT SW
250F (RISING)
DIODE
A B
TRANS-B GND-B
SNSR ALT EXC
SNSR ALT EXC

#1
SNSR
DIODE
BATT
#2
ALTERNATOR
ALT EXC
TRANS-A ALT BAT
B
A B
NOT USED
GND-A
A
DIODE
C D
A B
TRANS-C GND-C
DIODE
TRANS-D
B
GND-D
DIODE
DIODE
A B
TRANS-E GND-E
PARK BRAKE SOLENOID

B A
GND-3 BRK SOL
GND-3
SWI-86 SW2-87a SW1-87a O P Q R S T 10 OHM 30W D1 D2 D4 D5 D3 R1

87 86 85 30 85 30 85 30 87a 86 86 86 85 30 86 87a 87a 87a 87a 87 87 87 87
SW2-86 GND 85 SPARE_COIL
GROUND (AT STARTER MOTOR)
A B C D E
FUL GAG
(10A) OPT-1 (15A) OPT-3
(15A) OPT-2
A B
FUL GAG GND-4
REV AL GND-5
BACK-UP ALARM FUEL LEVEL SENDER

A B C
GND1 GND2 GND3

SL SWB
WORK LIGHT OPTION
WL2 D6 D7 D8 D9
F-N-R AND GEAR SELECTOR

WL SWB HTR SW FAN SW
87 86 85 30 85 30 85 30 85 30 87a 86 86 86 87a 87a 87a 87 87 87
U V
SP-1 SP-2 SP-3
FAN/HTR W/W
LIGHTS ACC
HR MTR PS IGN FUL SOL 2 AMPS
FUEL SOLENOID OIL PRESSURE SWITCH (ON ENGINE)
G6-42A, G9-43A, G10-43A
OIL PRESSURE SENDER
WATER TEMP. SENDER
MY0680
DASH PANEL
HOUR METER DATCON P/N 56458-10
PARK BRAKE LIGHT
SW2-86
OIL PRESSURE SWITCH (ON ENGINE) ORANGE
GND-7
BLUE
WHITE
RED
GND 85 GND 85 EXTRA EXTRA EXTRA SWING SIDESHIFT MAST SWING SWING
5 4 3 2 1
N.C.
+ N.O.
BLACK
OPT-1
F
MAST EXTRA SWING SIDESHIFT
REV ALARM
86 86 85 30 85 30
85 30
WARN LT CK AUX ELEC2 OPT GND1 GND2 GND3

GND 85
AUX ELEC1
SL SWB D9 U V
WL2
WL SWB
87 86 87a 85 30
D6
D7
D8
87
87
87
OPT-3
85 30
OPT-2
G6-42A, G9-43A, G10-43A

GND 12V
8 7 4 5 6 1 2 3 6 5 4 8 7 1 2 3
OIL
FUEL
12 UDC
B+
GND
TEMP
4 IN 1 GAGE BEEDE
HORN LIGHT
STEER LIGHT
BAT
ACC
STRT
MAST SW1-87a SIDESHIFT SWING SW2-87a EXTRA

SWING
GND 85 SW1-86 SW1-87a SW1-86 GND 85 SW2-86 SW2-87a SW2-86
IGN
MAST
STAB-SW1 STAB-PWR
STAB-SW2
GND-8
SW1-86
SW1-87a
SW2-87a
DIODE
SIDESHIFT SIDESHIFT MAST MAST
STABILIZER PROXIMITY SENSOR

SW2-86 O P Q R
GND 85 SIDESHIFT EXTRA MAST SWING
STABILIZER VALVE
SWI-86
SW2-87a
SW1-87a GND 85
SPARE_COIL
A B C D E S T D4 D5 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
TO COMMON GROUND ON ENGINE BELL HOUSIING
D1
10 OHM 30W R1
D2
D3
87 87a 87a
87
87
87 87
86
87a
85 30
86
87a
86
87a
STABILIZER OPTION
HTR FAN SW SW ACC GROUND (YELLOW)
86
87a
85 30
86
87a
85 30
86
87a
"TM" EXTRA (ORANGE) "A" OPEN
85 30
FAN/HTR
W/W
LIGHTS
H "S" MAST (BLACK) "LT" SIDESHIFT (RED) "RT" SWING (BLUE) W X
J K L Y (10A) GAGES (10A) STEER (30A) OPT_PWR (25A) SPARE BAT (15A) KEY (10A) HORN
N SL_SWA SPARE_BAT
D10
MOTOROLA MR 752 OR EQUIV
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
(10A) RELAYS
GND AA BAT
WL_SWA
Electrical System
W/W_SW
AUX ELECTRIC OPTION
9-11
LIGHT SW
WORK LT
GND L
LIGHT-1

8 1 4 7
BAT
ACC
LIGHT-2
GND L
REV AL TRANS-E TRANS-E TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1 TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR 2 BAT-1 1 3 4 5 6 7 8 10 9 11 12 13 14 15 16 17
18 REV AL
1 2 5 6 3
STRT
IGN
MIRROR-LT
CAB FIREWALL
GND L
GND L
LIGHT SW
LIGHT-2
18 17 16 15 14 TR LT SW BRK SOL CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT 5 4 3 BACK LT GND-1 1 GND-1 2 BACK LT 6 WORK LT 7 GND-2 8 STOP LT 9 PS IGN 10 OIL GAG 12 BRK SOL CLT TMP 11 13 TR LT SW
GND L1 IND LT
MIRROR-LT
GND
GND
LIGHT SW
WORK LT
OPT-1
OPT-3
BACK LT
STOP LT
G GND1 GND2 GND3
STOP LT
SL SWB
GND L
D7 D8 D9 U V
AUX ELEC1 OPT
AUX ELEC2
GND L
GND L
WARN LT CK
LIGHT-1
WL2
WL SWB
D6
HTR SW
86 85 30 87a 85 30 86 85 30 86 87a 87a
FAN SW W/W LIGHTS ACC
86
87a
85 30
FAN/HTR
H W X
GND DL
87
87
87
87
BACK-UP LIGHT (GREEN)
STOP LIGHT (RED) REAR TAIL LIGHT ASSEMBLY
TAIL LT
REV ALARM
86 86 85 30 86 85 30 85 30 86 85 30
OPT-2
GND L1
MOTOROLA MR 752 OR EQUIV BAT WL_SWA SPARE_BAT SL_SWA
IND LT
STOP LT
STOP SW
9-12
DASH PANEL
PARK BRAKE LIGHT
WORK LIGHT INDICATOR
Electrical System
MY0690
GND L1 IND LT
FRONT WORK LIGHT (ON CAB)
OIL
FUEL
12 UDC
8 7 4 5 6 1
WORK LIGHT CARLING SWITCH P/N V1D1S00BAZC00-000
B+

GND 12V
8 1 4 5 6
3 2
GND
2 3
TEMP
4 IN 1 GAGE BEEDE
A
STEER LIGHT
HORN LIGHT
FRONT WORK LIGHT
REV AL
SWI-86
SW2-87a SW2-86
SW1-87a
GND 85
SPARE_COIL
GND 1
BACK-UP ALARM
GND 2 GND-5
A B C D E
WORK LT C B A STOP LT BACK LT
O P Q R S T D2 D3
87 87a 87a 87a 87 87
D1 D4 D5 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
10 OHM 30W R1
87 87a
87
86
87a
85 30
TAIL LIGHT (BLACK)
J K L Y (25A) W/W (10A) GAGES AA (10A) STEER (15A) KEY (10A) HORN (25A) LIGHTS (10A) RELAYS (25A) SPARE BAT (30A) OPT_PWR GND
D10
(25A) FAN/HTR
3-FRONT
DOME LT
GND DL
W/W_SW
DOME LT WORK LT STOP SW
DOME LIGHT SWITCH
DOME LIGHT
WORK LIGHT OPTION
G6-42A, G9-43A, G10-43A
STOPLT SW
BLACK
TEMP
5 6
BEACON SW
A
STEER LIGHT
BEACON-1
4 IN 1 GAGE BEEDE
A
SWI-86 SW2-87a SW2-86 O P Q R D1 D2 D3
87 87 87 87 87
GRAY
TILT PWR1
TILT PWR2
GND L
BEACON SW

7 4 5 6
BAT
ACC
S T (15A) OPT-3
STRT
10 OHM 30W R1 D4 D5 (10A) OPT-1 (15A) OPT-2

87a 85 30 87a 85 30 86 85 30 86 86 85 30 85 30 87a 87a 87a
IGN
OPT-1
OPT-2
F
REV ALARM
86
WARN LT CK AUX ELEC1 OPT
AUX ELEC2
G SL SWB WL2 D6
87 87 85 30 86 85 30 87a 87 85 30 86 87a 85 30 86 87a 87
GND1 GND2 GND3
WL SWB D7
D8 D9
OPT-3
86
U V
HTR FAN SW SW
86 87a
GND-15
H W X
I SW1-87a O P Q R M D10 N (25A) FAN/HTR (25A) W/W (25A) LIGHTS (10A) RELAYS J K L (10A) STEER (10A) GAGES MOTOROLA MR 752 OR EQUIV (15A) KEY (10A) HORN (30A) OPT_PWR (25A) SPARE BAT SL_SWA SPARE_BAT GND 85 SPARE_COIL
SWI-86
SW2-87a
SW2-86
Y GND AA
A B C D E D4
87 87
OPT-1
G GND1 GND2 GND3
SL SWB
GND L
D9 U V
WL2
WL SWB
87 86 85 30 87a
D6
D7
D8
TILT DWN GND-15
TILT UP GND-16
87
87
87
HTR FAN SW SW ACC
86
87a
85 30
86
87a
85 30
86
87a
85 30
FAN/HTR
W/W
LIGHTS
3-FRONT
H W X DIODE
DIODE
J K L Y (10A) STEER AA BAT SPARE_BAT (25A) SPARE BAT (15A) KEY (10A) HORN GND (30A) OPT_PWR
D10
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
(10A) RELAYS
(10A) GAGES
IND LT
WL_SWA
SL_SWA
Electrical System
MY0700
W/W_SW
MAIN CONTROL VALVE
MAIN CONTROL VALVE
BEACON LIGHT OPTION
TILT ON JOYSTICK OPTION
TILT UP
F OPT
REV ALARM
86 85 30
WARN LT CK AUX ELEC2
AUX ELEC1
OPT-3
85 30 86 85 30
85 30
OPT-2
86
87a 87a
86
87a
85 30
86
87a
87a
TILT DOWN
87
87
87
W/W_SW
WL_SWA
IND LT
10 OHM 30W R1 D5 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
BEACON-1
D1
S T
D2
D3
BAT
GND-16
FAN/HTR W/W LIGHTS ACC
TILT DOWN
A B C D E
TILT UP
G6-42A, G9-43A, G10-43A

DASH PANEL
JOYSTICK
RED
BEACON LIGHT (ON CAB)

BEACON LIGHT INDICATOR
PARK BRAKE LIGHT
GND L1 IND LT
BLUE
OIL
FUEL
12 UDC
8 7 4 5 6 1
BEACON LIGHT CARLING SWITCH P/N V1D1S00BAZC00-000
B+

GND 12V
7
2
GND
4
3
DEUTSCH 6-PIN DT 06-65
SW1-87a GND 85
SPARE_COIL
HORN LIGHT
9-13
WAS WSW
PAR WSW
LOW WSW HIG WSW
BAT HSW
A B C D E S T (15A) OPT-3 D3
87 87 87
O P Q R
D1 D4 D5 (10A) OPT-1 (15A) OPT-2
10 OHM 30W R1
D2
GND HSW
OPT-1
BAT HSW
GND HSW
PAR WSW
WAS WSW
LOW WSW
G GND1 GND2 GND3
HIG WSW
REV ALARM
86 86 85 30 85 30 86 85 30
WARN LT CK AUX ELEC1 OPT
AUX ELEC2
OPT-3
85 30
OPT-2
D10 AA BAT WL_SWA SPARE_BAT SL_SWA
MOTOROLA MR 752 OR EQUIV (10A) RELAYS (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (25A) SPARE BAT (30A) OPT_PWR GND
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
BAT HSW
HIG HSW
MED HSW
LOW HSW
A/C AND HEATER MOTOR
AIR CONDITIONING OPTION
GND HSW
9-14
BAT HSW GND HSW
Electrical System
SWI-86 SW2-87a SW2-86 SW1-87a GND 85
SPARE_COIL
THERMOSTATIC SWITCH A/C PRESSURE SWITCH (IN CAB)
CLUTCH ON COMPRESSOR 4A
87 87a 87a 87a
87
86
87a
86
87a
85 30
SL SWB
ON ENGINE
GND HSW
U V
WL2
WL SWB
87 87 85 30 86 85 30 87a 86 87a
D6
D7
D8 D9
BAT HSW
LIGHTS ACC
HTR SW
87
87
FAN SW
86
87a
85 30
86
87a
85 30
FAN/HTR
W/W
CONDENSER FANS (ON ROOF) A/C SWITCH IN RH CONSOLE

W X
M
17A
J K L Y
W/W_SW
HEATER SWITCH
"C"
86 87a 87
RELAY
85 30
MY0710
G6-42A, G9-43A, G10-43A
MY0720
DASH PANEL
PARK BRAKE LIGHT HOUR METER DATCON P/N 56458-10
OIL 12 UDC
1 B+ 2
BAT HSW
WAS WSW
BAT HSW
GND HSW
PAR WSW
LOW WSW GND HSW PAR WSW WAS WSW LOW WSW
BAT HSW
HIG WSW
HIG WSW
GND HSW
10 OHM 30W R1 D2 D3
87 87 87 87 87
D4 D5
(10A) OPT-1 (15A) OPT-3
(15A) OPT-2
OPT-1
F GND1 GND2 GND3
REV ALARM
86 85 30
WARN LT CK AUX ELEC1 OPT AUX ELEC2
SL SWB D7 D8 D9 U V
GND HSW
WL2 D6
87 86 87a 85 30 86 87a 85 30 86 85 30 86 85 30 87a 87a 87 87 87
WL SWB
BAT HSW
FAN/HTR W/W LIGHTS ACC
HTR SW
FAN SW
FAN MOTOR
HEATER SWITCH
HIG HSW
MED HSW
BAT HSW
OPT-3
85 30 86 85 30 86 85 30
OPT-2
86
87a 87a 86 85 30 87a 87a
87a
GND FAN
BAT FAN
LOW HSW
H W X
J K L (30A) OPT_PWR (10A) HORN
Y (25A) FAN/HTR (25A) W/W (10A) GAGES (10A) STEER (10A) RELAYS (25A) LIGHTS (15A) KEY GND AA BAT WL_SWA W/W_SW SL_SWA SPARE_BAT (25A) SPARE BAT
D10
HEATER MOTOR
BAT WSW
WASHER BOTTLE
Electrical System
ENCLOSED CAB OPTION
WAS WSW
GND HSW
G6-42A, G9-43A, G10-43A

FUEL

GND 12V
8 7 4 5 6
GND
1
TEMP
2 3
4 IN 1 GAGE BEEDE
STEER LIGHT
WIPER SWITCH HIG WSW LOW WSW
HORN LIGHT
IGNITION SWITCH POLLACK P/N 31-610 STEER SELECT CARLING SWITCH P/N VJD1S00BAZC00-000
BAT WSW WAS WSW PAR WSW

BAT ACC
8 1 4 5 6
8
STRT
7 2 3
IGN
HIG WSW LOW WSW PAR WSW

SWI-86 O P Q R D1 S T SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL
A B C D E
WIPER MOTOR
9-15
PB LT GND HOUR METER DATCON P/N 56458-10 DIODE
CLT TMP
TEMP
DIODE
ST RLY
SHFT PWR 1
BRK SW
ST RLY PWR
HORN LIGHT
SEALED ENDS
PS IGN
KEY PWR KEY STRT
HORN HRN PWR
KEY ACC
TR LT
TRANSMISSION
A B
TRANS-E GND-E
GND-D GND-C
GND-A GND-B GND-1
ZENER DIODE
-E D N G
GND-2
SWI-86 SW2-87a SW1-87a O P Q R S T D2 D4 D5 D3 GND 85
SW2-86 SPARE_COIL
GND-3
A B C D E D1
FUL GAG FUL GAG

A B
GND-7 GND-8 GND-6
OPT-1
OPT-3
F OPT G
REV ALARM WARN LT CK AUX ELEC1 AUX ELEC2
85 30
85 30
OPT-2
BACK LT
STOP LT
WORK LT
SEALED ENDS
1 2 3 4 5 6 7 8
SHFT PWR 1 SHIFT-A SHIFT-B SHIFT STRT SHIFT-C TRANS-E TRANS-D SHFT PWR 2
Y GND D10 MOTOROLA MR 752 OR EQUIV (25A) LIGHTS (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (25A) FAN/HTR (25A) W/W (10A) RELAYS (30A) OPT_PWR (25A) SPARE BAT AA BATT
OIL GAG

I J K L
CLT TMP
9-16
DASH PANEL
C
9.5.2
Electrical System
G6-42A - S/N 0160011059 Thru 0160021194 G9-43A - S/N 0160011059 Thru 0160020822
MY0730
STR CRB
A
GAG PWR
PARK BRAKE LIGHT
OIL GAG
OIL
FUEL
12 UDC
STR CRB GND-7

B
FUL GAG HMTR GND

GND 12V
B+
PARK BRAKE CARLING SWITCH P/N VDD1B6ABARC00-000 HR MTR
GND-7
2W
STEER SELECT VALVE

4W
INST GND
GND
BR SW PWR 2
STR AW
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 REV AL TRANS-E TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1
GND-8
A B
STR AW GND-8
4 IN 1 GAGE BEEDE
CAB FIREWALL
SP-3 SP-2 SP-1
30
86
ST RLY
STEER LIGHT
GND-6 87 85
STARTER RELAY
BAT
ACC
STRT SOL
STARTER MOTOR
STRT
BACK LT GND-1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BACK LT GND-1
IGN
HORN
GROUND BATTERY 12VDC GROUND (AT ENGINE POD)
HORN

TR LT SW
250F (RISING)
A B
TRANS-B GND-B
SNSR ALT EXC
SNSR ALT EXC

#1
ZENER DIODE
SNSR ALT EXC

A B
BATT
#2
ALTERNATOR
TRANS-A GND-A
NOT USED
ALT BAT
A C D E
ZENER DIODE
A B
TRANS-C GND-C
PARK BRAKE SOLENOID ZENER DIODE
A B
TRANS-D GND-D
ZENER DIODE
DIODE
GND-3 BRK SOL
10 OHM 30W R1
87 86 85 30 85 30 87a 86 86 86 86 85 30 87a 87a 87a 87a 87 87 87 87
(10A) OPT-1 (15A) OPT-3
(15A) OPT-2
REV AL
GND-4
GND-5
BACK-UP ALARM FUEL LEVEL SENDER
GND1 GND2 GND3

SL SWB
F-N-R AND GEAR SELECTOR

WL2 WL SWB D6 D8 D9 D7
U V
WORK LIGHT OPTION
87 87 87a 85 30 86 85 30 87a
87 87a 85 30 86 85 30 86 87a
87
SP-1 SP-2 SP-3
HTR SW
86
FAN SW FAN/HTR W/W LIGHTS ACC
HR MTR PS IGN FUL SOL

H W X
DEUTSCH P/N DT06-8S LOCKING WEDGE W8S
2 AMPS
WL_SWA SL_SWA SPARE_BAT W/W_SW
OIL PRESSURE SENDER
WATER TEMP. SENDER
G6-42A, G9-43A, G10-43A
DASH PANEL
2
3 1 2 3 6 5 4 6
MAST SW1-87a SIDESHIFT

