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1. BEACON WORKLIGHTS OPTIONS WORKLIGHT 2 OPTIONS VEC BEACON SEU K MET WIES pw 1 AUX ELECTRICS crm p paca Cen boue 2 2 foom cr er pomer lt e noue ir INE F pene crew ae rene lt creme 1 n i n Bonur lt swiss worker el J 1 BO s CA TOND capitan 1 e casir ono pper SESS 1 a T T ato pa raana 2 42 amn l 1 2 coo se 4 E UEIXIIIFM UEXNXXIXT a loc n LESE usse DASH BLOWER HEATER BE eg cq vu us SEES 29 Silsila 9 ak Ill bg 668 Edge E rd Al 2 A 5555 an en iuge gt ELECTRIC ied z OPTION rali EH Y Y
2. MAL1290 Note Disconnecting one or both extend retract hydraulic tubes 9 may be required to gain access to the hose guide mounting bolts After removing both hose guides re connect one or both extend retract hydraulic tubes BEFORE proceeding 10 Loosen and remove the tilt cylinder hose guide 10 and if equipped the auxiliary hose guide from the rear of the third second section Note The hose guide mounting bolts also hold the push pin beams in place 11 Remove the left and right push beam pins 11 12 Start the machine and SLOWLY extend the extend retract cylinder 1 2 ft 305 609 mm or until the push beam assembly can be accessed through the front of the third boom section Note Only the push beam extend retract cylinder assembly should move during this procedure The extend chain rod will move toward the front of boom Do Not allow the rod to come into contact with the chain and or chain roller 13 Shut machine OFF 14 Properly disconnect the battery 3 17 Cy 9 930 15 Loosen and remove four bolts 12 guide bar 13 and chain retainer 14 from front of push beam 16 Disconnect extend
3. Bu Boom 3 5 BOOM SECTION 4 Slowly loosen and remove the extend retract REMOVAL INSTALLATION cylinder counterbalance valve 3 Plug M27x1 5 open port on extend retract cylinder to prevent dirt debris from entering hydraulic system 3 5 1 Second and Third Boom Section Removal 5 Remove retaining clips from extend retract cylinder mounting pin 4 remove extend retract cylinder pin Nate 22 zr 6 Remove four mounting bolts securing the strong Temporary Brackets for diagrams of the Temporary back 5 to the first boom section Extend Bracket and Temporary Retract Bracket designed to hold the chains place on the push beam 7 Remove strong back 5 from rear of boom during disassembly and reassembly 8 Remove right or left side wear pads shims and These brackets are NOT a purchasable part and must be backing plates 6 from rear of second boom section manufactured locally Label and tag each set of wear pads being removed They are solely designed to aid in the removal and 9 Remove the top wear pads shims and backing installation of the push beam assembly plates 7 from the rear of the second boom section Label and tag each set of wear pads being removed Note Refer to Section 8 8 Hydraulic Cyl
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6. 2 3 TORQUE CHARTS 2 3 1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Tensil T T L 271 poles Size TPI BoltDia e Areal Load Dry Loctite 2627 or 111 or 140 Vibra TITE 131 In Sq In LB IN LB N m IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 380 8 0 9 6 0 7 48 0 1120 0 00661 420 9 1 0 7 0 8 6 32 0 1380 0 00909 580 16 1 8 12 1 4 40 0 1380 0 01015 610 18 2 0 13 1 5 8 32 0 1640 0 01400 900 30 34 22 2 5 36 0 1640 0 01474 940 31 3 5 23 2 6 10 24 0 1900 0 01750 1120 43 4 8 32 3 5 32 0 1900 0 02000 1285 49 5 5 36 4 1 4 20 0 2500 0 0318 2020 96 10 8 75 9 105 12 28 0 2500 0 0364 2320 120 13 5 86 10 135 15 Sq In LB FT LB N m FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 3340 17 23 18 18 19 26 16 22 24 0 3125 0 0580 3700 19 26 14 19 21 29 17 23 3 8 16 0 3750 0 0775 4940 30 41 23 31 35 48 28 38 24 0 3750 0 0878 5600 35 47 25 34 40 54 32 43 7 16 14 0 4375 0 1063 6800 50 68 35 47 55 75 45 61 20 0 4375 0 1187 7550 55 75 40 54 60 82 50 68 1 2 13 0 5000 0 1419 9050 75 102 55 75 85 116 68 92 20 0 5000 0 1599 10700 90 122 65 88 100 136 80 108 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 1338 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 14