1 2 8 7 5 4
GND 85 SW1-86 SW1-87a SW1-86
IGN
MAST
SWING SW2-87a EXTRA
GND 85 SW2-86 SW2-87a SW2-86
OIL PRESSURE SWITCH (ON ENGINE)
BLUE
WHITE
RED
SW1-86 SW2-87a SW2-86
N.C.
N.O.
SW1-87a
ORANGE
BLACK
SWING
GND-7
OPT-1
OPT-2
F OPT
MAST SWING SIDESHIFT
REV ALARM
86 86

EXTRA
AUX ELEC2 GND1 GND2 GND3
GND 85
SL SWB D8 D9 U V
WL2
WL SWB
87 85 30 86 85 30 87a
D6
D7
87 87a
87
87
OPT-3
G6-42A, G9-43A, G10-43A

GND 12V
7 4 5 6
PARK BRAKE LIGHT
OIL
FUEL
12 UDC
B+
GND
TEMP
4 IN 1 GAGE BEEDE
STEER LIGHT
STAB-SW1 STAB-PWR
STAB-SW2
HORN LIGHT

8 7
GND-8
BAT
ACC
STRT
DIODE

GND 85 GND 85 EXTRA SWING SIDESHIFT MAST EXTRA EXTRA SWING SWING
STABILIZER VALVE
5 4 3 2 1
SIDESHIFT SIDESHIFT MAST MAST
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 O P Q R

EXTRA GND 85 SWING SIDESHIFT MAST
SPARE_COIL
STABILIZER OPTION
A B C D E S T (15A) OPT-3 D4 D5 (10A) OPT-1 (15A) OPT-2
D1
10 OHM 30W R1
D2
D3
87 87 85 30 85 30 87a 87a
87
87
87
86
87a
85 30
86
87a
85 30
86
87a 85 30
HTR FAN SW SW LIGHTS ACC
86
87a
85 30
86
87a
"TM" EXTRA (ORANGE) "A" OPEN GROUND (YELLOW)
85 30
86
FAN/HTR
W/W
H "S" MAST (BLACK) "LT" SIDESHIFT (RED) "RT" SWING (BLUE) W X
J K L (30A) OPT_PWR
Y (10A) GAGES (10A) STEER (15A) KEY (10A) HORN GND AA BAT SL_SWA SPARE_BAT (25A) SPARE BAT
D10
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
(10A) RELAYS
WL_SWA
Electrical System
MY0740
W/W_SW
AUX ELECTRIC OPTION
9-17
LIGHT SW
A A
STEER LIGHT
Electrical System
B B
HORN LIGHT
GND L
LIGHT-1
LIGHT-2
8 1 4
GND L

8 7
BAT
ACC
REV AL TRANS-E TRANS-E TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1 TRANS-D TRANS-C TRANS-A TRANS-B STR CRB STR AW SP-3 ALT EXC SP-2 SP-1 BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1 1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 16 17
18 REV AL
1 2 5 6 3
STRT
IGN
IGNITION SWITCH POLLACK P/N 31-610 STEER SELECT CARLING SWITCH P/N VJD1S00BAZC00-000
WORK LT
CAB FIREWALL
GND L
GND L
LIGHT SW
18 17 16 15 14 TR LT SW BRK SOL 12 BRK SOL CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT 11 10 9 8 7 6 5 4 3 BACK LT GND-1 1 GND-1 2 BACK LT CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT 13 TR LT SW
MIRROR-LT
LIGHT-2
GND L1 IND LT
GND
MIRROR-LT
GND
LIGHT SW
WORK LT
OPT-1
OPT-3
GND L1
BACK LT
STOP LT
WARN LT CK AUX ELEC1 OPT GND1 GND2 GND3 AUX ELEC2
SL SWB
GND L
D7 D8 D9 U V
GND L
GND L
REV ALARM
85 30 86 85 30 86 85 30
OPT-2
STOP LT
LIGHT-1
WL2
WL SWB
D6
HTR SW
86 85 30 87a 85 30 86 85 30 86 87a 87a
FAN SW W/W ACC LIGHTS
86
87a
85 30
FAN/HTR
H W X
GND DL
87
87
87
87
TAIL LT
WL_SWA SL_SWA SPARE_BAT
IND LT
STOP LT
STOP SW
9-18
DASH PANEL
MY0750
GND L1 IND LT
8 7 4 5 6 1
OIL
FUEL
12 UDC
B+

GND 12V
8
2
7 4
3
GND
1 2 5 6 3
TEMP
4 IN 1 GAGE BEEDE
FRONT WORK LIGHT
REV AL
SWI-86
SW2-87a SW2-86
SW1-87a
GND 85
SPARE_COIL
GND 1 GND 2
BACK-UP ALARM
WORK LT STOP LT BACK LT
C B A
A B C D E D3 D5
87 87a 87 87a 86 85 30 87 87
10 OHM 30W R1 D4 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2

87a
D1
O P Q R S T
GND-5
D2
87
87
86
87a
85 30
86
TAIL LIGHT (BLACK)
J K L Y (25A) LIGHTS (10A) GAGES AA BAT (10A) STEER (15A) KEY (10A) HORN (10A) RELAYS (25A) SPARE BAT (30A) OPT_PWR GND
D10
(25A) FAN/HTR
(25A) W/W
GND DL
W/W_SW
DOME LT DOME LIGHT DOME LIGHT SWITCH
WORK LIGHT OPTION
G6-42A, G9-43A, G10-43A
STOPLT SW
BLACK
A
SWI-86 O P Q R D1 D2 D3
87 87
TEMP
6
2 5
BEACON SW
A
STEER LIGHT
BEACON-1
4 IN 1 GAGE BEEDE
GRAY
D
TILT UP
TILT PWR1
GND L

7
A B C D E D4 D5
BEACON SW

4 5 6
BAT
ACC
S T (10A) (15A) (15A) OPT-1 OPT-2 OPT-3
STRT
10 OHM 30W R1
87 87 87 87a 85 30 86 86 85 30 85 30 86 85 30 87a 86 85 30 87a 87a 87a
IGN
OPT-1
OPT-2
F
REV ALARM WARN LT CK AUX ELEC1 OPT AUX ELEC2
G SL SWB WL2 WL SWB D6 D7 D8

87 87 85 30 86 87a 85 30 86 85 30 86 85 30 87a 87a 87 87
GND1 GND2 GND3
D9
OPT-3
86
U V
GND-15
HTR FAN SW SW
86 87a
GND-16
TILT UP
FAN/HTR
W/W LIGHTS
ACC
H W X
I SW2-86 O P Q R M D10 (25A) FAN/HTR (25A) W/W (25A) LIGHTS (10A) RELAYS N S T (15A) OPT-3 W/W_SW MOTOROLA MR 752 OR EQUIV J K L (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (30A) OPT_PWR (25A) SPARE BAT WL_SWA SL_SWA SW1-87a GND 85 SPARE_COIL
SWI-86
SW2-87a
Y GND AA
A B C D E
D1 D4 D5 (10A) OPT-1 (15A) OPT-2
BEACON-1
87 87
87
87
87
SPARE_BAT
OPT-1
OPT-2
F OPT GND1 GND2 GND3
REV ALARM
86 86 85 30
AUX ELEC1
OPT-3
86 85 30
87a 87a
85 30
86
87a
85 30
86
87a
85 30
87a
SL SWB
GND L
D9 U V
WL2
WL SWB
87 86 85 30 87a
D6
D7
D8
TILT DWN GND-15
TILT UP GND-16
87
87
87
HTR FAN SW SW ACC
86
87a
85 30
86
87a
85 30
86
87a
85 30
FAN/HTR
W/W
LIGHTS
H W X DIODE DIODE
J K L Y (10A) STEER AA (25A) SPARE BAT (15A) KEY (10A) HORN (30A) OPT_PWR GND
D10
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
(10A) RELAYS
(10A) GAGES
WL_SWA SPARE_BAT
SL_SWA
IND LT
BAT
W/W_SW
MAIN CONTROL VALVE
MAIN CONTROL VALVE
Electrical System
BEACON LIGHT OPTION
IND LT
10 OHM 30W R1
D2
D3
BAT
TILT DOWN
TILT DOWN
TILT PWR2
G6-42A, G9-43A, G10-43A

DASH PANEL
JOYSTICK
PARK BRAKE LIGHT
MY0760
GND L1 IND LT
RED
BLUE
OIL
FUEL
12 UDC
8 7 4 5 6 1
B+

GND 12V
7
2
8 4
3
GND
SW2-87a
SW2-86
SW1-87a
GND 85
SPARE_COIL
HORN LIGHT
9-19
WAS WSW
BAT HSW
Electrical System
A B C D E S T D4 D5 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
O P Q R
D1
10 OHM 30W R1
D2
D3
GND HSW
PAR WSW
LOW WSW E HIG WSW F
OPT-1
OPT-2
OPT-3
BAT HSW
GND HSW
PAR WSW
WAS WSW
LOW WSW
GND1 GND2 GND3
HIG WSW
D10 AA BAT SL_SWA SPARE_BAT
MOTOROLA MR 752 OR EQUIV (10A) GAGES (10A) STEER (25A) SPARE BAT (15A) KEY (10A) HORN (30A) OPT_PWR GND
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
(10A) RELAYS
BAT HSW
HIG HSW
MED HSW
LOW HSW
AIR CONDITIONING OPTION
GND HSW
9-20
BAT HSW GND HSW
SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL
SWI-86
THERMOSTATIC SWITCH A/C
PRESSURE SWITCH (IN CAB)
CLUTCH ON COMPRESSOR 4A ON ENGINE
87 87 86 87a 85 30 87a 86 85 30
87
87
87
86
87a
85 30
REV ALARM AUX ELEC2 OPT
86
87a
85 30
WARN LT CK
86
87a
85 30
AUX ELEC1
SL SWB
GND HSW
D9 U V
WL2 WL SWB
87 86 87a 85 30
D6
D7
D8
87
87
87
BAT HSW
ACC
FAN SW
86
87a
85 30
86
87a 85 30
86
87a
85 30
HTR SW
FAN/HTR
W/W
LIGHTS
CONDENSER FANS (ON ROOF)
M
W X
17A
J K L Y
WL_SWA
W/W_SW
HEATER SWITCH
"C"
86
87a 87
RELAY
85 30
MY0770
G6-42A, G9-43A, G10-43A
DASH PANEL
MY0780
FUEL
2
OIL
12 UDC
B+

GND 12V
8 1 4 5 6 2 3 7
GND
WAS WSW
BAT HSW
BAT HSW
GND HSW
GND HSW
PAR WSW
LOW WSW E BAT HSW GND HSW PAR WSW WAS WSW LOW WSW
HIG WSW
HIG WSW F
10 OHM 30W R1 D2 D3
87 87 87 87
D4 D5
(10A) OPT-1 (15A) OPT-3
(15A) OPT-2
87
OPT-1
F GND1 GND2 GND3
REV ALARM
86 85 30
WARN LT CK AUX ELEC1 OPT AUX ELEC2
OPT-3
85 30 86 86 85 30 85 30
OPT-2
86
87a 87a 86 85 30 87a 87a
87a
A GND HSW
GND FAN
WL2
WL SWB D9
87 86 87a 85 30 86 85 30 86 85 30 87a 87a 87 87
D6
D7 D8
U V
87
BAT HSW
SL SWB
BAT FAN
HIG HSW
MED HSW
LOW HSW
W X
J K L (25A) W/W (10A) GAGES (10A) STEER (25A) LIGHTS (10A) RELAYS (15A) KEY (10A) HORN (30A) OPT_PWR
Y GND AA BAT WL_SWA W/W_SW SL_SWA SPARE_BAT (25A) SPARE BAT
D10
(25A) FAN/HTR
Electrical System
BAT WSW
HEATER MOTOR
WASHER BOTTLE
ENCLOSED CAB OPTION
WAS WSW
GND HSW
G6-42A, G9-43A, G10-43A

STEER LIGHT
TEMP
4 IN 1 GAGE BEEDE
WIPER SWITCH HIG WSW LOW WSW
HORN LIGHT
BAT WSW PAR WSW
WAS WSW

8 1 4 5 6 2 3 7
BAT
ACC
STRT
IGN
HIG WSW LOW WSW PAR WSW

SWI-86 O P Q R S T SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL
A B C D E
D1
WIPER MOTOR
BAT HSW
W/W LIGHTS ACC
HTR SW
FAN SW
86
87a
HEATER SWITCH
85 30
FAN MOTOR
FAN/HTR
9-21
ST RLY
SHFT PWR 1
BRK SW
GAG PWR
HORN LIGHT
INST GND
INST GND
STEER SELECT CARLING SWITCH P/N VJD1S00B-AZC00-000

8 7 8 7
PRE-HEAT CARLING SWITCH P/N V2D1B60B-AEC3V-100

INST GND
HORN CARLING SWITCH P/N V2D1S00B-AZC00-000

1 4 5 6 3 6 2 5 4 2 3 1
GP SIG
GP SW
HORN
HRN PWR
PS IGN
IGNITION SWITCH
TR LT
SEALED ENDS
BR SW PWR
PS IGN
KEY PWR KEY STRT
PS IGN
KEY ACC
SHIFT-B TR LT BRK SW KEY STRT SHIFT STRT

D1
A B C D E
O P Q R S T
ALT EXC TRANS-B TR LT SW BRK SOL REV AL BACK LT
10 OHM 30W R1 D2
87 86 85 30 87a 86 87a 85 30 87 87 86 87a
D3
D4
87 85 30 86 87a 85 30
D5
87 86 87a 85 30
(10A) OPT-1
(15A) OPT-2
(15A) OPT-3
OPT-1
OPT-2
KEY ACC
G SL SWB
GND1 GND2 GND3
WL2 D6 HTR SW FAN SW

86 87a 85 30 87
OPT-3
SHFT PWR 2
F
REV ALARM WARN LT CK
AUX ELEC1
AUX ELEC2
OPT
WL SWB D7
87 86 87a 85 30
U V
D8
87 86 87a 85 30
STOP LT WORK LT
D9
87 86 87a 85 30
FAN/HTR
W/W
LIGHTS
ACC
TO TRANSMISSION SHIFTER
INST GND
H
1 2 3 4 5 6 7 8
W X
SHFT PWR 1 TRANS-A SHIFT-B SHIFT STRT TRANS-C TRANS-E TRANS-D SHFT PWR 2

STR PWR GAG PWR HRN PWR KEY PWR
I J K L
Y M
D10 (NOT REQUIRED)
GND-2
GND MOTOROLA MR 752 OR EQUIV N (25A) FAN/HTR (25A) W/W (25A) LIGHTS (10A) RELAYS (10A) GAGES (10A) STEER (25A) SPARE BAT (15A) KEY (10A) HORN (30A) OPT_PWR AA BATT WL_SWA W/W_SW
GND-1 BAT-2 BAT-1
SL_SWA SPARE_BAT
9-22
DASH PANEL
GAG PWR
9.5.3
GAG PWR
PARK BRAKE LIGHT

PB LT GND

INST GND
OIL GAG
2
OIL
FUEL
12 UDC
FUL GAG
B+
PARK BRAKE CARLING SWITCH P/N VDD1B6AB-ARC00-000

GND 12V
HR MTR
7 4 5 6 8 1
HMTR GND
INST GND BR SW PWR

2 3
GND
CLT TMP
TEMP
Electrical System
4 IN 1 GAGE BEEDE
GAG PWR
STEER LIGHT
TO ENGINE HARNESS
PRE-HEAT SWITCH INSTALLED FOR CAT/PERKINS ENGINES ONLY.
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
CAB FIREWALL
SP-3 SP-2 SP-1
BAT ACC
GP SIG GP SW TR LT SW BRK SOL CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT
TO ENGINE HARNESS SHEET 2
STRT
BACK LT GND-1
IGN
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
SWI-86 SW2-87a SW1-87a
SW2-86
GND 85
SPARE_COIL
G6-42A - S/N 0160021195 Thru 0160040678 G9-43A/G10-43A - S/N 0160020823 Thru 0160040465 Excluding 0160040468 & 0160040672
MY1371
G6-42A, G9-43A, G10-43A
Electrical System
JOHN DEERE ENGINE
TO CAB INSTRUMENT PANEL HARNESS
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DIODE
STR CRB GND-7
A B
STR CRB GND-7
2W
STEER SELECT VALVE
4W
DIODE
STR AW GND-8
A B
STR AW GND-8
CAB FIREWALL
ST RLY PWR
30
86
ST RLY
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
GND-6
87
85
TR LT SW BRK SOL CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT BAT-2 BAT-1 SNSR ALT BAT
STARTER RELAY
STRT SOL
STARTER MOTOR
BACK LT GND-1
HORN
GROUND
HORN GROUND (AT ENGINE POD)
BATTERY 12VDC
TO TRANSMISSION HARNESS
GND-1
GND-2
GND-7 GND-8 GND-6
1 2 3 4 5 6 7 8 9 10 11 12
TRANS-A TRANS-B TRANS-C TRANS-D TRANS-E BRK SOL TR LT SW GND-9 GND-10 GND-11 GND-12 GND-13
SNSR ALT EXC
SNSR ALT EXC
#1
SNSR ALT EXC NOT USED
BATT
#2
ALTERNATOR
ALT BAT
BRK SOL
GND-3
FUL GAG
PARK BRAKE SOLENOID
FUL GAG GND-4
WORK LIGHT OPTION

A B C
SEALED ENDS
FUEL LEVEL SENDER
DIODE
WORK LT
BACK LT
STOP LT
SP-1 SP-2 SP-3 GND-3
BRK SOL HR MTR PS IGN FUL SOL

CLT TMP OIL GAG
REV AL GND-5
BACK-UP ALARM
MY1390
2 AMPS
OIL PRESSURE SENDER
WATER TEMP. SENDER
G6-42A, G9-43A, G10-43A
9-23
Electrical System
PERKINS ENGINE
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DIODE
STR CRB GND-7
A B
STR CRB GND-7
2W
STEER SELECT VALVE
4W
DIODE
STR AW GND-8
A B
STR AW GND-8
CAB FIREWALL
ST RLY PWR
30
86
ST RLY
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
GND-6
87
85
GND-6
GP SIG GP SW TR LT SW BRK SOL CLT TMP OIL GAG PS IGN STOP LT GND-2 WORK LT BAT-2 BAT-1 GP PWR ALT BAT 1 ALT BAT 2
STARTER RELAY
STRT SOL
STARTER MOTOR
BACK LT GND-1
HORN
GROUND
HORN GROUND (AT ENGINE POD)

1 2 3 4 5 6 7 8 9 10 11 12 TRANS-A TRANS-B TRANS-C TRANS-D TRANS-E BRK SOL TR LT SW GND-9 GND-10 GND-11 GND-12 GND-13 GND-13 GND-12 GND-11
BATTERY 12VDC
ALT EXC ALT BAT 2 ALT BAT 1
D+ BATT W
TO TRANSMISSION HARNESS
ALTERNATOR PARK BRAKE SOLENOID
GND-10 GND-9 GND-1
DIODE
GND-2
GND-7 GND-8
GND-6 GND-3 GND-5
GND-3 BRK SOL
GND-3 BRK SOL
REV AL GND-14 FUL GAG GND-15 GND-5
BACK-UP ALARM
FUL GAG GND-4
WORK LIGHT OPTION

A B C
SEALED ENDS
FUEL LEVEL SENDER
FUSE, 50 AMP SLOW BLOW

SP-1 SP-2 SP-3 GP PWR FP PWR GP SIG
86
GLOW PLUGS
GP RLY
30
WORK LT
BACK LT
STOP LT
GND-6
85
87
GLOW PLG
GLOW PLUG RELAY

GND-6
CLT TMP
MY1380
PS IGN PS IGN GND-6 PS IGN FUEL PUMP FP RLY HR MTR PS IGN GP SW FP PWR FP RLY FUEL PUMP GND-14 PS IGN GND-14
OIL GAG
A B C
A B
85 86 87 30 87A
1 2
OIL PRESSURE SENDER
WATER TEMP. SENDER
OIL PRESSURE SWITCH 5 PSI
COLD START ADVANCE SOLENOID
FUEL SOLENOID
FUSE 7.5 AMP
FUEL PUMP RELAY
FUEL PUMP
9-24
1 2
G6-42A, G9-43A, G10-43A
Electrical System

GND-13 TR LT SW
DANA TRANSMISSION
250F (RISING)
A B
TRANS-B GND-9
B
TRANSMISSION
A B
TRANS-A GND-9
DIODE
ZENER DIODE
A C
TRANS-A TRANS-B TRANS-C TRANS-D TRANS-E TR LT SW GND-9 GND-10 GND-11 GND-12 GND-13
ZENER DIODE
A B
TRANS-C GND-10
1 2 3 4 5 6 7 8 9 10 11 12
TO ENGINE HARNESS
ZENER DIODE
D
A
TRANS-D GND-11
E
ZENER DIODE
A B
TRANS-E GND-12
DANA SHIFTER
1 2 3 4 F N R 1 2 3 4 1 2 3 4
ZENER DIODE
SHFT PWR 1 TRANS-A SHIFT-B SHIFT STRT TRANS-C TRANS-E TRANS-D SHFT PWR 2 CAB INSTRUMENT PANEL HARNESS SHEET 1
1 2 3 4 5 6 7 8
MY1411
G6-42A, G9-43A, G10-43A
9-25
Electrical System
DASH PANEL

OIL 12 UDC
1 B+ 2
FUEL

8 7 4 5 6
GND
12V
GND TEMP
1 2 3
3
4 IN 1 GAGE BEEDE
STEER LIGHT HORN LIGHT

8 1 7 4 5 6

8 1 2 3 7 4 5 6
8 7 4 5 6
MAST SW1-87a SIDESHIFT
1 2 3
GND 85 SW1-86 SW1-87a SW1-86
7 4 5 6
2 3
SWING SW2-87a EXTRA
1 2 3
GND 85 SW2-86 SW2-87a SW2-86
MAST SWING
SW1-86
SW1-87a SW2-87a SW2-86
MAST SIDESHIFT GND 85 SWING EXTRA PLUG
A B C D E F
BLACK RED WHITE GREEN ORANGE PLUG
SWI-86 A B C D E 10 OHM 30W R1

87 86 87a 85 30
SW2-87a
SW2-86
SW1-87a
GND 85
SPARE_COIL O P Q R
D1 D2
87
S T D3
87 85 30 86 87a 85 30
D4
87 86 87a 85 30
D5
87
OPT-1
OPT-2
F G
WARN LT CK
AUX ELEC1
AUX ELEC2
OPT
GND1 GND2 GND3 SL SWB WL2 WL SWB D6

87
OPT-3
REV ALARM
D7
D8
D9
U V
87 85 30 86 87a 85 30
87 86 87a 85 30
87 86 87a 85 30
HTR SW
FAN SW
86
87a

"TM" EXTRA (ORANGE) "A" OPEN GROUND (YELLOW) W X "LT" SIDESHIFT (RED)
86
87a
86
87a
85 30
FAN/HTR
W/W
LIGHTS
ACC
H "S" MAST (BLACK) "RT" SWING (BLUE)
I J K L M D10 N MOTOROLA MR 752 OR EQUIV (25A) FAN/HTR (30A) OPT_PWR
Y (25A) W/W (25A) LIGHTS (10A) RELAYS (10A) GAGES (10A) STEER (25A) SPARE BAT (15A) KEY (10A) HORN GND AA BAT WL_SWA W/W_SW SL_SWA SPARE_BAT
AUX ELECTRIC OPTION
A B C D E F
(10A) OPT-1
(15A) OPT-2
(15A) OPT-3
MY1420
9-26
G6-42A, G9-43A, G10-43A
DASH PANEL
A
STEER LIGHT
LIGHT SW
WORK LT

8 1 4 7
LIGHT-1
GND L
LIGHT-2
GND L

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BAT-1 HR MTR HORN FUL GAG ST RLY BAT-2 SP-1 SP-2 ALT EXC SP-3 STR AW STR CRB TRANS-B TRANS-A TRANS-C TRANS-D TRANS-E REV AL
CAB FIREWALL
MIRROR-LT
LIGHT SW
18 17 16 15 TR LT SW BRK SOL CLT TMP 12 11 10 9 8 7 6 5 4 BACK LT GND-1 1 2 GND-1 3 BACK LT WORK LT GND-2 STOP LT PS IGN OIL GAG CLT TMP 13 BRK SOL 14 TR LT SW
GND L1 IND LT
GND L
GND L
LIGHT-2
GND
LIGHT SW
WORK LT
GND
SWI-86
PS IGN STOP LT GND-2 WORK LT
SW2-87a
SW2-86
SW1-87a
GND 85
OIL GAG
SPARE_COIL
MIRROR-LT
OPT-1
OPT-2
BACK LT
STOP LT
GND L1
G GND1 GND2 GND3 U V
STOP LT
LIGHT-1
WL2
WL SWB D7 D9 D8
D6
HTR SW
85 30 86 87a 85 30 86 85 30 86 85 30 87a 87a
FAN SW FAN/HTR LIGHTS W/W ACC
86
87a
H W X
GND DL
87
87
87
87
SL SWB
GND L
GND L
GND L
TAIL LT
AUX ELEC1 OPT
OPT-3
W/W_SW
SPARE_BAT
IND LT
STOP LT
STOP SW
G6-42A, G9-43A, G10-43A

PARK BRAKE LIGHT
GND L1 IND LT
OIL
2 B+
FUEL
12 UDC

7 4 5 6 1
GND 12V
8 7 4 5 6
3 2
GND
1 2 3
3
TEMP
4 IN 1 GAGE BEEDE
HORN LIGHT
1 3 6
2 5
FRONT WORK LIGHT
REV AL
GND 1
BACK-UP ALARM
GND 2
WORK LT C STOP LT B BACK LT A
A B C D E D2 D3 D5
87 85 30 86 85 30 87a 87 85 30 86 87a 85 30 86 87a 87 87
GND-5
D1 D4 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
O P Q R S T
10 OHM 30W R1
86 87a
87
86
87a
85 30
REV ALARM WARN LT CK AUX ELEC2
TAIL LIGHT (BLACK)
J K L Y GND AA BAT WL_SWA SL_SWA (25A) FAN/HTR (25A) W/W (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (25A) LIGHTS (10A) RELAYS (25A) SPARE BAT (30A) OPT_PWR
D10
GND DL
DOME LT DOME LIGHT DOME LIGHT SWITCH
WORK LIGHT OPTION
Electrical System
MY1440
STOPLT SW
9-27
STEER LIGHT
Electrical System
HORN LIGHT

8 1 4 5 6 2 3 7
BEACON SW
GND L
BEACON SW
BEACON-1
OIL PRESSURE SWITCH (ON ENGINE)
GND-7
BLUE
WHITE
RED
ORANGE
SWI-86 O P Q R S T
SW2-87a
SW2-86
SW1-87a
GND 85
SPARE_COIL
N.C.
N.O.
BLACK
87 86 87a 85 30 86 86 85 30 85 30 87a 87a
87
87
87 87
86
87a
85 30
OPT-1
OPT-2
AUX ELEC1 OPT GND1 GND2 GND3
OPT-3
REV ALARM AUX ELEC2
86
87a
85 30
WARN LT CK
SL SWB
GND L
D8 D9 U V
BEACON-1
9-28
DASH PANEL
PARK BRAKE LIGHT
GND L1 IND LT
OIL 12 UDC
2 B+
FUEL

7 4 5 6 1
GND 12V
8 7 4 5 6
3 2
GND
1 2 3
3
TEMP
4 IN 1 GAGE BEEDE
STAB-SW1 STAB-PWR
STAB-SW2
GND-8
DIODE
A B C D E D3 D5 D4 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
STABILIZER VALVE
D1
10 OHM 30W R1
D2
WL2
WL SWB
87 86 87a 85 30 86 85 30 87a 87
D6
D7
REAR AXLE STABILIZER OPTION
87
87
HTR SW LIGHTS ACC
FAN SW
86
87a
85 30
86
87a
85 30
FAN/HTR
W/W
H W X
J K L
Y GND AA BAT WL_SWA SPARE_BAT SL_SWA (25A) LIGHTS (10A) RELAYS (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (25A) SPARE BAT (30A) OPT_PWR
D10
(25A) FAN/HTR
(25A) W/W
MY1450
W/W_SW
G6-42A, G9-43A, G10-43A
BEACON LIGHT OPTION
Electrical System
JOYSTICK
RED BLUE
BLACK
A B
TILT SPEED CONTROL
ADJUSTABLE TILT ON JOYSTICK OPTION

O P Q R D1 D2
87 86 87a 85 30 87
GRAY
C D
RED
SW2-87a
SW2-86
SW1-87a
GND 85
SPARE_COIL
YELLOW
TILT PWR 1
S T
TILT PWR
D3
87 85 30 86 87a 85 30
D4
87 86 87a 85 30
D5
87
(10A) OPT-1
(15A) OPT-2
(15A) OPT-3
OPT-1
OPT-2
F G SL SWB WL2 WL SWB D6

87
WARN LT CK
AUX ELEC1
AUX ELEC2
OPT
OPT-3
REV ALARM
86
87a
86
87a
85 30
TILT PWR
GND1 GND2 GND3
D7
D8
D9
U V
87 85 30 86 87a 85 30
87 86 87a 85 30
87 86 85 30
86
FAN/HTR
W/W
LIGHTS
ACC
Y (25A) W/W (25A) LIGHTS (10A) RELAYS (10A) GAGES (10A) STEER (25A) SPARE BAT (15A) KEY (10A) HORN GND AA BAT WL_SWA W/W_SW SL_SWA SPARE_BAT
TILT DWN GND-15
TILT UP GND-16
GND-15
DIODE
DIODE
MAIN CONTROL VALVE
MAIN CONTROL VALVE
GND-16
TILT DWN TILT UP
W X
A B
TILT DWN TILT UP
HTR SW
FAN SW
87a
87a
TILT PWR 1
TILT PWR 2
TILT PWR 2
TILT DWN
TILT UP
MY1460
G6-42A, G9-43A, G10-43A
9-29
Electrical System
JOYSTICK
RED BLUE
BLACK A B

87 86 87a 85 30
GRAY C D
SW2-87a
SW2-86
SW1-87a
GND 85
SPARE_COIL
D1 D2
87
S T D3
87 85 30 86 87a 85 30
D4
87 86 87a 85 30
D5
87
(10A) OPT-1
(15A) OPT-2
(15A) OPT-3
OPT-1
OPT-2
F G
WARN LT CK
AUX ELEC1
AUX ELEC2
OPT
GND1 GND2 GND3 SL SWB WL2 WL SWB D6

87
OPT-3
REV ALARM
86
87a
86
87a
85 30
GND-15
87 85 30 86 87a 85 30
87 86 87a 85 30
87 86 87a 85 30
HTR SW
FAN SW
86
87a
FAN/HTR
W/W
LIGHTS
ACC
H W X
Y (25A) W/W (25A) LIGHTS (10A) RELAYS (10A) GAGES (10A) STEER (25A) SPARE BAT (15A) KEY (10A) HORN GND AA BAT
W/W_SW
SPARE_BAT
TILT DWN GND-15
TILT UP GND-16
DIODE
DIODE
TILT UP
TILT DOWN
WL_SWA
SL_SWA
GND-16
D7
D8
D9
U V
TILT DOWN
TILT PWR1
TILT PWR2
TILT UP
O P Q R
MAIN CONTROL VALVE
MAIN CONTROL VALVE
MY1470
9-30
G6-42A, G9-43A, G10-43A
WAS WSW
BAT HSW
A B C D E S T D3 D5 D4 (10A) OPT-1 (15A) OPT-3 (15A) OPT-2
O P Q R
D1
10 OHM 30W R1
D2
GND HSW
PAR WSW
LOW WSW
E
HIG WSW
F
OPT-1
OPT-2
BAT HSW
PAR WSW
WAS WSW
LOW WSW
GND1 GND2 GND3
SL SWB
GND HSW
D8 D9 U V
HIG WSW
GND HSW
AUX ELEC1 OPT
OPT-3
N BAT WL_SWA SPARE_BAT SL_SWA
BAT HSW
HIG HSW
MED HSW
LOW HSW
GND HSW
G6-42A, G9-43A, G10-43A

BAT HSW GND HSW
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL
THERMOSTATIC SWITCH A/C
PRESSURE SWITCH (IN CAB)
CLUTCH ON COMPRESSOR 4A
87 86 87a 85 30 86 86 85 30 85 30 87a 87a
87
87
87 87
86
87a
85 30
REV ALARM AUX ELEC2
86
87a
85 30
WARN LT CK
WL2
WL SWB
87 86 87a 85 30 86 85 30 87a 87
D6
D7
ON ENGINE
87
87
BAT HSW
LIGHTS ACC
FAN SW
86
87a
85 30
86
87a
85 30
HTR SW
FAN/HTR
W/W
CONDENSER FANS (ON ROOF) A/C SWITCH IN RH CONSOLE

W X
M
17A
J K L Y GND AA (10A) RELAYS (10A) GAGES (10A) STEER (15A) KEY (10A) HORN (25A) SPARE BAT (30A) OPT_PWR
D10
(25A) FAN/HTR
(25A) W/W
(25A) LIGHTS
W/W_SW
HEATER SWITCH
"C"
86
87a
87
RELAY
85
3-FRONT
30
AIR CONDITIONING OPTION (JOHN DEERE ONLY)

MY1490
Electrical System
9-31
KEY/IGN
KEY BAT PWR
(SHIELD/020)
(CAN L/905, GREEN) (CAN H/904, YELLOW)
KEY START KEY IGN
C B A C B A
(SHIELD/020) (CAN L/905,GREEN) (CAN H/904, YELLOW) (SHIELD/020) (CAN L/905,GREEN) (CAN H/904, YELLOW) FUL LVL DASH GND GAGE PWR ENG STOP LT TRANS TMP SW ENG WARN LT WAIT TO START LT PLUGGED (D BLU, 18 GA GXL)
1
KEY ACC SHIELD CAN L CAN H
(SHIELD/020) (CAN L/905) (CAN H/904) SHIELDED CABLE
C B A
STONERIDGE GAUGE
FUL LVL DASH GND GAGE PWR ENG STOP LT TRANS TMP SW ENG WARN LT WAIT TO START LT
(BLK, 18 GA GXL) (RED, 18 GA GXL) (ORG, 18 GA GXL) (D BLU, 18 GA GXL) (ORG, 18 GA GXL) (WHT, 18 GA GXL) PLUGGED
HORN PWR HORN
HORN PWR HORN
GND FAULT
ENG STOP (RED, 18 GA GXL)
ENG WARN (RED, 18 GA GXL)
MAIN DASH PANEL
PK BRK SOL
PK BRK SOL STR CRB STR AW TRAN/BRK PWR DCLUTCH IN
STR CRB STEER/SWAY PWR STR AW TRAN/BRK PWR
ST RLY
ST RLY
SHIFT PWR 1
SHIFT PWR 1 TILT UP TILT DN DCLUTCH AUX A AUX B ACC MOD GND
9.5.4
Electrical System
G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040465 & After including 0160040468 & 0160040672
15 25 26 27 18 19 24
DASH GND
TRANS SOL Y1 TRANS SOL TRANS SOL Y3 TRANS SOL Y6 SHIFT PWR 2 REVERSE SOL PLUGGED TRANS SOL Y5 KEY START SHIFT PWR 1 PLUGGED PLUGGED
PLUGGED PLUGGED
1 2
TRANS SOL Y1 TRANS SOL Y3 TRANS SOL Y5 TRANS SOL SHIFT PWR 1 KEY START REVERSE SOL SHIFT PWR 2
TRANSMISSION SHIFTER
TRANS SOL Y1 TRANS SOL Y3 TRANS SOL Y5 TRANS SOL SHIFT PWR 1 KEY START REVERSE SOL SHIFT PWR 2 TRANS SOL Y6
CAB CONTROL HARNESS HD34-24-31PT
ON-IDLE IVR THR SGN/915 THR RTN/914 THR SUP/911 IVS SHIFTER GND SP ACCY PWR SP CAB GND 1 SP CAB GND 2
30 31 14 15 13 29 12 17 18 19
THR SGN/915 THR RTN/914 THR SUP/911 IVS ON-IDLE IVR
12 TURNS PER FOOT TWIST
3 1 4 5 2
87a 30 87 86 85
REVERSE RELAY
TRAN/BRK PWR REVERSE SP-1 SP-2 SP-3
PLUGGED TRAN/BRK PWR REVERSE REVERSE SOL SHIFTER GND
PLUGGED
3 1 4 5 2
87a 30 87 86 85
WARN LIGHT TEST RELAY
TRANS TMP SW SP BAT PWR SP BAT PWR
PLUGGED SHIFTER GND TRANS TMP SW KEY START SHIFTER GND
GEAR
AC CLUTCH SP-1 SP-2 SP-3 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 AC CLUTCH
9-32
6 3 2 2 5 4 1 3 4 5 6 7 8
MY6300 B
G6-42A, G9-43A, G10-43A

1 4 2 3 31 30 29
12
5 6 22 13
21 20
DASH PANEL HARNESS HD34-24-31ST
(RED, 18 GA GXL)
TRANS TMP WRN (RED, 18 GA GXL)
7 11 17
16
3 2
HORN
WAIT TO START
10 8 9
23 14
STEER/SWAY PWR
PARK BRAKE
STEER MODE
6 5
1 2
120 OHM
C B A
CAN TERMINATOR
C B A
DCLUTCH IN KEY IGN TILT UP TILT DN DCLUTCH AUX A AUX B ACC MOD GND PK BRK SOL GND FAULT C B A (SHIELD/020) (CAN H/904, YELLOW) (CAN L/905,GREEN)
F4
F3
F2
F1
GEAR
R3 E4, E3
R2
R1
CAB
E6, E3
E5, E3
E5, E2
E5, E1
E4, E2
E4, E1
TRANSMISSION LEGEND TURNER
ACTIVATED TRANS SOLENOIDS
NO SOLENOIDS INGAUGED
SEE SHEET 3
SW3
CAB BULK HEAD