7. oni sw sung r3 HARE EELE Live i NI H31VM uyg EEE g 3 5 3 mw H E TE BE 5 Bee allel HAE BE Be SRAAAA RR RS ii sirr rT rid 7920 DIAGNOSTIC 9 12 G6 42A G9 43A G10 43A Electrical System ine Schematic if equipped for LS Eng 9 5 6 PUMP DISPLACEMENT MODULE TRANS SOLY3 16 TRANS SOLYS 16 E p g ALTERNATOR 38 En aq 46 TES me lt BLOCK GROUND I 3 O E BRN TRANS 85 e le le 6 6 I sie MO PK BRK SOL 214 BLKENG GND 16 p BLKENG bb BE BLK ENG GND iove x muco
8. 8 11 AUXILIARY i 1 HYDRAULICS ME 1 PORTS PEE o MERE TILT CYLINDER eae ps p H fj 1 c T i 4 lee ee ILE l 81 E i A MAIN CONTROL i B3 VALVE len ip Bl NN E 38 EJ COMPENSATING EM 1 ER 1 E EP Pes CYLINDER 1 poni pose Err Reever L m decre Wes Deos L en E P e AUXILIARY HYDRAULICS OPTION eH 1 1 1 y 1 1 1 1 AE M LG D E M CC CU 1 1 a 5 i ___ _ fis is Ps i MAIN CONTROL p 5 1 5 5 4 VALVE ag N E E EJ 3 i Ez gt i i 1 n iow rr 1 4 EG H HYDRAULIC 8 COOLER 1 Cg STABILIZER a Dee 1 i VALVE CREE Ei E MAN BLOCK VALVE RETURN amp gt X
9. 9 17717 10 8 9 7800 14 Label disconnect and hose attached to coolant surge tank 7 Remove coolant surge tank and mounting plate 15 Loosen clamps on both hoses attached to charge air cooler 8 Work hoses and tubes off charge air cooler Position hoses and tubes out of way to allow radiator removal or remove hoses and tubes from engine Plug and or cap openings on charge air cooler and tubes to prevent dirt and debris from entering system 16 Loosen clamps on both hoses attached to radiator 9 Work hoses off radiator Position hoses out of way to allow radiator removal or remove hoses from engine Inspect hoses and replace if necessary Plug and or cap openings on radiator and hoses to prevent dirt and debris from entering system 17 Place a suitable container beneath transmission cooler fittings Transfer any transmission oil into properly labeled container Dispose of properly G6 42A G9 43A G10 43A 18 Label disconnect and cap both transmission cooler hoses at radiator 10 Cap fittings and openings to prevent dirt and debris from entering transmission 19 Remove fan guard 11 20 Loosen and remove bolts from radiator fan shroud 12 Pull fan shroud back and over fan assembly 21 Carefully lift and remove radiator assembly Note If more clearance is needed to remove radiator engine fan may be removed for easier a
10. Fault SPN FMI Lamp SPN m Codes Codes Codes Color Description Cummins 2321 190 2 None Engine Speed Engine Speed Position Sensor 1 Data Erratic Intermittent or Incorrect 2322 723 2 None Engine Speed Engine Speed Position Sensor 2 Data Erratic Sensor 2 Intermittent or Incorrect 2349 2791 5 Amber Not Available EGR Valve Control Circuit Current below normal or open circuit 2353 2791 6 EGR Valve Control Circuit Current above normal or grounded circuit 2357 2791 7 Amber Not Available EGR Valve Control Circuit Mechanical system not responding or out of adjustment Fuel Filter Differential Pressure Data Valid But 2372 95 16 Above Normal Operating Range Moderately Severe Level Exhaust Gas Exhaust Gas Pressure Sensor Circuit Voltage a ANDET Pressure Above Normal or Shorted to High Source Exhaust Gas Exhaust Gas Pressure Sensor Circuit Voltage d 1299 i Amber Pressure Below Normal or Shorted to Low Source 2 Exhaust Gas Recirculation EGR Temperature 2375 412 3 Amber EGR Sensor Circuit Voltage Above Normal or Shorted to High Source Temperature Exhaust Gas Recirculation EGR Temperature 2376 412 4 Amber EGR Sensor Circuit Voltage Below Normal or Shorted to Low Source Temperature Fan Clutch aa 2377 647 3 Amber Output Device Fan Control Circuit Voltage Above Normal or Shorted to High Source Driver Amber 2448 111 17 Blink Coolant Leve