26 27 1 3 5 4 8 7 2 9 6 11 10 20 21 22 25 23 16 28 24
SW1
F
1 2 2 1 3 3
4 4 R
HOBBS
N F
SW4
SW2
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
SW3
R 4 3 2 1 3 4 R
SW1
F N
HOBBS
N F
SW4 A B C D E F
SW2
THROTTLE
WILLIAMS (SUSPENDED)
F4
F3
F2
F1
N1
R4
R3
R2
R1
N4 Y6 (ONLY IF PARK BRAKE OFF)
Y2,Y3,Y5,Y6
Y2,Y3,Y4,Y6
Y1,Y3,Y5,Y6
Y1,Y3,Y4,Y6
Y2,Y3,Y6
Y1,Y3,Y6
Y2,Y6
Y1,Y6
TRANSMISSION LEGEND ZF
ACTIVATED TRANS SOLENOIDS
Y6 (ONLY IF PARK BRAKE OFF)
SEE SHEET 2
OPTIONS
2 3 4
S/W LT PWR
BEACON
1 2
STOP LT
WORKLIGHTS
3
OPTIONS VEC
HEATER/BLOWER
WIPER
F1 20 F5 20
WORKLIGHT/ BEACON OPTION
STOPLIGHT SWITCH
6
DOME/BCN GND STOP LT BCN PWR
1 3
87
86
85
87
86
87a 30
2
86 85 87 86 87a 30 85
2
AUX ELEC1
87a 30
87
GREEN-4
87
86
4
OPTION (25A)
86 85 87 86 87a 30 85 85
4
87a 30
87a 30
87
87
86
F4
F3
F2
7
85
7
87a 30
BLUE-3
25
15
SWING EXTRA SW2 87A SW2 86 MAST SW1 87A SIDESHIFT SW1 86 AUX SW GND PLUGGED PLUGGED PLUGGED
25A OPT 15A OPT 2 OPT PWR 1 AUX SW GND 5A ROOF WIPER PWR OPT PWR 2 OPT PWR 3 OPT PWR 4
PLUGGED QC GND 25A OPT GND 15A OPT 2 GND 5A ROOF WIPER GND OPT GND 1 OPT GND 2 D FAN GND
EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY HEATER GND HTR CNTRL B EMPTY HEATER PWR
WIPER HI WIPER LO
WIPER LO WIPER HI WIPER PARK EMPTY EMPTY
WIPER PARK WASHER
WIPER PWR
D FAN PWR D FAN GND
SWING EXTRA SW2 87A SW2 86 MAST SW1 87A SIDESHIFT
SW1 86 AUX SW GND PLUGGED PLUGGED PLUGGED
ROOF WIPER MOTOR

OPTION 25 A A B
OPTION 2 B 15 A A
M
D FAN PWR HEATER PWR WIPER PWR HEATER GND D FAN GND PLUGGED
A B C D E F
15A OPT 2 GND 15A OPT 2
25A OPT 25A OPT GND
HEATER HI HEATER MED HEATER LOW HEATER GND
D FAN PWR HEATER PWR WIPER PWR HEATER GND D FAN GND PLUGGED HTR TEMP BLOWER
(RED)
8K OHM
A M L C H B
5A ROOF WIPER PWR 5A ROOF WIPER GND
ENCLOSED CAB OPTION

A/C SWITCH
AUX ELEC PWR
M 17A M
A 87
86 85
30
QUICK CONNECT
1
THERMOSTATIC SWITCH A/C SEE SHEET 1
PRESSURE SWITCH
AC SW
3
AC SW
4 6
86 85
30
25A OPT 25A OPT GND
AUX RLYS PWR
87
A/C RELAY
25A OPT GND
SIDESHIFT
PLUGGED
SWING EXTRA
MAST
OPT PWR 1
OPT PWR 2 OPT PWR 3 OPT PWR 4
OPT GND 1 OPT GND 2 QC PWR 1 QC PWR 2 QC GND 5 QC GND 7
19 8
17
15
10 12 14
16 18 7 9 11 13 2 1 4 3
OPTIONS HARNESS HD36-24-19PE
Electrical System
MY6310 B
TO CHASSIS ASSEMBLY
AUX RLYS PWR KEY ACC WORK LT STOP LT
AC CLUTCH
PRS SW
(RED/WHITE)
(BLACK)
HEATER PWR
CONDENSER FANS (ON ROOF)
FAN SW C
24 KOHM,1W
RLY 87 25A OPT GND

A B
HEATER GND HTR CNTRL A HEATER PWR
RESISTOR LOCATED APPROX 10" BEHIND HEATER TEMP SWITCH CONNECTION IN ENCLOSED CAB OPTIONS HARNESS
WASHER
G6-42A, G9-43A, G10-43A

87a 30 85
AUX ELECTRICS
F7 10 F8 10
STOP LT BCN PWR DOME LT CAB LT PWR S/W LT PWR WORK LT CAB LT GND DOME/BCN GND DOME LT DOME LIGHT
A
1
4 6 2
BCN/FAN
1
F6 20
LIGHTS
3
WORK LT
8
A B C D E F G H
WIPER PWR HEATER PWR KEY ACC BCN PWR D FAN PWR DOME LT CAB LT PWR S/W LT PWR DOME LT CAB LT PWR S/W LT PWR BCN LT DOME/BCN GND
A B
BEACON
OPTION (15A)
A B
5
AUX ELEC2
SW1 86 HEATER GND CAB LT GND DOME/BCN GND AUX ELEC PWR SW1 87A CAB LT GND DOME/BCN GND
7 5
CAB LTS CAB LT GND
LEFT CAB LIGHTS CAB LTS CAB LT GND

A B
A B C D E F G H
SW2 86 SW2 87A
RIGHT
BLACK-1 H G F E D C B A
GRAY-2 H G F E D C B A
OPTIONS FUSE LEGEND

DASH FAN BLOWER MOTOR
WIPER MOTOR
HEATER VALVE
M M
WIPER H LW P
WINDSHIELD WASHER MOTOR
M
1 2 3 4 5 6 7 8 9 10 B
F1 F2 F3 F4 F5 F6 F7 F8 20A 5A 15A 25A 20A 20A 10A 10A WIPER PWR 5A ROOF WIPER PWR 15A OPTION PWR 2 25A OPTION PWR HEATER/BLOWER PWR LIGHT PWR BEACON PWR DASH FAN PWR
A B
A B C D
AUX ELECTRIC OPTION
1 2 3 4 5 6 7 8 9 10 11 12
9-33
9-34
Electrical System
ACCESSORY MODULE OPTION

TAGNAME KEY IGN IGNITION INPUT 1 5 EXC TILT +5 ANALOG EXCITATION VOLTAGE FORK TILT SIGNAL A INPUT OUTPUT OUTPUT INPUT OUTPUT INPUT INPUT I/O I/O OUTPUT INPUT ANALOG GROUND POWER POWER ANALOG POWER ANALOG ANALOG SERIAL SERIAL SERIAL SERIAL +5 ANALOG EXCITATION VOLTAGE AUX HYD SIGNAL A ANALOG GROUND FORK TILT SIGNAL B AUX HYD SIGNAL B CANBUS HIGH CANBUS LOW RS-232 TRANSMIT RS-232 RECEIVE ANALOG OUTPUT TILT SIG A TILT GND 5 EXC AUX AUX SIG A AUX GND TILT SIG B AUX SIG B CAN H/904 CAN L/905 TX RX POWER 2 3 4 5 J2 (GREY) 7 8 9 10 11 12 6 INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT ACCESSORY MODULE GROUND JOYSTICK TRIGGER FOR DE-CLUTCH TRANSMISSION DE-CLUTCH INPUT SPARE DIGITAL INPUT ROLLER / JOYSTICK SELECT TILT UP VALUE TILT DOWN VALVE AUX HYD VALVE A AUX HYD VALVE B TRANSMISSION DE-CLUTCH OUTPUT DIGITAL DIGITAL GND RLY FAULT SIG DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL POWER POWER ACC MOD GND TRIG DCLUTCH IN DI2 ROLLER SEL TILT UP TILT DN AUX A AUX B DCLUTCH GND FAULT DESCRIPTION TYPE
CONNECTOR PIN
J1 (BLACK)
10
11
12
1 2 3 4
SEE SHEET 1
1 2 3 4 5 6 7 8 9 10 11 12
SEE SHEET 1
NOTE: FOR BASE MACHINE OR FAILED ACCESSORY MODULE ONLY
5 6
PLUGGED PLUGGED GND FAULT PLUGGED
7 8 9 10 11 12
CAN SHIELD CAN L/905 CAN H/904 DCLUTCH IN KEY IGN TILT UP TILT DN DCLUTCH AUX A AUX B ACC MOD GND PK BRK SOL PLUGGED GND FAULT PLUGGED DCLUTCH IN IGN TILT UP TILT DN DCLUTCH AUX A AUX B ACC MOD GND PK BRK SOL PLUGGED GND FAULT PLUGGED
KEY IGN
5
G SERIES
6 3 2 4 1 7 8
KEY IGN ACC MOD GND TRIG DCLUTCH IN DI2 ROLLER SEL TILT UP TILT DN AUX A AUX B DCLUTCH GND FAULT TRIG TILT SIG A TILT GND TILT SIG B 5 EXC TILT PLUGGED PLUGGED
OPTIONAL PROPORTIONAL AUX. PADDLE
2 3 4 5 6 7 8 9 10 11 12
OPTIONAL FORK TILT ON JOYSTICK W/ DE-CLUTCH TRIGGER
J1 (BLACK)
ACCY. MODULE
5 EXC AUX AUX SIG A AUX GND
1 3 2
1 2 3 4 5 6 7 8 9 10 11 12
J2 (GREY)
AUX SIG B KEY IGN ROLLER SEL

4 5 6
5 EXC TILT TILT SIG A TILT GND 5 EXC AUX AUX SIG A AUX GND TILT SIG B AUX SIG B CAN H/904 CAN L/905 TX RX
NEUTRAL SWITCH
1 2 3 4
MY6320 B
JLG ANALYZER
G6-42A, G9-43A, G10-43A
GRN RED BLK
(-)
A B C D REVERSE LT GND HORN TRANS SOL Y1 REVERSE SOL TRANS SOL Y3 TRANS SOL TRANS SOL Y5 TRANS SOL Y6 KEY START SHIFT PWR 1 SHIFT PWR 2 REVERSE TRAN/BRK PWR SHIFTER GND THR SUP/911 THR SGN/915 THR RTN/914 SP BAT PWR SP ACCY PWR SP CAB GND 1 SP CAB GND 2 SP-1 SP-2 SP-3 TRANS TMP SW AC CLUTCH STAB/TILT PWR TILT UP TILT DN SP BAT PWR IVS ON-IDLE IVR KEY ACC AUX RLYS PWR STOP LT WORK LT EXTRA SWING QC PWR 1 OPT PWR 1 QC PWR 2 OPT PWR 2 QC GND 5 OPT PWR 3 QC GND 7 OPT PWR 4 AUX ELEC GND OPT GND 1 SIDESHIFT OPT GND 2 MAST
A B C D E F
BLK RED YEL BLU ORG PLUGGED
KEY BAT PWR KEY IGN KEY ACC KEY START DASH GND GAGE PWR HORN PWR STEER/SWAY PWR STR AW STR CRB HORN FUL LVL TRANS TMP SW ST RLY SHIFT PWR 1 PK BRK SOL GND FAULT AUX A AUX B WAIT TO START ENG WARN LT ENG STOP LT TRAN/BRK PWR ACC MOD GND TILT UP TILT DN DCLUTCH PLUGGED CAN H/904 CAN L/905 SHIELD /020
QC PWR 1 QC PWR 2 AUX ELEC GND QC GND 5 QC GND 7 PLUGGED
POSITIVE CABLE TO STARTER
AND ALTERNATOR
BAT GND
BAT GND
BAT POS
BAT POS
NEGATIVE CABLE TO ENG BLOCK
NEGATIVE CABLE FLAG TO CHASSIS FRAME
BLACK-6
GRAY-5
POWER DIST VEC
F2
ACCY-2
IGNITION-2
F5 15
87
86
87
86
85
87a 30
87a 30
85
F1 15
GREEN-4
IGNITION-1
ACCY-1
A B C D E F G H
DASH GND ALT EXC SP ACCY PWR AUX RLYS PWR OPT GND 1 KEY ACC TRAN/BRK PWR OPT GND 2
87
86
85
87
86
87a 30
F4
F9
87a 30
85
F8
F3
F7
CB4
CB3
CB1
F10
20
25
20 10
25
20 15
10
CB2 20 F11 10
10
15
F12
BLUE-3
A B C D E F G H
SP CAB GND 1 SP CAB GND 2 SP GND 1 AC CLUTCH GND AUX ELEC GND LT GND STR/FUL GND ACC MOD GND SHIFT PWR 2 DCLUTCH
87
86
SHIFTER GND OPT PWR 2 KEY IGN SP BAT PWR ECU IGN/012 OPT PWR 1 GAGE PWR ECU BAT/022
ENG GND OPT PWR 3 HORN PWR STEER/SWAY PWR OPT PWR 4 STAB/TILT PWR KEY BAT PWR ECU GND/050
85
30
TRANSMISSION DECLUTCH RELAY
STR/FUL GND PK BRK SOL
12 TURNS PER FOOT TWIST CABLE

FUSE FUSE FUSE FUSE F1 F2 F3 F4 F5 F6 F7
20 7 8 1 13 5 2 14 15 16 4 19 21 22 25 26 3 28 6 10 11 12
POWER DISTRIBUTION FUSE/BREAKER LEGEND 20A 20A 20A 20A 15A 5A 10A 10A 15A 10A 15A
23 24
9 17 27
PROPORTIONAL HYDRALIC AUX. VALVE
2 1 2 1
VLV GND AUX A VLV GND AUX B
OPTION POWER 3 OPTION POWER 4 OPTION POWER 1 OPTION POWER 2 TRANS/PARK BRK PWR ALTERNATOR EXCITE ENGINE ECU IGN PWR GAGE (INST PANEL) PWR SPARE ACCESSORY PWR AUX ELECTRIC PWR HORN PWR
29
18 23 24
TRANS SOL Y1 REVERSE SOL TRANS SOL Y3 TRANS SOL TRANS SOL Y5 ECU GND/050 TRANS SOL Y6
ST RLY PLUGGED
CAN H/904 CAN L/905 SHIELD /020 ENG GND
PLUGGED PLUGGED
ALT EXC
ALL WHEEL STEER MODE VALVE CRAB
1 2
STR CRB STR/FUL GND
FUEL SNDR
B A
STR/FUL GND FUL LVL
WAIT TO START LT ENG WARN LT ENG STOP LT ECU IGN/012 ECU BAT/022
TRANS TMP SW PLUGGED
PLUGGED
1 2
PK BRK SOL
STR AW STR/FUL GND
THR SUP/911 THR SGN/915 THR RTN/914
IVS ON-IDLE IVR
TILT-ON JOYSTICK VALVE
2 1
2 1
VLV GND TILT UP VLV GND TILT DN
F8
25A
SPARE BATTERY PWR
CHASSIS HARNESS HD34-24-29PE
F9 F10
25A 10A
ENGINE ECU BAT PWR STEER/SWAY PWR
TO POWER UNIT ASSEMBLY
F11 F12
10A 15A
R. AXLE STAB/TILT KEY BATTERY PWR
GND FAULT
A 87 30
Electrical System
MY6330 B
85 86
VLV GND ACC MOD GND
GROUND FAULT RLY
PLUGGED MAST SIDESHIFT AUX ELEC GND SWING EXTRA
F6 10
PLUGGED
12 VDC BATTERY
REVERSE STOP LT WORK LT LT GND
CABLE
AC CLUTCH SP-3 SP-2 SP-1 SP BAT PWR SP ACCY PWR SP GND 1 AC CLUTCH GND
A B C D E F
BLK RED YEL BLU ORG
G6-42A, G9-43A, G10-43A

TO CAB ASSEMBLY
(OPT) TAIL LIGHT
REVERSE ALARM HORN
1 2
(OPT)
TO DASH PANEL HARNESS HD36-24-31PT CHASSIS HARNESS
A B C D E F
BU STOP TAIL
NEGATIVE CABLE TO CAB FIREWALL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
TO CAB CONTROL HARNESS HD36-24-31ST CHASSIS HARNESS CHASSIS HARNESS
TO OPTIONS HARNESS HD34-24-19SE
A/C COMPRESSOR
QC DIVERTOR VALVE
(OPT) AUXILIARY ELECTRIC A S LT RT TM
A B
9-35
1 2 FC37
ENGINE HARNESS HD36-24-29PE TO CHASSIS ASSEMBLY
GRN CAN L/905
YEL CAN H/904
BRN CAN SHIELD/020
X40 BLK ENG GND S06 BLK ENG GND BLK ENG GND BLU TRANS TMP SW VIO PK BRK SOL S07
BRN CAN SHIELD/020
CUMMINS ENGINE ECM CONNECTION (60 PIN)
VIO PK BRK SOL
4 3 2 1 BLK SPARE GND RED SPARE BAT RED SPARE IGN S42
TRANSMISSION HARNESS CONNECTION
BRN CAN SHIELD/020
MOLDED DIODE
DIAGNOSTIC CONNECTOR
DIAGNOSTIC POWER FUSE 30A
1 FC36-1
1 FC36-2
BLK ENG GND RED STRT RLY
MOLDED DIODE
WHT GRID HTR
BLK GRID HTR RTN
A B
Y2 Y3
A B
TRANS SOL Y2 ENG GND

START SOL FUSE 80A
BRN CAN SHIELD/020 GRN CAN L/905 YEL CAN H/904
X23
1 RL18-86
1 RL18-30
2 1 RL20 RED STRT PWR 1 RL20-2
RED STRT SOL 1 RL20-1
Y4
A B
TRANS SOL Y4 ENG GND TRANS SOL Y5 ENG GND PRK BRK SOL ENG GND TRANS TMP SW ENG GND
1 RL18-85
1 RL18-87
3 2 1
85
86
30
120 OHM
Y5
A B
87
9-36
TO BATTERY POSITIVE X10 X44 BLK ECM GND S12 RED ECM PWR S09 BLK ECM GND RED ECM PWR YEL CAN H/904 X03 BLK ECM GND BLK ECM GND RED ECM PWR RED ECM PWR 1 2 3 4 BLK ECM GND BLK ECM GND RED ECM PWR RED ECM PWR
POWER UNIT
TO BATTERY NEGATIVE
ECM PWR FUSE 30A
ECM POWER
X11 TO ENGINE BLOCK
X02
RED ECM PWR BRN TRANS SOL 6
WHT IVS S16 S15 S17 S26
Electrical System
GRN CAN L/905 S25 BLU ON-IDLE
BRN TRANS SOL 5 BRN TRANS SOL BRN IVR BLU ON-IDLE BRN TRANS SOL 3 BRN REVERSE SOL YEL WAIT TO START LT BRN TRANS SOL 1 WHT IVS BLU TRANS TMP SW BRN CAN SHIELD/020 GRN CAN L/905 YEL CAN H/904 RED STRT RLY YEL THR RTN/914 GRN THR SGN/915 BRN THR SUP/911 RED ALT EXC YEL ENG STOP LT YEL ENG WARN LT VIO PK BRK SOL BRN THR SUP/911 YEL THR RTN/914 BLK ENG GND BLK ECM GND/050 RED ECM BAT/022 RED ECU IGN/012 S41
29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
X04
GRN THR SGN/915
BRN IVR YEL ENG WARN LT BLK GRID HTR RTN RED ECU IGN/012 YEL ENG STOP LT
VIO PK BRK SOL BRN TRANS SOL 6 BRN TRANS SOL 5 BRN TRANS SOL BRN TRANS SOL 3 BRN REVERSE SOL BRN TRANS SOL 1
12 11 10 9 8 7 6 5 4 3 2 1
X05
PARK BRAKE SOL

1 2 MS32
2 1
BLK ENG GND VIO PK BRK SOL
YEL WAIT TO START LT WHT GRID HTR
X13
BRN CAN SHIELD/020 S24 GRN CAN L/905 YEL CAN H/904 RED ECM BAT/022 BLK ECM GND/050 S39 BLK SPARE GND RED ECM BAT/022 RED ECM BAT/022 ALT PWR FUSE 150A
NC 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 NC
X21
CUMMINS ENGINE
FC22 2 1
1 1
RED ALT PWR
RED ALT PWR RED ALT PWR RED ALT PWR
X28
M
RED STRT SOL -
X27
X29
ALTERNATOR
IP35 1 X43 RED STRT PWR -
3 2 1
RED ALT EXC
X34
BLK ENG GND
TRANSMISSION LEGEND
GEAR
RED STRT RLY
MS33 2 1
ACTIVATED TRANS SOLENOIDS F1 F2 F3 F4 R1 R2 R3

GRID HEATER RELAY START RELAY
Y1
A B
FC30-1 1 RED STRT PWR

FC30-2 1 RED STRT PWR -
Y1,Y3,Y4,Y6 Y1,Y3,Y5,Y6 Y1,Y3,Y6 Y1,Y6 Y2,Y3,Y4,Y6 Y2,Y3,Y5,Y6 Y2,Y3,Y6 R4 N1 N2 N3 N4 Y2,Y6 Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF) Y6 (ONLY IF PARK BRAKE OFF)
ZF TRANSMISSION
Y6
A B
250 F
1 2 3 4 5 6 7 8 9 10 11 12
A B
E1
A B A B
TRANS SOL E1 ENG GND TRANS SOL E2 ENG GND TRANS SOL E3 ENG GND TRANS SOL E4 ENG GND TRANS SOL E5 ENG GND TRANS SOL E6 ENG GND TRANS TMP SW
TRANSMISSION LEGEND TURNER

GEAR F1 F2 F3 F4 R1 R2 R3 N ACTIVATED TRANS SOLENOIDS E5, E1 E5, E2 E5, E3 E6, E3 E4, E1 E4, E2 E4, E3 NO SOLENOIDS INGAUGED
E2 E3
A B
E4
A B
E5
A B
E6
A B A
250 F
TURNER TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11 12
MY6340 B
G6-42A, G9-43A, G10-43A
S08 S09 BRN CAN SHIELD S10 RED MOD IGN PWR BLK MOD PUMP GND
X02 MATES WITH CONNECTOR (X23) OF THE ENGINE HARNESS. (1001125280)

X02
1 2 3
YEL CAN H/904 GRN CAN L/905 BRN CAN SHIELD
YEL CAN H/904 GRN CAN L/905
1 2 3 4 5 6 7 8 9 10 11 12 N/C X03
BLK MOD PUMP GND WHT PUMP VAL SIG X06 WHT PUMP VAL SIG
BLK MOD PUMP GND S07 RED MOD IGN PWR X01
X01 MATES WITH CONNECTOR (X40) ON THE ENGINE HARNESS. (1001125280)
4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12
J1 (BLACK)
VARIABLE DISPLACEMENT PUMP SOLENIOD

2 1
J2 (GREY)
G6-42A, G9-43A, G10-43A

G 9-43A & G10-43A (ONLY) VARIABLE DISPLACEMENT PUMP SCHEMATIC
X04
120 OHM
* NOTE: CAN TERMINATING RESISTOR ON X05 WAS THE CAN TERMINATING RESISTOR ON (X23) OF THE ENGINE HARNESS, PRIOR TO MATING OF X02 AND (X23).
3 2 1 X05 BRN CAN SHIELD GRN CAN L/905 YEL CAN H/904
MY6350 B
Electrical System
9-37
Electrical System
9.6
9.6.1
CIRCUIT BREAKDOWNS
Constant Power Circuit from Battery
ENGINE HARNESS
ST RLY PWR
30 86
87
85
STARTER RELAY
STRT SOL BAT-2 BAT-1 SNSR ALT BAT
STARTER MOTOR
GROUND
GROUND (AT ENGINE POD)
BATTERY 12VDC
SNSR
SNSR
#1 BATT #2
ALTERNATOR
BAT-2
BAT-1
TO PCB DEUTSCH P/N HD-34-24-18-SN
ALT BAT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PCB DEUTSCH P/N HD-36-24-18-PN
BATT
AA
D9
87 86 87a 85 30
D5
87 86 87a 85 30
D8
87 86 87a 85 30
D7
87 86 87a 85 30
D6
87 86 87a 85 30
ACC
OPT SPARE BAT
LIGHTS
W/W
FAN/HTR
(30A) OPT_PWR
(10A) HORN
(15A) KEY
(25A) SPARE BAT
(25A) LIGHTS
(25A) W/W
(25A) FAN/HTR
K L
TO DASH PANEL

8 7 4 5 6
DASH PANEL
BAT
ACC
1
STRT
2 3
IGN
KEY PWR
HORN PWR
MY0810
9-38
G6-42A, G9-43A, G10-43A
OPTIONS VEC
WIPER HEATER/BLOWER
87 86 85 87 86 86 86 85 85 87a 30 87a 30 85
NEGATIVE CABLE
LIGHTS BCN/FAN
87
86
85
87a 30
MAIN DASH PANEL

CAB CONTROL HARNESS
OPTION (15A) OPTION (25A)
87 86 85 87a 30 87a 30 87
BAT POS
87
86
87
86
85
87a 30
87a 30
85
OPT PWR 1
OPT PWR 2 OPT PWR 3 OPT PWR 4
SP BAT PWR
KEY BAT PWR
HORN PWR
IGNITION-1
ACCY-1
POWER DIST VEC

DASH PANEL HARNESS HD34-24-31ST DASH PANEL HARNESS HD36-24-31PT
SP BAT PWR
87
86
85
87
86
87a 30
87a 30
85
F8
F9
CB4
CB3
F7
CB2
CB1
F12
20
20
25
25
20 15
20
15
OPT PWR 3
OPT PWR 1
SP BAT PWR
KEY BAT PWR
SP BAT PWR
OPT PWR 2
OPT PWR 4
HORN PWR
OPT PWR 2
SP BAT PWR
OPT PWR 1
ECU BAT/022
OPT PWR 3 HORN PWR
OPT PWR 4
KEY BAT PWR
ECU BAT/022
TO POWER UNIT ASSEMBLY

1 2 3 4 5 6 7 8 9
CHASSIS HARNESS HD34-24-29PE
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
TO BATTERY POSITIVE X02
X04
TO CHASSIS ASSEMBLY
S42
X10 S09
1 2 FC37
ECM PWR FUSE 30A
ENGINE HARNESS HD36-24-29PE

FC22 RED ECM BAT/022 1 RED ECM BAT/022 2
30A DIAGNOSTIC POWER FUSE
RED ECM PWR RED ECM PWR
ECM POWER
RED SPARE BAT

1 2
1 2 3 4
Electrical System
MY6360 B
RED ECM PWR -
X40
POWER UNIT
X21
1 2 3 4 5 6 7 8 9 NC
SP BAT PWR
G6-42A, G9-43A, G10-43A

HORN
2
KEY/IGN
12 VDC BATTERY
POSITIVE CABLE TO STARTER AND ALTERNATOR

3
GRAY-5
ACCY-2
IGNITION-2
BAT POS
TO CHASSIS HARNESS
TO CHASSIS HARNESS
87a 30 87
TO CHASSIS ASSEMBLY
OPTIONS HARNESS HD36-24-19PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
TO DASH PANEL HARNESS TO CAB CONTROL HARNESS

CHASSIS HARNESS HD36-24-31ST CHASSIS HARNESS HD36-24-31PT
TO OPTIONS HARNESS
CHASSIS HARNESS HD34-24-19SE
(OPT)
A/C COMPRESSOR
9-39
Electrical System 9.6.2 Start Circuit

JOHN DEERE
ENGINE HARNESS
30 ST RLY
86
ST RLY PWR
87
85
STARTER RELAY
STRT SOL
PS IGN FUL SOL 2 AMPS

HR MTR
STARTER MOTOR
GROUND
BATTERY 12VDC
SNSR
SNSR ALT EXEC

#1 BATT #2
ALTERNATOR
ALT EXEC
HR MTR
PS IGN
ST RLY
BAT-2
BAT-1
ALT BAT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PS IGN
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
ALT EXEC HR MTR AA ST RLY BATT
ST RLY HR MTR
PCB
D2
Q
87
TR LT SW
O
87a 85 30
10 OHM 30W R1
D9
F-N-R AND GEAR SELECTOR DEUTSCH P/N DT06-8S LOCKING WEDGE W8S
1 2 3 4 5 6 7 8
86
TO TRANSMISSION TEMPERATURE SWITCH
WARN LT CK
(15A) KEY
KEY PWR
87 86 87a 85 30
SHIFT STRT
ACC
KEY ACC
DASH PANEL
KEY STRT
GND 12V
KEY ACC
ST RLY
8 1 2 3
7 4 5 6
TR LT

HR MTR
BAT
KEY PWR
ACC

PS IGN
STRT
BR SW PWR
IGN
BR SW PWR
MY1640
9-40
G6-42A, G9-43A, G10-43A
Electrical System
PERKINS
ENGINE HARNESS
ST RLY
PS IGN FUL SOL HR MTR
30
86
PS IGN FUEL PUMP FP RLY
FUEL PUMP
PS IGN PS IGN
FP PWR FP RLY
PS IGN
HR MTR PS IGN GP SW
ST RLY PWR
87
85
85 86 87 30 87A
STARTER RELAY
STRT SOL
A B
1 2
1 2
A B C
COLD START ADVANCE SOLENOID

GP SW
FUEL SOLENOID
FUSE 7.5 AMP
FUEL PUMP RELAY
FUEL PUMP
OIL PRESSURE SWITCH 5 PSI
GP PWR BAT-2 BAT-1 SNSR ALT BAT
STARTER MOTOR
GP PWR FP PWR
FUSE, 50 AMP SLOW BLOW
GLOW PLUGS
GROUND
GP RLY
30
GP SIG
86
85
87
GLOW PLG
BATTERY 12VDC
GLOW PLUG RELAY

SNSR SNSR ALT EXEC
#1 BATT #2
ALTERNATOR
ALT EXEC
HR MTR
GP SIG
ST RLY
GP SW
PS IGN
BAT-2
BAT-1
ALT BAT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PS IGN
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
ALT EXEC HR MTR AA ST RLY BATT
ST RLY HR MTR
PCB
D2
Q
87
TR LT SW
O
87a 85 30
10 OHM 30W R1
D9
TO TRANSMISSION TEMPERATURE SWITCH
F-N-R AND GEAR SELECTOR DEUTSCH P/N DT06-8S LOCKING WEDGE W8S
1 2 3 4 5 6 7 8
86
WARN LT CK
(15A) KEY
KEY PWR
87 86 87a 85 30
SHIFT STRT
ACC
KEY ACC
DASH PANEL
KEY STRT
GND 12V
KEY ACC
ST RLY
8 1 2 3
7 4 5 6
TR LT

HR MTR
BAT
KEY PWR
ACC

PS IGN
STRT
BR SW PWR
IGN
BR SW PWR
MY1630
G6-42A, G9-43A, G10-43A
9-41
Electrical System
CUMMINS
MAIN DASH PANEL

STONERIDGE GAUGE
STEER MODE
1 2 3 4 6 7
STEER/SWAY PWR
WAIT TO START (RED, 18 GA GXL)

6 5 4 1
TRANS TMP WRN (RED, 18 GA GXL) ENG WARN (RED, 18 GA GXL) ENG STOP (RED, 18 GA GXL)
3 2
PARK BRAKE
1
SW1
F N
SW1
F N
TO CHASSIS ASSEMBLY OPTIONS HARNESS HD36-24-19PE
HOBBS
N
SW2
HOBBS
N
SW2
OPTIONS VEC
WIPER HEATER/BLOWER
87a 30 87a 30 87 86 85 87 86 85
(RED, 18 GA GXL)
KEY/IGN
HORN
TRAN/BRK PWR DCLUTCH IN
3 4 6
ST RLY
SW3
SW3
SW4
LIGHTS BCN/FAN
5
1
2 1 1
2 1
87a 30
87a 30
87
86
87
86
85
85
AUX ELEC1
3 4 5
6 7 8
87a 30
87
86
OPTION (15A)
OPTION (25A)
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
87a 30 87a 30 87 86 85 87 86 85
85
AUX ELEC2
GAGE PWR
SHIFT PWR 1
SHIFT PWR 1 KEY START
HORN PWR
KEY BAT PWR
WARN LIGHT TEST RELAY
KEY START SHIFT PWR 1
87a 30
87
86
REVERSE RELAY
KEY START KEY IGN
KEY ACC
87a 30
87
86
85
25
87a 30
87
86
TRAN/BRK PWR
SP BAT PWR SP ACCY PWR
PLUGGED
SP BAT PWR
OPT PWR 3
OPT PWR 1
OPT PWR 2
OPT PWR 4
DASH PANEL HARNESS
CAB CONTROL HARNESS
2 1
OPTIONS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12
DCLUTCH IN KEY IGN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
M
(OPT)
A/C COMPRESSOR
GAGE PWR HORN PWR STEER/SWAY PWR
TRAN/BRK PWR
TRAN/BRK PWR
STAB/TILT PWR
KEY ACC AUX RLYS PWR
CHASSIS HARNESS HD36-24-31PT

CHASSIS HARNESS HD36-24-31ST

SP BAT PWR OPT PWR 1 OPT PWR 2 OPT PWR 3 OPT PWR 4
CHASSIS HARNESS HD34-24-19SE
KEY BAT PWR KEY IGN KEY ACC KEY START
BAT POS
BAT POS
NEGATIVE CABLE
+
12 VDC BATTERY
A BLACK-6 C A GRAY-5 C

ACCY-2
87a 30 87 86 85
POWER DIST VEC

5
F2 IGNITION-2
87a 30 87 86 85
F5 15 F6 10
KEY IGN
F1 15 IGNITION-1
87a 30 87 86 85
ACCY-1
87a 30 87 86 85
A B C D E F G H A B C D E F G H
GREEN-4
ALT EXC SP ACCY PWR AUX RLYS PWR KEY ACC TRAN/BRK PWR
DCLUTCH IN
CB4
CB2 20 F11 10
CB3
CB1
F10
20
20 10
20 15
25
10
25
10
OPTIONAL FORK TILT ON JOYSTICK W/ DE-CLUTCH TRIGGER
1 2
3 4
OPTIONAL PROPORTIONAL AUX. PADDLE
JLG ANALYZER
OPT PWR 3 HORN PWR STEER/SWAY PWR OPT PWR 4 STAB/TILT PWR KEY BAT PWR
OPT PWR 2 KEY IGN SP BAT PWR ECU IGN/012 OPT PWR 1 GAGE PWR ECU BAT/022
15
F12
BLUE-3
F4
F8
F3
F9
F7
ST RLY SHIFT PWR 1
ST RLY
ECU IGN/012 ECU BAT/022
TO POWER UNIT ASSEMBLY CHASSIS HARNESS HD34-24-29PE
RED MOD IGN PWR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 X04
TO CHASSIS ASSEMBLY ENGINE HARNESS HD36-24-29PE
J1 (BLACK)
J2 (GREY)
POWER UNIT
NC 9 8 7 6 5 4 3 2 1 X21
S42
G 9-43A/G10-43A (ONLY) VARIABLE DISPLACEMENT PUMP SCHEMATIC

ALT PWR FUSE 150A
1 FC36-1
START SOL FUSE 80A
FC30-2 1 FC30-1 1
RED STRT PWR RED STRT PWR
1 X43
RED STRT PWR -
1 FC36-2
1 2 FC37
MOLDED DIODE
MS33 2 1
RED STRT RLY
2 RED STRT RLY 1 RL20 RED STRT PWR 1 RL20-2 RED STRT SOL 1 RL20-1
ALT EXC
X02 4 3 2 1
X03
ECM POWER
MY6400
9-42
G6-42A, G9-43A, G10-43A
SP BAT PWR
KEY START
85
85
BLUE-3
GREEN-4
SW4
2 3 4 5 6 7 8 9 10 11 12
KEY IGN
KEY IGN
J1 (BLACK)
ACCY. MODULE
1 3 2
4 4 5 6
7 7 8
6 3 2 4 4 1
1 2 3 4 5 6 7 8 9 10 11 12
NEUTRAL SWITCH
J2 (GREY)
X04
X03 1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 X01 X40
1 2 3 4 5 6 7 8 9 10 11 12 N/C
RED MOD IGN PWR
RED SPARE BAT RED SPARE IGN -
RED ECM BAT/022 RED ECU IGN/012 RED ECU IGN/012
RED STRT RLY
RED ALT EXC
M
FC22 2 1
S41
ALTERNATOR
3 2 1 X34 RED ALT EXC IP35 X29 RED STRT SOL 1 1 X27 RED ALT PWR
RED ECM BAT/022
RED ECM BAT/022 RED ECM BAT/022
TO BATTERY POSITIVE
X10
RED ECM PWR S09 RED ECM PWR RED ECM PWR
RED ALT PWR
ECM PWR FUSE 30A START RELAY
X28 1 RED ECU IGN/012 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 NC
Electrical System 9.6.3 Charging Circuit
ENGINE HARNESS
STRT SOL
STARTER MOTOR
SNSR ALT BAT
GROUND
BATTERY 12VDC
SNSR ALT EXC
SNSR ALT EXC

#1 BATT #2
ALTERNATOR
ALT EXC
TO PCB DEUTSCH P/N HD-34-24-18-SN
ALT BAT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PCB DEUTSCH P/N HD-36-24-18-PN
D9
O
10 OHM 30W R1
87 86 87a 85 30
(10A) GAGES
ACC
J
TO DASH PANEL
DASH PANEL
GAG PWR
OIL 12 UDC
1 B+
FUEL
2
GND TEMP
4 IN 1 GAGE BEEDE
MY0800
G6-42A, G9-43A, G10-43A
9-43
Electrical System
MAIN DASH PANEL
STONERIDGE GAUGE
6 5 3 2
4 1
(RED, 18 GA GXL)
3 4 5
6 7 8
KEY BAT PWR KEY IGN
GAGE PWR
NEGATIVE CABLE TO CAB FIREWALL
HD36-24-31PT DASH PANEL HARNESS
BAT POS
BAT POS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
+
12 VDC BATTERY
KEY BAT PWR KEY IGN

A C
BLACK-6
GRAY-5
POWER DIST VEC

5
F2 IGNITION-2
IGNITION-1
87a 30 87 86 85
A B C D E F G H A B C D E F G H
ALT EXC
10
10
25
GAGE PWR ECU BAT/022
ECU IGN/012
KEY BAT PWR
KEY IGN
15
F12
BLUE-3
F4
F3
F9
GREEN-4
87a 30
87
86
85
GAGE PWR
TO DASH PANEL HARNESS CHASSIS HARNESS HD34-24-31ST
GAGE PWR
KEY/IGN
ECU IGN/012 ECU BAT/022
CHASSIS HARNESS HD34-24-29PE TO POWER UNIT ASSEMBLY
X40 NC 9 8 7 6 5 4 3 2 1 X21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
ALT EXC
RED ALT EXC
ALTERNATOR
3 2 1
START SOL FUSE 80A
4 3 2 1 X04
FC22 2 1 RED ECM BAT/022 RED ECM BAT/022
RED SPARE IGN -
RED SPARE BAT -
RED ECM BAT/022 RED ECU IGN/012
TO CHASSIS ASSEMBLY ENGINE HARNESS HD36-24-29PE
RED ECM BAT/022
X34 IP35 RED ALT EXC