11. MY3890 Remove right or left side wear pads shims backing plates 9 from rear of third boom section Label and tag each set of wear pads being removed Remove the top wear pads shims and backing plates 10 from rear of third boom section Label and tag each set of wear pads being removed Place a suitable sling around the third boom section Slowly pull the third boom section approximately 25 out of the second boom section Lower the third boom section onto a suitable support 10 11 12 MY3870 LIT LIT Remove all wear pads shims and backing plates 11 from front inside of second boom section Label and tag each set of wear pads being removed Remove wear pad mounting plates 12 from front inside of second boom section Relocate sling or using two slings for better stability balance third boom section and slowly pull third boon section out of second boom section Lower third boom section onto suitable supports G6 42A G9 43A G10 43A Pe 3 5 3 Push Beam Extend Retract Cylinder Removal A CAUTION The complete push beam assembly weighs over 1 200 Ib 545 kg 13 MY4060 5 57 5 9 14 17 16 15 1 Loosen the Temporary Extend Chain Retention Bracke
12. 14 m G6 42A IIO a 15 H Lb IH MN AI E ees call pacer yo qH Note Note position of belleville washers for reassembly MAL2660 3 19 al Boom 16 Install the belleville washers 13 to the extend chain anchor 14 as previously removed at the rear of the first boom section 17 Install adjustment and lock nut 15 to extend chain anchor 14 at the rear of first boom section G6 42A G9 43A G10 43A 18 17 MAL2670 18 Remove the rope or wire from the retract chain 16 19 Install the belleville washers 17 to the retract chain clevis 16 as previously removed at the bottom front of the first boom section 20 Install adjustment and lock nut 18 to retract chain clevis 16 at bottom front of first boom section Note Note position of belleville washer for reassembly 20 19 21 Install both hose retainer brackets 19 22 Remove the plugs and caps from the tilt hoses and auxiliary hoses 23 Connect both tilt hoses 20 and both auxiliary hoses not shown to the hose retainer brackets 19 at the bottom front inside the boom MAL1310 24 Properly conne
13. 8 16 8 7 Control erem ES 8 17 8 8 Hydraulic Cylinders 1 8 23 ii G6 42A G9 43A G10 43A Section Subject Page Section 9 Electrical Systemi oe uc csc anc D D ew D OO ue 9 1 9 1 Electrical Component Terminology 9 3 9 2 Specifications i scettr peser Eun E Eom d n ee Dade a RP eee 9 5 9 3 Safety Information 1 2 0 2 9 5 9 4 Fuses and Relays 2 2222 eue Rus aene ORUM 9 5 9 5 Electrical System Schematics 4 9 8 9 6 Engine Start Circuit 9 14 9 7 Charging Circuit 5 ges belt 9 15 9 8 Window Wiper Washer Windshield Wiper 9 17 9 9 Fan eniak embed ebd d dd detiene 9 19 9 10 Solenoids Sensors and 9 20 9 11 Display Gauge and Dash 9 24 9 12 Hand Held Analyzer G9 43A 6110 4 9 27 9 13 SAE Diagnostic Trouble and Fault 9 38 G6 42A G9 43A G10 43A
14. SYNLONYLS H3ZAIVNV JINON 1OH LNOO AN3IN3OV IdSIG dAINd HNL dnjes nual ssald uoneanByuoo uodn Burpuedep jou sueeJos esee d e qissod swous eu uonezuouine pue 1 sseooy uoneiqijeo 1deoxe e pue jjnejop S sseooy sBumes e npo N 2 10 sseooy eu G6 42A G9 43A G10 43A 9 36 Electrical System a Pump Fault Codes DTC Event Comment Latched 211 Power Cycle 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 No 33427 Anti Stall Valve Open Circuit Anti stall digital output was open circuit 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 75 Normal operation will resume when issue is resolved Yes 33426 Anti Stall Valve Short to Battery The anti stall digital output was shorted to battery This fault may be caused by improper wiring or a control module issue
15. coor Pus ET zi s ias P ek ENCLOSED CAB ROOF WIPER e OPTION MOTOR 55 DEAN PWR D FAN PWR AA ba eaen pim lt lt an T 28 Es EH SESS 1 mascots Truce T B 8 11 wry EN a Aa INNER 1 AIC SWITCH RESISTOR LOCATED TT 2 APPROX 10 BEHIND HEATER TEMP SWITCH 4 ul ENCLOSED CAB 3 RLY 67 OPTIONS HARNESS 21 x 1 CONDENSER FANS ROOF a ay MA THERMOSTATIC SWITCH A C PRESSURE SWITCH See D e3 5 EE TE 1 cor 1 dela 28 588559 Y vv 7717 OPTIONS HARNESS 1001112039 TO CONNECTOR 3 SHEETS 3 4 lt pi 9 lt lt J Electrical System Accessory Module Schematic G9 43A amp G10 43A 9 5 3
16. i M P is 15 Between bottom front of first and second boom sections feed a rope or wire to both tilt hoses not shown and if equipped both auxiliary hoses and secure to the second or third boom section 16 Place a suitable sling around the second boom section Slowly pull the second and third boom sections approximately 25 out of the first boom section Lower the second and third boom sections onto a suitable support CIT 12 13 12 Tf MY3840 17 Remove all wear pads shims and backing plates 12 from the front inside of the first boom section Label and tag each set of wear pads being removed 18 Remove the top and bottom mounting plates 13 from the front inside of the first boom section Label and tag each mounting plate being removed 19 Relocate sling or using two slings for better stability balance two boom sections and slowly pull them out of first boom section being careful not to damage hydraulic hoses or chains Lower second and third boom sections onto suitable supports G6 42A G9 43A G10 43A 3 5 2 Third Boom Section Removal omr MY3880 1 Loosen and remove the tilt cylinder hose guide 1 and if equipped the auxiliary hose guide from the rear of the third second section Note The hose guide mounting
17. 0 8 20 8 7 4 Steering Orbitrol Valve 8 21 8 7 5 Steer Select 8 21 8 7 6 Outrigger Valve 910 4 8 22 8 8 Hydraulic 8 23 8 8 1 General Cylinder Removal 8 23 8 8 2 Cylinder Pressure 0 8 25 8 8 3 Steering 8 25 8 8 4 Cylinder Torque Specifications G6 42A 8 26 8 8 5 Cylinder Torque Specifications G9 43A amp 510 4 8 27 G6 42A G9 43A G10 43A Hydraulic System 81 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 8 1 1 G6 42A Components EXTEND RETRACT CYLINDER INSIDE BOOM LIFT LOWER CYLINDER TILT CYLINDER HYDRAULIC FLUID RESERVOIR PRIORITY MAIN CONTROL VALVE MY8090 COMPENSATION CYLINDER 8 2 G6 42A G9 43A G10 43A
18. 3 18 3 8 Boom 3 20 3 8 1 Chain Tension Inspection G6 42A 3 20 3 8 2 Chain Tension Adjustment G6 42A 3 21 3 8 3 Chain Tension Inspection 49 43 010 4 3 23 3 8 4 Chain Tension Adjustment G9 43A G10 43A 3 23 G6 42A G9 43A G10 43A 3 1 3 2 3 9 3 10 3 11 3 12 3 13 3 14 3 15 Quick Switch 3 25 3 9 1 Hydraulic Quick Switch Removal 3 25 3 9 2 Quick Switch Removal 3 26 3 9 3 Quick Switch 1 3 26 Boom Wear Pads ec AA 3 26 3 10 1 Wear Pad 3 26 3 10 2 Wear Pad Installation and Lubrication 3 26 3 10 3 Section Wear Pad Pathway Lubrication 3 27 Boom Extend and 3 28 3 11 1 Boom Chain 3 28 3 11 2 Expose Chains for 3 28 3 11 3 Inspection Guidelines 3 29 3 11 4 Chain Lubricat
19. 1 Remove extend chain lock nut 1 and loosen adjustment nut 2 until belleville washers 3 are free to turn on extend rod 2 Verify the belleville washers 3 are in the correct order as shown Remove the extend chain adjustment nut 2 and correct if required 3 23 Ge Boom A i 3 Remove lock nut 4 from retract chain clevis 5 4 Set the retract chain adjustment nut face 6 flush with the end of the retract clevis 5 Verify the belleville washers 7 are in the correct order as shown Remove the retract chain adjustment nut 6 and correct if required Note Belleville washers shown the un compressed state O MAL2740 6 If dimension is greater than 17 000 in 421 8 mm push the third section boom IN until dimension A is less than 17 000 in 421 8 mm 3 24 MAL2580 C i 7 With dimension A less than 17 000 in 421 8 mm 11 12 8 verify the extend rod Belleville washers and retract chain Belleville washers are loose Tighten the extend chain rod adjusting nut 2 until dimension A is 17 438 17 562 in 443 0 446 1 mm Install and temporarily tighten the extend chain lock nut 1 A o z SS UA Tighten the retract chain adjustment nut 6 until the bel