FC30-2 1 FC30-1 1
RED ALT PWR 1 X27

1 FC36-1 1 FC36-2 RED STRT PWR
S41
S42
TO BATTERY POSITIVE
X10
RED ECM PWR -
ALT PWR FUSE 150A
RED ALT PWR X28 1
ECM PWR FUSE 30A
1 2 FC37
S09
RED ECU IGN/012
RED ECM PWR RED ECM PWR
1 RED STRT PWR X43 2 1 RL20 1 RL20-2 1 RL20-1 RELAY START
X02
X03 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 NC
ECM POWER
MY6440B
9-44
G6-42A, G9-43A, G10-43A
Electrical System
9.7
9.7.1
ENGINE START CIRCUIT

Starter
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the wires from the solenoid stud. Remove the positive (+) battery cable from the starter. Label and disconnect the wire from the starter solenoid housing stud. Record how the wires are installed to ensure correct installation later. 6. Loosen, but DO NOT remove, the three fasteners securing the starter to the flywheel housing. Support the starter securely, as it is relatively heavy and will fall if not supported. 7. Support the starter and remove the fasteners securing the starter to the engine. Remove the negative (-) ground cable from its starter mounting bolt. 8. Remove the starter from the machine. d. Starter Installation
a. Testing the Starter on the Engine If the starter does not engage when the ignition key switch is turned, check the following: 1. The main fuse may be blown, requiring replacement. Check for the cause of the blown fuse. 2. There may be a defect in the ignition key switch, ignition wiring or starter solenoid. 3. Check battery condition. Clean the battery posts and the connectors at each end of the battery cables. 4. Check for broken wiring and damaged insulation on the wiring. Replace all broken or damaged wiring. 5. Check all connections at the starter solenoid, key switch and wiring harness plugs. Clean and tighten all connections. 6. If the starter still does not operate after these checks have been performed, check the starting circuit. b. Starter Circuit Checks 1. Check wires and connections for looseness, corrosion, damage, etc. 2. If a whirring noise is heard but the engine does not turn over, the starter is spinning but not engaging the flywheel. The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective. Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine. 3. If the starter only clicks it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection. Check the battery state of charge and battery condition first, then check the cables and cable connections. 4. For additional information on the starting circuit, refer to Section 9.5, Electrical System Schematics. c. Starter Removal Remove the starter only if it fails. To remove the starter: 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.
1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with the three fasteners. 2. Connect the positive (+) battery cable to the upper solenoid stud. Install the wires to the upper solenoid stud, and secure with lock washer and nut. 3. Connect the wire to the solenoid mounting stud. 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.
G6-42A, G9-43A, G10-43A
9-45
Electrical System
9.8
CHARGING CIRCUIT
Before using a battery charger, an attempt can be made to recharge the battery by jump-starting the machine (Refer to the appropriate Operation & Safety Manual). Allow the engine to run, which will enable the alternator to charge the battery. If the engine alternator charging warning indicator illuminates, perform the following checks: 1. Check all battery cable connections at the battery, and verify that they are clean and tight. 2. Check the external alternator wiring and connections, and verify that they are in good condition. 3. Check the fan belt condition and tension. 4. Run the engine and check the alternator for noise. A loose drive pulley, loose mounting hardware, worn or dirty internal alternator bearings, a defective stator or defective diodes can cause noise. Replace a worn or defective alternator.
9. While supporting the alternator with one hand, remove the upper (longer) mounting hardware from the upper alternator mount. Remove the alternator from the machine. b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper (longer) mounting hardware through the alternator mount. Thread the longer capscrew into the alternator front mount. DO NOT tighten completely at this time. 2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounting capscrew. Tighten the lower capscrew and upper capscrew securely. 3. Place a drive ratchet into the square hole on the serpentine belt tensioner bracket. Apply pressure against the tensioner bracket and route the serpentine belt onto the alternator and engine pulleys. Release and check the tensioner pulley to verify that it is pivoting freely in order to provide the proper tension on the belt. Check for proper belt alignment. (Refer to the appropriate Operation & Safety Manual.) 4. Connect the previously labeled wire leads to the alternator. 5. Properly connect the battery. 6. Close and secure the engine cover. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.8.1
Alternator
a. Alternator 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool 4. Properly disconnect the battery. 5. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket. 6. While lifting the automatic belt tensioner away from the belt, remove the fan serpentine belt. Note: Record how the alternator is installed to ensure correct installation later. 7. Label and disconnect the wire leads attached to the alternator. 8. Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine.
9-46
G6-42A, G9-43A, G10-43A
Electrical System
9.9
WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR
b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. c. Inspection and Replacement Inspect the motor terminals for continuity. Replace motor if continuity is not found. d. Installation and Testing 1. Install all required hardware to the motor assembly. 2. Align motor with the mounting holes and bolt the motor to the mounting bracket. 3. Connect the wiper linkage to the wiper motor shaft. Note: Align the wiper linkage arm with the flat on the motor shaft to ensure wiper stroke covers window area, and it does not swipe past the glass area. 4. Connect the cab harness connectors to windshield wiper motor connectors. 5. Replace the main dash panel to its original orientation. Secure with the previously used screws. 6. Properly connect the battery. 7. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved. 8. If previously removed, install hydraulic hoses under the dash. (Refer to Section 4.3.1, Steering Column and Orbitrol Valve.) 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
a. Removal Note: It may be necessary to remove several hydraulic hoses from behind the dash in order to remove and install the wiper motor housing. (Refer to Section 4.3.1, Steering Column and Orbitrol Valve.) 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
3
MY0440
5. Remove the screws that secure the main dash panel. Pull out the dash panel to gain access to the wiper motor (3). 6. Disconnect the cab harness connectors from the wiper motor. 7. Remove the linkage attached to the wiper motor. 8. Loosen and remove the four bolts holding the wiper motor to the mounting bracket. Note: Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing. 9. Remove the motor from the inside of the cab.
G6-42A, G9-43A, G10-43A
9-47
Electrical System 9.9.1 Windshield/Rear Window Washer Reservoir

2. Connect the cab wiring harness connectors to the reservoir connectors. 3. Install the reservoir tank onto the mounting bracket. Note: Attach the ground strap to the lower right bolt hole of washer bottle. 4. Install the lock washers and nuts and secure.
4
5. Fill the washer fluid reservoir with washer fluid. 6. Properly connect the battery. 7. Turn the ignition key switch to the RUN position and press the washer switch. Verify that fluid is sprayed on both the windshield and rear glass.
MY0420
8. Close and secure the engine cover. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
The windshield washer motor and reservoir (4) is located in the cab behind the seat. It is labeled as a unit and cannot be serviced separately. a. 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the nuts and the lock washers from the washer mounting bolts. 6. Pull the washer reservoir out and away from the mounting bracket. 7. Rotate the washer reservoir, label and remove the cab harness connectors from the washer reservoir connectors. 8. Remove the windshield washer hoses from the reservoir. b. Disassembly DO NOT disassemble the pump. The pump is not serviceable. Replace pump if found to be defective. c. Installation and Testing 1. Connect the windshield washer hoses to the reservoir. 9-48
9.10
9.10.1
CAB HEATER AND FAN

Cab Heater Controls
Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. a. Cab Heater Controls 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
5
5
MY6170
G6-42A, G9-43A, G10-43A
Electrical System
5. Remove the screws from the cab heater and fan control panel (5). 6. Pull the control panel out from the panel and disconnect the variable speed fan control cab harness connector and disconnect the temperature cable. 7. Remove the control from the panel. b. Disassembly DO NOT disassemble the cab heater and fan controls. The controls are not serviceable. Replace controls if found to be defective. c. Installation and Testing 1. Check that the variable speed fan control is in the OFF position. 2. Install the temperature control cable to the back of the control. 3. Install the hex locknut on the shaft and tighten. 4. Connect the cab harness connector to the variable speed fan control. 5. Install the screws securing the control panel to the dash panel. 6. Properly connect the battery. 7. Turn the ignition key to the ON position and check the fan speeds. If further repair is needed, refer to Section 9.5, Electrical System Schematics. 8. Start the machine and allow engine to warm to operating temperature. Check heat control at different levels. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6
MY0450
9.11
9.11.1
SOLENOIDS AND SENDERS

Fuel Shut-off Solenoid
a. Fuel Shut-off Solenoid 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
JOHN DEERE
PERKINS
MY1620
5. Disconnect the wiring connector at the fuel shut-off solenoid (6) lead. 6. Remove the fuel shut-off solenoid from the fuel injector pump.
G6-42A, G9-43A, G10-43A
9-49
Electrical System
b. Fuel Shut-off Solenoid Disassembly DO NOT disassemble a fuel shut-off solenoid. Replace a defective fuel shut-off solenoid with a new part. c. Fuel Shut-off Solenoid Inspection and Replacement Use a 12-volt DC source and ground to test the solenoid. Energize the solenoid, and watch for the plunger to retract. If the plunger does not retract, replace the fuel shut-off solenoid with a new part. d. Fuel Shut-off Solenoid Installation 1. Clean the exterior of the fuel injector pump. 2. Install the fuel shut-off solenoid on the fuel injection pump. Do Not Over Tighten. 3. Connect the wiring connector at the fuel shut-off solenoid lead. 4. Properly connect the battery. 5. Start the engine. If the engine starts, the fuel shut-off solenoid is functioning. If the engine fails to start, the fuel shut-off run solenoid may have a poor ground connection. Visually check the wiring at the fuel shut-off solenoid leads and/or check for continuity with a voltmeter as required. 6. Check for fuel and/or oil leakage around the solenoid. 7. Close and secure the engine cover. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
MY0470
5. Disconnect the wiring connector at the park brake solenoid lead.
6. Remove the nut on the end of the park brake coil (7). 7. Remove the park brake coil. 8. Remove the park brake solenoid (8). (Remove only if the electrical coil is found to not be faulty.) b. Disassembly DO NOT disassemble the solenoid. The solenoid is not serviceable. Replace solenoid if found to be defective. c. Park Brake Solenoid Valve Installation Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 1. If necessary, install the park brake solenoid in its original orientation. 2. Slide the park brake coil over the solenoid. Tighten the nut to secure the solenoid. DO NOT overtighten. 3. Connect the wiring connector to the park brake coil lead. 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.
9.11.2
Park Brake Solenoid Valve
G6-42A - All G9-43A/G10-43A - Before S/N 0160040675 excluding 0160040468 & 016040672 a. Park Brake Solenoid Valve 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
9-50
G6-42A, G9-43A, G10-43A
Electrical System
G9-43A/G10-43A - S/N 0160040675 and After including 0160040468 & 016040672 a. Park Brake Solenoid Valve 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Disconnect the wiring connector at the park brake solenoid lead.
7
b. Disassembly DO NOT disassemble the solenoid. The solenoid is not serviceable. Replace solenoid if found to be defective. c. Park Brake Solenoid Valve Installation Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 1. If necessary, install the park brake solenoid in its original orientation. 2. Slide the park brake coil over the solenoid. Tighten the nut to secure the solenoid. DO NOT overtighten. 3. Connect the wiring connector to the park brake coil lead. 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.
MY1140
6. Remove the nut on the end of the park brake coil (7). 7. Remove the park brake coil. 8. Remove the park brake solenoid (8). (Remove only if the electrical coil is found to not be faulty.)
G6-42A, G9-43A, G10-43A
9-51
Electrical System 9.11.3 Transmission Solenoid Valves 9.11.4 Transmission Temperature Sender
ZF DANA
The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Note: If the transmission is not shifting properly, the transmission shift control switch (travel select lever), wiring harness or transmission shift solenoids (9) should be checked in order to determine which component is defective. Specific information to determine which travel position and corresponding component is not responding can be found in the detailed transmission service instructions (covering repair, disassembly, reassembly and adjustment information) are provided in the DanaSpicer T12000 Transmission Repair Manual, (JLG P/N 31200163) or the ZF Powershift Transmission 4WG-92/98 Repair Manual, (JLG P/N 31200241) and can be obtained by calling your local JLG Service distributor. Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.
DANA
a. Transmission Temperature Sender Removal
MY6210
10
10
The transmission temperature sender (10) is located on the left side of the transmission housing. 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the transmission temperature sender connector from the wiring harness connector.
6. The sender is threaded into the transmission housing. Remove the sender. b. Transmission Temperature Sender Inspection and Replacement
MY6180
Inspect the sender and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part.
9
ZF
c. Transmission Temperature Sender Installation and Testing 1. Thread the transmission temperature sender into the transmission housing snugly, then connect the sender connector to the wiring harness connector. 2. Properly connect the battery. 3. Check for proper fluid level.
9 9 9
MY6200
9-52
G6-42A, G9-43A, G10-43A
Electrical System
4. Start the engine, allow it to reach operating temperature and observe the operators display cluster for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, damaged transmission, improper or low fluid, etc. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
PERKINS
9.11.5
Engine Coolant Temperature Sender / Switch

2
MY1580
a. Engine Coolant Temperature Sender 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the engine coolant temperature sender / switch connector from the wiring harness connector.
JOHN DEERE
6. The Engine Coolant Temperature sender (1) is threaded into the engine block. Remove the sender. b. Engine Coolant Temperature Sender / Switch Inspection and Replacement Inspect the sender / switch and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part. c. Engine Coolant Temperature Sender Installation and Testing 1. Thread the engine coolant temperature sender into the engine block snugly, then connect the sender connector to the wiring harness connector. 2. Properly connect the battery. 3. Check for proper coolant level. 4. Start the engine, allow it to reach operating temperature and observe the operators instrument cluster for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, improper or low coolant, obstructed or faulty radiator, coolant pump, loose fan belt, defective instrument display, etc. 5. Close and secure the engine cover.
2
MY0450
6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
G6-42A, G9-43A, G10-43A
9-53
Electrical System 9.11.6 Engine Oil Pressure Sender 9.11.7 Fuel Level Sender
a. Engine Oil Pressure Sender 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow system fluids to cool. 4. Properly disconnect the battery. 5. The engine oil pressure sender (2) is threaded into the engine block. Remove the sender. b. Engine Oil Pressure Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part. c. Engine Oil Pressure Sender Installation and Testing 1. Thread the engine oil pressure sender into the engine block snugly, then connect the sender connector to the wiring harness connector. 2. Properly connect the battery. 3. Check for proper oil level. 4. Start the engine, and observe the operators display for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, low oil, obstructed or faulty oil pump, defective instrument display. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
a. Fuel Level Indicator Testing 1. The fuel level sender wiring harness leads can be accessed from the top of the fuel tank. Disconnect the fuel level sender wiring harness leads. With the help of an assistant, touch both harness leads together. 2. From the operators cab, have the assistant turn the ignition key switch to the RUN position. DO NOT start the engine. Observe the fuel level indicator needle on the operators instrument cluster. The reading must be at the FULL mark. 3. Turn the ignition key switch to the OFF position. The fuel level indicator needle should return to the EMPTY position. b. Fuel Level Circuit Tests
MY4340
If the fuel level sender (3) is suspected of giving a false reading, perform the following checks: 1. If the fuel level indicator needle does not move, check the fuel tank for fuel. 2. Check for loose or defective wiring, faulty ground connections, and corrosion on the fuel tank sender and wiring lead. 3. If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN position, use a test lamp to determine whether current is flowing from the ignition switch to the fuel level sender.
9-54
G6-42A, G9-43A, G10-43A
Electrical System
4. If the fuel level indicator does not move and a faulty or defective fuel level sender in the fuel tank has been ruled out, and in addition, wiring and connectors have been checked and ruled out, the fuel level indicator is defective and must be replaced. 5. Check that the ignition terminal has current and that the fuse in the fuse panel is not blown. 6. Check for broken, shorted, frayed, disconnected or damaged wiring between the fuel level indicator wiring at the cab, fuse and relay panel, ignition key switch, and from the fuel level sender on the fuel tank through the wiring in the cab. 7. Check the fuel level sender. A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving. Refer to Section 9.5, Electrical System Schematics, for further information.
9.11.8
Front and Rear Axle Proximity Sensors
The sensors used on each axle allow the steering to be changed to one of three different settings. The sensors will not allow the change to be completed unless both axles are in the central location. Each sensor is mounted in the center of each steer cylinder. a. Removal 1. Open engine cover. Allow system fluids to cool. 2. Properly disconnect the battery. 3. Unplug the axle proximity sensor from the wiring harness. 4. Remove the bolts holding the sensor to the steering cylinder barrel. b. Disassembly 1. Inspect the sensor and the wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new sensor. c. Installation and Testing 1. Install the bolts holding the sensor to the steering cylinder barrel. 2. Connect the axle proximity sensor to the wiring harness. 3. Properly connect the battery. 4. Close and secure engine cover. 5. Start the machine, select a steering mode, turn the steering wheel until the display unit shows the steering has been "locked" into the selected mode. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.12
9.12.1
DISPLAY MONITOR AND GAUGES

Analog Gauges
a. Gauge 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.
G6-42A, G9-43A, G10-43A
9-55
Electrical System
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery.
Before S/N 0160040675 excluding 0160040468 & 0160040672
b. Disassembly DO NOT disassemble the gauge. The gauge is not serviceable. Replace the gauge if found to be defective. c. Gauge Installation and Testing 1. Install the gauge (12) in the dash. Install the gauge bracket. 2. Connect the previously labeled wires to the gauge. 3. Install the dash panel with the previously used hardware (11). 4. Properly connect the battery. 5. Turn the ignition to the ON position to check the gauge values. 6. Close and secure the engine cover.
12
11
PERKINS
7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9.13
12 11
DASH SWITCHES
Ignition Key Switch
9.13.1
Note: For information on the front windshield wiper, rear window wiper and washer systems, refer to Section 9.9, Window Wiper/Washer Windshield Wiper Motor.
DEERE
MY1840
a. Ignition Switch 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 the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the screws securing the dash panel.
S/N 0160040675 & After including 0160040468 & 0160040672
12
11
CUMMINS S/N 0160040678 & AFTER INCLUDING 0160039394 & 0160039397 MY5060
6. Remove the hex nut securing the ignition key switch to the dash. 7. Label and disconnect the ignition switch wires and remove the switch from the machine.
5. Remove the screws (11) securing the dash panel. 6. Label and disconnect the wires from the gauge, remove the gauge bracket. 7. Pull the gauge (12) out from the dash.
9-56
G6-42A, G9-43A, G10-43A
Electrical System
b. Disassembly DO NOT disassemble the ignition switch. Replace a defective switch with a new part. c. Inspection and Replacement To determine the proper operation of the ignition key switch, test the terminals on the back of the switch for continuity with an ohmmeter.
13
AC C
T BA
9.13.2
Dash Switches
a. Switch 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 the steering wheel, stating that the machine should not be operated.
ACC
3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. There are three frames with three switches in each frame.
IG
Test the ignition key switch for continuity, by checking from the BAT terminal (13) to each of the remaining terminals in their corresponding switch position. If all terminals do not show proper continuity, replace the ignition switch. d. Ignition Switch Installation 1. Connect the ignition key switch to the previously labeled wires. 2. Align the ignition switch in the dash so that when it is in the OFF position, the key slot is positioned vertically (straight up and down). Install the hex nut securing the ignition switch to the dash. DO NOT overtighten. 3. Install the dash panel with the previously used hardware. 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. Note: If further information is needed, refer to Section 9.5, Electrical System Schematics.
G6-42A, G9-43A, G10-43A
ST
N
IG N
MY0830
BAT
6. Pull the frame out of the dash, disconnect the harness connector to the switch in question and push the switch out of the frame. b. Disassembly DO NOT disassemble the dash switch. Replace a defective switch with a new part. c. Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions. Replace a defective or faulty switch with a new switch. d. Switch Installation 1. Connect the switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel and snap into position. 3. Properly connect the battery. 4. Start the machine and check the replaced switch for proper function. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
9-57
Electrical System
9.14
VARIABLE DISPLACEMENT PUMP CONTROL (G9-43A/G10-43A S/N 0160040675 AND AFTER INCLUDING 0160040468 & 016040672)
3
MY6220
The Variable Displacement Control Pump (1) is equipped with an electrical solenoid (Anti-Stall Valve) and controls the mechanical swivel within the pump. Trouble shooting can be performed by using the JLG Analyzer (P/N 1001103758) and connecting to the adaptor (2) near the pump displacement control (3).
9.14.1
Pump Displacement Analyzer Software Version A

TMH PUMP DISPLACEMENT CONTROL MODULE ANALYZER STRUCTURE
MENU: HELP: PRESS ENTER
MENU: DIAGNOSTICS
MENU: ACCESS LEVEL X
ENGINE SPEED: XXXX RPM
ENGINE TORQUE: XXX %
ANTI-STALL COMMAND: XXXXmA
ANTI-STALL ACTUAL: XXXXmA
CONTROL MODULE: VOLTAGE XX.XX
DIAGNOSTICS: VERSIONS
CONTROL MODULE: SOFTWARE Px.x
ANALYZER: ANALYZER SW VER
MY6230
9-58
G6-42A, G9-43A, G10-43A
Electrical System 9.14.2 Diagnostics Menu
MENU Engine Speed: XXXX RPM Engine Torque: XXX% Anti-Stall Command: XXXXmA Anti-Stall Actual: XXXXmA Control Module Voltage: XX.XV
SUB-MENU
COMMENT Displays the engine speed transmitted by the ECM. Displays the engine torque (0-120%) transmitted by the ECM. Displays the anti-stall valve current corresponding to the present engine speed and torque. Displays the actual anti-stall valve current measured by the ECM. Displays the battery voltage reading for the control module.
Diagnostics: Versions
Control Module Software: Px.x Analyzer: Analyzer Ver 6.2
Displays the CMs software version. Displays the JLG Analyzers software version.
G6-42A, G9-43A, G10-43A
9-59
Electrical System
9.15
HAND HELD ANALYZER (G9-43A/G10-43A S/N 0160040675 AND AFTER INCLUDING 0160040468 & 016040672)
The hand held analyzer can be used in place of the cab display panel.
2 3 4
MZ6040
1. Cable Connector. 2. Analyzer Display Screen. 3. Escape Key: To return home or access previous menu. 4. Enter Key: Stores and selects Top Level, Sub Level and Items Menus. 5. Up/Down Arrow Keys: Change adjustable values. 6. Left and Right Arrow Keys: Used to move between Top Level, Sub Levels and Item Menus.
9.15.1
Analyzer Usage
Help messages can be viewed using the Analyzer (P/N 1001103758). The Help messages can be accessed by pressing the ENTER key while viewing the current Help message. The Help message shall be EVERYTHING OK when no fault is present. For more information, contact the local JLG dealer.
9-60
G6-42A, G9-43A, G10-43A
9.15.2
G6-42A, G9-43A, G10-43A
Analyzer Software - Version A
The Access Level Menu controls security for Control Module settings. Access Level 2 is the default and allows view access to all menus, except Calibration. Access Level 1 (33271) provides view, edit and calibration authorization. Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
Electrical System
MAL0890A
9-61
Electrical System
9.16
JOYSTICK FAULT CODES (G9-43A/G10-43A S/N 0160040675 AND AFTER INCLUDING 0160040468 & 016040672) Event
Power Cycle
DTC
211
Comment
No motion restrictions This Help Message is issued at each power-up. This serves to indicate which messages have been recorded in Logged Help since the last power-up event.
Latched
No
2127
Aux Joystick Not In Neutral Position At Power Up
Auxiliary Hydraulic A & B prevented The auxiliary hydraulic joystick must be in the neutral position (established by Calibration) when the control system is energized or it is ignored until is momentarily returns to neutral. Active when AUX HYDRAULIC is ENABLED
No
2123
Joystick Trigger Switch Active At Power Up
De-Clutch functionality prevented (transmission always engaged) The trigger for de-clutch should be open (released) when the control system is energized or is ignored until it momentarily opens.
No
2125
Joystick Roller Not In The Neutral Position At Power Up
Fork Tilt Up & Down prevented The left roller must be in the neutral position (established by Calibration) when the control system is energized or it is ignored until is momentarily returns to neutral. Auxiliary Hydraulic A & B prevented The auxiliary joysticks neutral switch was open while the analog voltage was in the active range, or the neutral switch was closed while the analog voltage was in the neutral range. Auxiliary hydraulics will be prevented until the next power cycle. This fault may be caused by improper joystick calibration, improper wiring, a joystick issue or a control module issue. Neutral switch must be open for 0%; closed beyond 25%
No
2356
Auxiliary Hydraulic Joystick Neutral Disagreement
Yes
2357
Auxiliary Hydraulic Joystick Out Of Range High
Auxiliary Hydraulic A & B prevented The auxiliary joystick analog voltage was measured to be greater than 4.85V. Auxiliary hydraulics will be prevented until the next power cycle. This fault may be caused by improper wiring, a joystick issue or a control module issue. Active when Machine Setups AUX HYDRAULIC is set to ENABLED
Yes
9-62
G6-42A, G9-43A, G10-43A
Electrical System
DTC
2358
Event
Auxiliary Hydraulic Joystick Out Of Range Low
Comment
Auxiliary Hydraulic A & B prevented The auxiliary joysticks analog voltage was measured to be less than 0.15V. Auxiliary hydraulics will be prevented until the next power cycle. Active when Machine Setups AUX HYDRAULIC is set to ENABLED
Latched
Yes
2397
Fork Tilt Joystick Voltage Disagreement
Fork Tilt Up & Down prevented Analog feedback from the joysticks tilt roller did not agree within 25% for 1000mS. Fork tilt up and down will be prevented until the next power cycle. This fault may be caused by improper wiring, a joystick issue or a control module issue. Fork Tilt Up & Down prevented Analog feedback from the joysticks tilt roller was measured to be greater than 4.85V. Fork tilt up and down will be prevented until the next power cycle. This fault may be caused by improper wiring, a joystick issue or a control module issue. Fork Tilt Up & Down prevented Analog feedback from the joysticks tilt roller was measured to be less than 0.15V. Fork tilt up and down will be prevented until the next power cycle. This fault may be caused by improper wiring, a joystick issue or a control module issue. The desired current is greater than 250mA, but the actual current is less then 75mA The fork tilt up digital output was open-circuit. This fault may be caused by improper wiring or a control module issue.
Yes
2398
Fork Tilt Joystick Out Of Range High
Yes
2399
Fork Tilt Joystick Out Of Range Low
Yes
33191
Fork Tilt Valve Open Circuit
Yes
33192
Fork Tilt Valve Short To Battery
Fork Tilt Up & Down, Auxiliary Hydraulics functionality prevented The fork tilt up or down digital output was shorted to battery. Fork tilt up or down will be prevented until the next powercycle. This fault may be caused by improper wiring or a control module issue. The desired current is greater than 250mA, but the actual current is less than 75mA.
Yes
33193
Fork Tilt Up Valve Short To Ground
The actual current is greater than 200mA, PWM is 95%, and the digital output drivers diagnostic feedback is low The fork tilt up digital output was shorted to ground. This fault may be caused by improper wiring or a control module issue.
Yes
G6-42A, G9-43A, G10-43A
9-63
Electrical System
DTC
33194
Event
Fork Tilt Down Valve Open Circuit
Comment
The desired current is greater than 250mA, but the actual current is less then 75mA The fork tilt down digital output was open-circuit. This fault may be caused by improper wiring or a control module issue.
Latched
Yes
33195
Fork Tilt Down Valve Short To Ground
The actual current is greater than 200mA, PWM is 95%, and the digital output drivers diagnostic feedback is low The fork tilt down digital output was shorted to ground. This fault may be caused by improper wiring or a control module issue.
Yes
33196
Auxiliary Function A Valve - Open Circuit
The desired current is greater than 250mA, but the actual current is less then 75mA The auxiliary hydraulic A or B digital output was open-circuit. This fault may be caused by improper wiring or a control module issue.
Yes
33197
Auxiliary Function A/B Valve - Short To Battery
Fork Tilt Up & Down, Auxiliary Hydraulics functionality prevented The auxiliary hydraulic A digital output was shorted to battery. Auxiliary hydraulics will be prevented until the next power cycle. This fault may be caused by improper wiring or a control module issue. Active when Machine Setups AUX HYDRAULIC is set to ENABLED The desired current is 0mA and the digital output drivers diagnostic feedback is low Low-Side Fault Relay de-energized
Yes
33198
Auxiliary Function A Valve - Short To Ground
The actual current is greater than 200mA, PWM is 95%, and the digital output drivers diagnostic feedback is low The auxiliary hydraulic A digital output was shorted to ground. This fault may be caused by improper wiring or a control module issue. Active when Machine Setups AUX HYDRAULIC is set to ENABLED
Yes
33199
Auxiliary Function B Valve - Open Circuit
The desired current is greater than 250mA, but the actual current is less then 75mA The auxiliary hydraulic B digital output was opencircuit. This fault may be caused by improper wiring or a control module issue. Active when Machine Setups AUX HYDRAULIC is set to ENABLED
Yes
9-64
G6-42A, G9-43A, G10-43A
Electrical System
DTC
33200
Event
Auxiliary Function B Valve - Short To Ground
Comment
The actual current is greater than 200mA, PWM is 95%, and the digital output drivers diagnostic feedback is low The auxiliary hydraulic B digital output was shorted to ground. This fault may be caused by improper wiring or a control module issue. Active when Machine Setups AUX HYDRAULIC is set to ENABLED
Latched
Yes
441
Battery Voltage Too Low System Shutdown
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented Battery voltage is less than 8.0V so the control module has prevented associated functionality.
No
442
Battery Voltage Too High System Shutdown
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented Battery voltage is greater than 8.0V so the control module has prevented associated functionality. Low-Side Fault Relay de-energized
Yes
447
Reference Voltage Out Of Range
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented The control modules +5V reference was measured greater than 5.4V or less than 4.6V for 1000mS. Since this reference voltage supplies the joystick(s), fork tilt and auxiliary hydraulic functions must be prevented. Low-Side Fault Relay de-energized
Yes
998
Eeprom Failure Check All Settings
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented The control module detected an issue with the non-volatile memory used to retain Personalities and Calibrations. Verify all settings using the JLG Analyzer. Low-Side Fault Relay de-energized
Yes
2239
Function Problem Joystick Calibration Faulty
Fork Tilt Up & Down, prevented The joystick calibration has never been performed, is improper or calibration attempt has failed. Recalibrate the Fork Tilt and Auxiliary Hydraulic (optional) joysticks to clear this fault. Auxiliary Hydraulics prevented if Machine Setups AUX HYDRAULIC is ENABLED
No
G6-42A, G9-43A, G10-43A
9-65
Electrical System
DTC
259
Event
Model Change - Hydraulics Suspended - Cycle Ems
Comment
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented The user changed the Model Selection using a JLG Analyzer. All functions are being prevented until the EMS is cycled. Machine Setups MODEL was changed via JLG Analyzer
Latched
Yes
9-66
G6-42A, G9-43A, G10-43A
Electrical System
9.17
ENGINE INDICATOR LAMPS - PERKINS

Shutdown Lamp ON Lamp State Bulb Check Lamp Indication When the ignition is turned on, the EMS shall illuminate each bulb for 2 seconds and extinguish them afterwards With both lamps off whilst engine is running then are no currently active warnings, diagnostics or events Should the warning lamp illuminate during engine running, this indicates that an Active diagnostic (Electrical fault) is present Should the warning lamp illuminate and the shutdown lamp flash during engine running, this indicates that an Active diagnostic (Electrical fault) is present. The diagnostic is sufficiently serious to invoke engine derate Should the warning lamp flash during engine running, this indicates that one or more of the engine protection strategy warning values have been exceeded, but not to a level that will invoke Derate or Shutdown Should both the Warning Lamp and Shutdown Lamp flash during engine running, this indicates that one, or more of the engine protection strategy values have been exceeded beyond the level required to invoke engine derate Should both the Warning Lamp and Shutdown Lamp illuminate during engine running this indicates that either: 1. One or more of the engine protection strategy shutdown values has been exceeded 2. A serious Active diagnostic has been detected
Shortly after (time duration to be agreed) engine will shutdown
Warning Lamp ON
Engine State Key on, but engine has yet to be cranked
OFF
OFF
No Faults Present
Engine is running with no detected faults Engine is running normally, but has one or more faults with engine management system Engine is running, but has one or more Active diagnostic events that have initiated engine derate Engine is running normally, but has one or more monitored engine parameters outside of the acceptable range Engine is running, but one or more of the monitored engine parameters has gone beyond that of warning only and has now exceeded those set for engine derate Engine is either shutdown or shutdown is imminent, one of more monitored engine parameters have gone beyond that of warning or derate and have now exceeded those set for engine shutdown, or a serious Active diagnostic has been detected
ON
OFF
Active Diagnostic
ON
FLASH
Derate (Invoked by Active Diagnostic)
FLASH
OFF
Warning (Warning only)
FLASH
FLASH
Derate (Warning and Derate)
ON
ON
Engine Shutdown
G6-42A, G9-43A, G10-43A
9-67
Electrical System
9.18
SAE DIAGNOSTIC TROUBLE CODES AND FAULT CODES - CUMMINS