20. Bide ule wed doe LONG 3 1 3 1 Boom System Component 3 3 3 2 Boom System Three 3 4 3 8 Boom Assembly 3 4 3 4 Complete Boom Removal Installation 3 5 3 5 Boom Section 3 6 3 6 Extend Retract Chain 3 15 3 7 Push Beam Extend Retract Cylinder 3 16 3 8 Boom 3 20 3 9 Quick Switch 2 3 25 3 10 Boom Wear Pads cor be exe eee nto tees 3 26 3 11 Boom Extend and Retract 3 28 3 12 ei rtis S pd nati A OE r acit ola Ebo uta 3 31 3 13 Emergency Boom Lowering 3 31 3 14 Troubleshooting instr 3 34 3 15 Push Beam Temporary 3 37 Section 4 Cab and issu oe ade hx ark uk C aa DO d ca e i 4 1 4 1 Operator Cab and Covers Component Terminology
21. 2 14 2 4 1 Travel Speeds 22222 41 aa ecc dug 2 14 2 4 2 Hydraulic Cylinder 2 14 2 4 3 Electrical SystemEngine System 2 16 2 4 4 Engine Specifications 2 16 2 4 5 BH UT 2 17 2 5 Fluid and Lubricant Capacities 2 18 2 5 1 Fluids if Equipped for ULS 2 18 2 5 2 Fluids if Equipped for 15 2 19 2 5 3 lt Ru Stee 2 20 2 6 Service and Maintenance Schedule 2 21 2 6 1 10 1st 50 amp 50 1 2 21 2 6 2 1st 250 250 amp 500 2 22 2 6 3 1000 1500 amp 2000 2 23 2 7 Lubrication 2 24 2 7 1 DO HOU s sss duh DERE 2 24 2 7 2 250 HOU iat sie ERR a eR 2 25 2 7 3 1000 PR 2 26 G6 42A G9 43A G10 43A 2 1 4 General Information and Specifications 2 1 REPLACEMENT PARTS AND WARRANTY INFORMATION MY8100 Before ordering parts or initiating service inquiries make note of th
22. Aux Hyd Roller The the technician will release the auxiliary hydraulic roller and press Center the ENTER key to confirm Calibrations The control system will display this message to advise that the Complete procedure was successful The technician will press the ESC key to leave this menu Calibrations The control system will display this message to advise that the Failed procedure was unsuccessful The technician will press the ESC key to leave this menu 9 30 G6 42A G9 43A G10 43A Electrical System c Joystick Fault Codes Neutral Disagreement The auxiliary joystick s 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 096 closed beyond 25 DTC Event Comment Latched 211 Power Cycle No motion restrictions No 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 2127 Aux Joystick Not In Neutral Auxiliary Hydraulic A amp B prevented No Position At Power Up The auxiliary hydraulic joystick must be in the neutral position
23. X 4 5 GiGi a A 88 EA S uo 74 e TURBOCHARGER THERMOSTAT IF EQUIPPED FOR ULS ALTERNATOR G6 42A G9 43A G10 43A Engine IF EQUIPPED FOR LS TURBOCHARGER THERMOSTAT OIL FILTER FUEL FILTER SECONDARY STARTER tr p zs 2 2 ALTERNATOR MY7960 G6 42A G9 43A G10 43A Engine 7 2 ENGINE COOLING SYSTEM 7 2 1 A 17 4 psi 1 2 Bar cap is used on the surge tank An incorrect or malfunctioning cap can result in the loss of coolant and a hot running engine Surge Tank Cap 7 2 2 Before considering thermostat replacement check the coolant level fan belt tension and instrument cluster temperature indicator Thermostat Replacement f engine seems to take a long time to warm up thermostat may be stuck in open position and requires replacement f engine runs hot check temperature of upper radiator hose f hose is not hot thermostat may be stuck in closed position f 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 Thermostat Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parki