SPN Codes 629 612 FMI Codes 12 2 Lamp Color Red Red SPN Description Controller #1 System Diagnostic Code #2 Boost Pressure Cummins Description Engine Control Module Critical internal failure Bad intelligent Device or Component Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic pickup sensor - Data Erratic, Intermittent, or incorrect Intake Manifold Pressure Sensor Circuit Voltage Above Normal, or Shorted to High Source Intake Manifold Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source Intake Manifold 1 Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Oil Pressure Low - Data Valid but Below Normal Operational Range - Moderately Severe Level Coolant Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source Coolant Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
Fault Codes 111 115
122
102
Amber
123
102
Amber
Boost Pressure
124
102
16
Amber
Boost Pressure
131
91
Red
Accelerator Pedal Position Accelerator Pedal Position Remote Accelerator
132
91
Red
133
974
Red
134
974
Red
Remote Accelerator
135 141 143 144 145
100 100 100 110 110
3 4 18 3 4
Amber Amber Amber Amber Amber
Engine Oil Pressure Engine Oil Pressure Engine Oil Pressure Engine Coolant Temperature Engine Coolant Temperature
9-68
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 146
SPN Codes 110
FMI Codes 16
Lamp Color Amber
SPN Description Engine Coolant Temperature Accelerator Pedal Position Accelerator Pedal Position Engine Coolant Temperature Intake Manifold #1 Temp Intake Manifold #1 Temp Intake Manifold #1 Temp 5 Volts DC Supply Cruise Control
Cummins Description Coolant Temperature High - Data Valid but Above Normal Operational Range - Moderately Severe Level Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period Coolant Temperature Low - Data Valid but Above Normal Operational Range - Most Severe Level Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source Intake Manifold Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Intake Manifold Air Temperature High - Data Valid but Above Normal Operational Range Most Severe Level Sensor Supply Voltage #2 Circuit - Voltage Below Normal, or Shorted to Low Source Cruise Control (Resistive) Signal Circuit Voltage Above Normal, or Shorted to High Source Cruise Control (Resistive) Signal Circuit Voltage Below Normal, or Shorted to Low Source Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High Source Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Coolant Level - Data Valid but Below Normal Operational Range - Moderately Severe Level Engine Automatic Start Lamp Driver Circuit Voltage Above Normal, or Shorted to High Source Additional Auxiliary Diagnostic Codes logged Condition Exists
147
91
Red
148
91
Red
151
110
Red
153
105
Amber
154
105
Amber
155
105
Red
187 193
3510 520199
4 3
Amber Amber
194
520199
Amber
Cruise Control
195 196 197 199
111 111 111 1661
3 4 18 4
Amber Amber Amber Amber
Coolant Level Coolant Level Coolant Level Engine Automatic Start Lamp J1939 Error
211
1484
31
None
G6-42A, G9-43A, G10-43A
9-69
Electrical System
Fault Codes 212
SPN Codes 175
FMI Codes 3
Lamp Color Amber
SPN Description Oil Temperature
Cummins Description Engine Oil Temperature Sensor 1 Circuit Voltage Above Normal, or Shorted to High Source Engine Oil Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low Source Engine Oil Temperature - Data Valid but Above Normal Operational Range - Most Severe Level Barometric Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Barometric Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Sensor Supply Voltage #2 Circuit - Voltage Above Normal, or Shorted to High Source Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Coolant Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level Engine Speed High - Data Valid but Above Normal Operational Range - Most Severe Level Coolant Level Low - Data Valid but Below Normal Operational Range - Most Severe Level External Speed Input (Multiple Unit Synchronization) - Data Erratic, Intermittent, or Incorrect Sensor Supply Voltage #3 Circuit - Voltage Below Normal, or Shorted to Low Source Sensor Supply Voltage #3 Circuit - Voltage Above Normal, or Shorted to High Source Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect Vehicle Speed Sensor Circuit tampering has been detected - Abnormal Rate of Change Red Stop Lamp Driver Circuit - Voltage Below Normal, or Shorted to Low Source
213
175
Amber
Oil Temperature
214 221 222 227 231 232 233
175 108 108 3510 109 109 109
0 3 4 3 3 4 18
Red Amber Amber Amber Amber Amber Amber
Oil Temperature Barometric Pressure Barometric Pressure 5 Volts DC Supply Coolant Pressure Coolant Pressure Coolant Pressure
234 235 237
190 111 644
0 1 2
Red Red Amber
Engine Speed Coolant Level External Speed Input
238 239 241 242 244
3511 3511 84 84 623
4 3 2 10 4
Amber Amber Amber Amber Amber
System Diagnostic code #1 System Diagnostic code #2 Wheel-based Vehicle Speed Wheel-based Vehicle Speed Red Stop Lamp
9-70
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 245 249
SPN Codes 647 171
FMI Codes 4 3
Lamp Color Amber Amber
SPN Description Fan Clutch Output Device Driver Ambient Air Temperature Ambient Air Temperature Fuel Temperature
Cummins Description Fan Control Circuit - Voltage Below Normal, or Shorted to Low Source Ambient Air Temperature Sensor Circuit Voltage Above Normal, or Shorted to High Source Ambient Air Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low Source Engine Fuel Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level AEB15.60 Page 149 of 157 Engine Fuel Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted to High Source Engine Fuel Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low Source Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect High Fuel Pressure Solenoid Valve Circuit Voltage Below Normal, or Shorted to Low Source High Fuel Pressure Solenoid Valve Circuit Voltage Above Normal, or Shorted to High Source High Fuel Pressure Solenoid Valve #1 Mechanical System Not Responding Properly or Out of Adjustment Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit - Voltage Below Normal, or Shorted to Low Source SAE J1939 Multiplexing PGN Timeout Error Abnormal Update Rate SAE J1939 Multiplexing Configuration ErrorOut of Calibration SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error - Received Network Data In Error SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error - Received Network Data In Error 9-71
256
171
Amber
261
174
16
Amber
263
174
Amber
Fuel Temperature
265
174
Amber
Fuel Temperature
268 271
94 1347
2 4
Amber Amber
Fuel Delivery Pressure Fuel Pump Pressurizing Assembly #1 Fuel Pump Pressurizing Assembly #1 Fuel Pump Pressurizing Assembly #1 Internal Sensor Voltage Supply SAE J1939 Datalink SAE J1939 Datalink Accelerator Pedal Position Remote Accelerator
272
1347
Amber
281
1347
Amber
284
1043
Amber
285 286 287
639 639 91
9 13 19
Amber Amber Red
288
974
19
Red
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 292 293
SPN Codes 441 441
FMI Codes 14 3
Lamp Color Red Amber
SPN Description Auxiliary Temperature 1 OEM Temperature
Cummins Description Auxiliary Temperature Sensor Input 1 - Special Instructions Auxiliary Temperature Sensor Input #1 Circuit Voltage Above Normal, or Shorted to High Source Auxiliary Temperature Sensor Input #1 Circuit Voltage Below Normal, or Shorted to Low Source Barometric Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect Auxiliary Pressure Sensor Input 1 - Special Instructions Auxiliary Pressure Sensor Input #2 Circuit Voltage Above Normal, or Shorted to High Source Auxiliary Pressure Sensor Input #2 Circuit Voltage Below Normal, or Shorted to Low Source Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect Injector Solenoid Cylinder #1 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #5 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #6 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #2 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #4 Circuit - Current Below Normal, or Open Circuit Coolant Temperature Sensor Circuit - Data Erratic, Intermittent, or Incorrect Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Above Normal, or Shorted to High Source Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Below Normal, or Shorted to Low Source
G6-42A, G9-43A, G10-43A
294
441
Amber
OEM Temperature
295 296 297
108 1388 1388
2 14 3
Amber Red Amber
Barometric Pressure Auxiliary Pressure Auxiliary Pressure
298
1388
Amber
Auxiliary Pressure
319 322 323 324 325 331 332 334 338
251 651 655 653 656 652 654 110 1267
2 5 5 5 5 5 5 2 3
Maint Amber Amber Amber Amber Amber Amber Amber Amber
Real Time Clock Power Injector Cylinder #01 Injector Cylinder #05 Injector Cylinder #03 Injector Cylinder #06 Injector Cylinder #02 Injector Cylinder #04 Engine Coolant Temperature Vehicle Accessories Relay Driver Vehicle Accessories Relay Driver
339
1267
Amber
9-72
Electrical System
Fault Codes 341 342 343
SPN Codes 630 630 629
FMI Codes 2 13 12
Lamp Color Amber Red Amber
SPN Description Calibration Memory Calibration Memory Controller #1
Cummins Description Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect Electronic Calibration Code Incompatibility - Out of Calibration Engine Control Module Warning internal hardware failure - Bad Intelligent Device or Component Transmission Output Shaft Speed - Data Valid but Above Normal Operational Range Moderately Severe Level Injector Power Supply - Bad Intelligent Device or Component Sensor Supply Voltage #1 Circuit - Voltage Below Normal, or Shorted to Low Source Sensor Supply Voltage #1 Circuit - Voltage Above Normal, or Shorted to High Source Oil Pressure Low - Data Valid but Below Normal Operational Range - Most Severe Level Water in Fuel Indicator High - Data Valid but Above Normal Operational Range - Least Severe Level Coolant Level - Data Erratic, Intermittent, or Incorrect Engine Oil Temperature - Data Erratic, Intermittent, or Incorrect Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to High Source Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Intermittent, or Incorrect Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect Battery #1 Voltage Low - Data Valid but Below Normal Operational Range - Moderately Severe Level
349
191
16
Amber
Transmission Output Shaft Speed Controller #1 5 Volts DC Supply 5 Volts DC Supply Engine Oil Pressure Water in Fuel Indicator Coolant Level Oil Temperature Water in Fuel Indicator Water in Fuel Indicator Accelerator Pedal Low Idle Switch Accelerator Pedal Low Idle Switch Engine Oil Pressure Electrical Potential (Voltage)
351 352 386 415 418
627 3509 3509 100 97
12 4 3 1 15
Amber Amber Amber Red Maint.
422 425 428 429 431 432 435 441
111 175 97 97 558 558 100 168
2 2 3 4 2 13 2 18
Amber Amber Amber Amber Amber Red Amber Amber
G6-42A, G9-43A, G10-43A
9-73
Electrical System
Fault Codes 442
SPN Codes 168
FMI Codes 16
Lamp Color Amber
SPN Description Electrical Potential (Voltage) Injector Metering Rail 1 Pressure Injector Metering Rail 1 Pressure Injector Metering Rail 1 Pressure Intake Manifold
Cummins Description Battery #1 Voltage High - Data Valid but Above Normal Operational Range - Moderately Severe Level Fuel Pressure High - Data Valid but Above Normal Operational Range - Moderately Severe Level Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Intake Manifold 1 Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level Transmission Output Shaft Speed - Data Valid but Below Normal Operational Range Moderately Severe Level AEB15.60 Page 151 of 157 Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or Incorrect OEM Intermediate (PTO) Speed switch Validation - Data Erratic, Intermittent, or Incorrect Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High Source Auxiliary Alternate Torque Validation Switch Data Erratic, Intermittent, or Incorrect Auxiliary Input/Output 3 Circuit - Voltage Above Normal, or Shorted to High Source Fuel Delivery Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Fuel Delivery Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Accelerator Pedal or Lever Idle Validation Circuit - Voltage Below Normal, or Shorted to Low Source Injector Metering Rail #1 Pressure High - Data Valid but Above Normal Operational Range Moderately Severe Level
449
157
Red
451
157
Amber
452
157
Amber
488
105
16
Amber
489
191
18
Amber
Transmission Output Shaft Speed Switch Circuit
497
1377
Amber
523
611
Amber
System Diagnostic code #1 Circuit - Voltage Switch - Data Circuit - Voltage Fuel Delivery Pressure Fuel Delivery Pressure Accelerator Pedal Low Idle Switch Injector Metering Rail 1 Pressure
527 528 529 546 547 551
702 93 703 94 94 558
3 2 3 3 4 4
Amber Amber Amber Amber Amber Amber
553
157
16
Amber
9-74
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 554 559
SPN Codes 157 157
FMI Codes 2 18
Lamp Color Amber Amber
SPN Description Injector Metering Rail 1 Pressure Injector Metering Rail 1 Pressure Starter Solenoid Lockout Relay Driver Circuit Starter Solenoid Lockout Relay Driver Circuit Turbocharger 1 Speed Alternate Potential (voltage) Alternate Potential (voltage) Alternate Potential (voltage) Engine External Protection Input Engine Oil Change Interval Turbocharger 1 Speed Engine Speed Turbocharger #1 Compressor Inlet Temperature Turbocharger #1 Compressor Inlet Temperature Sensor Circuit Voltage
Cummins Description Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect Injector Metering Rail #1 Pressure Low - Data Valid but Below Normal Operational Range Moderately Severe Level Starter Relay Circuit - Voltage Above Normal, or Shorted to High Source Starter Relay Circuit - Voltage Below Normal, or Shorted to Low Source Turbocharger #1 Speed High - Data Valid but Above Normal Operational Range - Moderately Severe Level Electrical Charging System Voltage High - Data Valid but Above Normal Operational Range Moderately Severe Level Electrical Charging System Voltage Low - Data Valid but Below Normal Operational Range Moderately Severe Level Electrical Charging System Voltage Low - Data Valid but Below Normal Operational Range Most Severe Level Auxiliary Commanded Dual Output Shutdown Special Instructions Change Lubricating Oil and Filter - Condition Exists Turbocharger #1 Speed Low - Data Valid but Below Normal Operational Range - Moderately Severe Level Primary Engine Speed Sensor Error - Data Erratic, Intermittent, or Incorrect Turbocharger #1 Compressor Inlet Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source Turbocharger #1 Compressor Inlet Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source ECM Internal Temperature Sensor Circuit Voltage Above Normal, or Shorted to High Source 9-75
584
677
Amber
585
677
Amber
595
103
16
Amber
596
167
16
Amber
597
167
18
Amber
598
167
Red
599 649 687
640 1378 103
14 31 18
Red Maint Amber
689 691
190 1172
2 3
Amber Amber
692
1172
Amber
697
1136
Amber
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 698
SPN Codes 1136
FMI Codes 4
Lamp Color Amber
SPN Description Sensor Circuit Voltage Crankcase Pressure
Cummins Description ECM Internal Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low Source AEB15.60 Page 152 of 157 Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal, or Shorted to High Source Extended Crankcase Blow-by Pressure Circuit Voltage Below Normal, or Shorted to Low Source Engine Speed/Position #2 mechanical misalignment between camshaft and crankshaft sensors - Mechanical System Not Responding Properly or Out of Adjustment Electronic Control Module data lost - Condition Exists Engine Speed Sensor (Camshaft) Error - Data Erratic, Intermittent, or Incorrect Warning Auxiliary Equipment Sensor Input #3 (OEM Switch) - Root Cause Not Known Cylinder Power Imbalance Between Cylinders Data Erratic, Intermittent, or Incorrect Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect Injector Cylinder #1 - Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder #2 - Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder #3 - Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder #4 - Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder #5 - Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder #6 - Mechanical System Not Responding Properly or Out of Adjustment Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Above Normal, or Shorted to High Source
719
22
Amber
729
22
Amber
Crankcase Pressure
731
723
Amber
Engine Speed Sensor #2
757
2802
31
Amber
Electronic Control Module Engine Speed Sensor #2 Auxiliary Equipment Sensor Input Cylinder Power Power Supply Injector Cylinder #01 Injector Cylinder #02 Injector Cylinder #03 Injector Cylinder #04 Injector Cylinder #05 Injector Cylinder #06 Accelerator Pedal Position
778 779 951 1117 1139 1141 1142 1143 1144 1145 1239
723 703 166 627 651 652 653 654 655 656 2623
2 11 2 2 7 7 7 7 7 7 3
Amber Amber None None Amber Amber Amber Amber Amber Amber Amber
9-76
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 1241
SPN Codes 2623
FMI Codes 4
Lamp Color Amber
SPN Description Accelerator Pedal Position Accelerator Pedal Position Control Module Identification Input State Control Module Identification Input State Water in Fuel Indicator Injector Metering Rail Coolant Temperature Coolant Temperature Coolant Temperature
Cummins Description Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Below Normal, or Shorted to Low Source Accelerator Pedal or Lever Position Sensor 1 and 2 - Data Erratic, Intermittent, or Incorrect Control Module Identification Input State Error Data Erratic, Intermittent, or Incorrect Control Module Identification Input State Error Data Erratic, Intermittent, or Incorrect Water in Fuel Indicator - Data Valid but Above Normal Operational Range - Moderately Severe Level Injector Metering Rail 1 Pressure - Data Valid but Above Normal Operational Range - Most Severe Level Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted to High Source Coolant Temperature 2 Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Moderately Severe Level Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Most Severe Level Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted to High Source AEB15.60 Page 153 of 157 Coolant Pressure 2 Circuit - Voltage Below Normal, or Shorted to Low Source Coolant Pressure 2 - Data Valid but Below Normal Operational Range - Moderately Severe Level Engine Brake Actuator Driver 1 Circuit - Voltage Above Normal, or Shorted to High Source Engine Brake Actuator Driver 1 Circuit - Voltage Below Normal, or Shorted to Low Source Sensor Supply Voltage #4 Circuit - Voltage Above Normal, or Shorted to High Source 9-77
1242 1256
91 1563
2 2
Red Amber
1257
1563
Red
1852
97
16
Amber
1911
157
Amber
2111 2112 2113
52 52 52
3 4 16
Amber Amber Amber
2114 2115 2116
52 2981 2981
0 3 4
Red Amber Amber
Coolant Temperature Coolant Pressure Coolant Pressure
2117
2981
18
Amber
Coolant Pressure
2182 2183 2185
1072 1072 3512
3 4 3
Amber Amber Amber
Engine Brake Output #1 Engine Brake Output #1 System Diagnostic code #1
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 2186 2195 2215
SPN Codes 3512 703 94
FMI Codes 4 14 18
Lamp Color Amber Red Amber
SPN Description System Diagnostic code #1 Auxiliary Equipment Sensor Fuel Delivery Pressure Fuel Delivery Pressure Calibration Memory Injector Metering Rail 1 Pressure Fuel Delivery Pressure Fuel Delivery Pressure Battery Temperature
Cummins Description Sensor Supply Voltage #4 Circuit - Voltage Below Normal, or Shorted to Low Source Auxiliary Equipment Sensor Input 3 Engine Protection Critical - Special Instructions Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level ECM Program Memory (RAM) Corruption Condition Exists Injector Metering Rail 1 Pressure - Data Valid but Below Normal Operational Range - Most Severe Level Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational Range - Least Severe Level Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range - Least Severe Level Battery Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level Battery Temperature - Data Valid but Below Normal Operational Range - Moderately Severe Level Fuel Priming Pump Control Signal Circuit Voltage Above Normal, or Shorted to High Source Fuel Priming Pump Control Signal Circuit Voltage Below Normal, or Shorted to Low Source Fuel Inlet Meter Device - Data Valid but Above Normal Operational Range - Moderately Severe Level Fuel Inlet Meter Device flow demand lower than expected - Data Valid but Below Normal Operational Range - Moderately Severe Level Fueling Actuator #1 Circuit Error - Condition Exists
G6-42A, G9-43A, G10-43A
2216
94
Amber
2217 2249
630 157
31 1
Amber Amber
2261
94
15
Maint
2262
94
17
Maint
2263
1800
16
Amber
2264
1800
18
Amber
Battery Temperature
2265
1075
Amber
Electric Lift Pump for Engine Fuel Electric Lift Pump for Engine Fuel Fuel Inlet Meter Device Fuel Inlet Meter Device Fuel Control Valve #1
2266
1075
Amber
2292
611
16
Amber
2293
611
18
Amber
2311
633
31
Amber
9-78
Electrical System
Fault Codes 2321 2322 2345 2346
SPN Codes 190 723 103 2789
FMI Codes 2 2 10 15
Lamp Color None None Amber None
SPN Description Engine Speed Engine Speed Sensor #2 Turbocharger 1 Speed System Diagnostic Code #1 System Diagnostic Code #1 Engine Compression Brake Output #2 Engine Brake Output #3 Engine Compression Brake Output #2 Engine Brake Output #3 Engine Fuel Filter Differential Pressure Exhaust Gas Pressure Exhaust Gas Pressure Exhaust Gas Recirculation Temperature Exhaust Gas Recirculation Temperature Fan Clutch Output Device Driver Intake Air Heater #2 Intake Air Heater #2
Cummins Description Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect Turbocharger speed invalid rate of change detected - Abnormal Rate of Change Turbocharger Turbine Inlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level Turbocharger Compressor Outlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level Engine Brake Actuator Circuit #2 - Voltage Below Normal, or Shorted to Low Source Engine Brake Actuator Driver Output 3 Circuit Voltage Below Normal, or Shorted to Low Source Engine Brake Actuator Circuit #2 - Voltage Above Normal, or Shorted to High Source Engine Brake Actuator Driver 3 Circuit - Voltage Above Normal, or Shorted to High Source Fuel Filter Differential Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level Exhaust Gas Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Exhaust Gas Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Fan Control Circuit - Voltage Above Normal, or Shorted to High Source Intake Air Heater 2 Circuit - Voltage Below Normal, or Shorted to Low Source Intake Air Heater 2 Circuit - Voltage Above Normal, or Shorted to High Source 9-79
2347
2790
15
None
2363 2365
1073 1112
4 4
Amber Amber
2367 2368 2372
1073 1112 95
3 3 16
Amber Amber Amber
2373 2374 2375
1209 1209 412
3 4 3
Amber Amber Amber
2376
412
Amber
2377 2425 2426
647 730 730
3 4 3
Amber
G6-42A, G9-43A, G10-43A
Electrical System
Fault Codes 2555 2556 2557 2558 2963
SPN Codes 729 729 697 697 110
FMI Codes 3 4 3 4 15
Lamp Color Amber Amber Amber Amber None
SPN Description Inlet Air Heater Driver #1 Inlet Air Heater Driver #1 Auxiliary PWM Driver #1 Auxiliary PWM Driver #1 Engine Coolant Temperature Boost Pressure
Cummins Description Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source Auxiliary PWM Driver #1 - Voltage Above Normal, or Shorted to High Source Auxiliary PWM Driver #1 - Voltage Below Normal, or Shorted to Low Source Engine Coolant Temperature High - Data Valid but Above Normal Operational Range - Least Severe Level Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
2973
102
Amber
9-80
G6-42A, G9-43A, G10-43A
31200151
An Oshkosh Corporation Company
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417
JLG Worldwide Locations

JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Antonia Martins Luiz, 580 Distrito Industrial Joo Narezzi 13347-404 Indaiatuba - SP Brazil Phone: +55 19 3936 8870 Fax: +55 19 3935 2312 JLG Industries (UK) Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone: +44 (0)161 654 1000 Fax: +44 (0)161 654 1001 JLG Industries (Italia) s.r.l. Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: +39 029 359 5210 Fax: +39 029 359 5845 JLG France SAS Z.I. de Baulieu 47400 Fauillet France Phone: +33 (0)5 53 88 31 70 Fax: +33 (0)5 53 88 31 79
JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude-lhlpohl Germany Phone: +49 (0)421 69 350 20 Fax: +49 (0)421 69 350 45
JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N.T. Hong Kong Phone: +852 2639 5783 Fax: +852 2639 5797
JLG Europe B.V. Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone: +31 (0)23 565 5665 Fax: +31 (0)23 557 2493
JLG Polska UI. Krolewska 00-060 Warsawa Poland Phone: +48 (0)914 320 245 Fax: +48 (0)914 358 200
Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal, Barcelona Spain Phone: +34 93 772 4 700 Fax: +34 93 771 1762
JLG Sverige AB Enkopingsvagen 150 Box 704 SE - 176 27 Jarfalla Sweden Phone: +46 (0)850 659 500 Fax: +46 (0)850 659 534
www.jlg.com

G9 43A Service

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G9 43A Service

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Service Manual

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

An Oshkosh Corporation Company

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

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

Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Section 1 Safety Practices

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

DO NOT OPERATE TAGS

Safety Alert System and Signal Words

OPERATION & SAFETY MANUAL

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

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

Safety Practices 1.6.4 Operational Hazards

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

Section 2 General Information and Specifications

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

General Information and Specifications

REPLACEMENT PARTS AND WARRANTY INFORMATION

DO NOT GO NEAR LEAKS

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

General Information and Specifications

Values for Zinc Yellow Chromate Fasteners

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N

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

Values for Zinc Yellow Chromate Fasteners

Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 K=.18

Torque Loctite 262 OR Vibra-TITE 131 K=0.15

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

SOCKET HEAD CAP SCREWS

Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 OR Precoat 85 K=0.16

Torque Loctite 262 OR Vibra-TITE 131 K=0.15

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

SOCKET HEAD CAP SCREWS

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

General Information and Specifications 2.2.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners

Tensile Stress Area

Torque (Dry or Loctite 263TM)

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

Values for Zinc Yellow Chromate Fasteners

Tensile Stress Area

Torque Dry or Loctite 263

Torque Loctite 262 OR Vibra-TITE 131

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

Tensile Stress Area

Clamp Load See Note 4