24. 4 2 4 2 Operator Cab 4 4 4 3 Cab Components Ria eas Ee ea banked sods Gane 4 4 4 4 Cabs Removals 42 20 epp E eR ER eR Bee eects oi Noted 4 10 4 5 Installation ved cure gel wy ee Ae pew dw eeu dee ies 4 11 G6 42A G9 43A G10 43A i Section Subject Page Section 5 Axles Drive Shafts Wheels and 5 1 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 2 Axle Serial Number 5 4 5 3 Axle Specifications And Maintenance 5 4 5 4 Axle 5 4 5 5 Diive Shafts t roa e cor CAE se 5 9 5 6 Wheels 5 10 5 7 PME 5 11 5 8 Towing a Disabled 5 12 Section 6 TRANSMISSION 2 brach Ac dde dra kc Og 6 1 6 1 Transmission Assembly Component 6 2 6 2 Transmission Serial 6 3 6 3 Transmission Specifications And Maintenance 6 3 6 4 Tra
25. The control module s 5V reference was measured greater than 5 4V or less than 4 6V for 100085 Since this reference voltage supplies the joystick s fork tilt and auxiliary hydraulic functions must be prevented Low Side Fault Relay de energized 9 34 G6 42A G9 43A G10 43A Electrical System DTC Event Comment Latched 998 Eeprom Failure Check All Settings Fork Tilt Up amp Down Auxiliary Hydraulics amp De Clutch 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 amp Down prevented The joystick calibration has never been performed is improper or calibration attempt has failed Re calibrate the Fork Tilt and Auxiliary Hydraulic optional joysticks to clear this fault Auxiliary Hydraulics prevented if Machine Setup s AUX HYDRAULIC is ENABLED No 23100 Auxiliary Hydraulic Joystick Voltage Disagreement Auxiliary Hydraulic A amp B prevented Analog feedback from the joystick s auxiliary roller did not agree within 25 for 1000mS Auxiliary Hydraulics will be prevented until the next power cycle This fault may be caused by a joystick issue improper wiring or a control module
26. XINO 7 01 69 NO NOILdO NOISS3A 3ATVA TIVLS LENV WIOAHSS3H i AAAA W a EY 1 3dIS dWnd mir re 8 3 p gt 1 Pis 15 n preseg f Ate 4 Poesy N Ih 1 1 a a ry T saoz 1 E oy Ns JH 79 eel Sa s XE la d sr x ha SIS 29 TIVLS LLNV G6 42A G9 43A G10 43A MY8060 8 14 Hydraulic System 8 5 HYDRAULIC RESERVOIR 1 MY7850 The hydraulic reservoir 1 is located on frame between engine compartment and cab 8 5 1 1 Park machine on a firm level surface level machine fully retract the boom lower boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Hydraulic Oil Reservoir Draining 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery Note If equipped with extreme cold weather components the hydraulic oil heating element must be removed to drain the hydraulic tank 5 Remove drain plug 2 on hydraulic oil reservoir and drain hydraulic oil into a
27. If starter only clicks it may indicate that battery is discharged or that there is a loose or corroded battery cable connection Check battery state of charge and battery condition first then check cables and cable connections Foradditional information on the starting circuit refer to Section 9 5 Electrical System Schematics Check starter lockout relay Section 9 4 1 Engine Compartment Starter Removal Park machine on a firm level surface level machine fully retract the boom lower the boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open engine cover Allow system fluids to cool Properly disconnect the battery Remove wires from the solenoid stud Remove positive battery cable from starter Label and disconnect wire from starter solenoid housing stud Record how wires are installed to ensure correct installation later Loosen but DO NOT remove fasteners securing starter to flywheel housing Support starter securely as it is relatively heavy and will fall if not supported Support starter and remove fasteners securing starter to engine Remove negative ground cable Remove starter from machine Starter Installation Position the starter in its mounting opening on flywheel housing Install negative ground cable to starte
28. 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 Adda diesel fuel emulsifying agent to the tank Refer to the manufacturer s 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 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 lf a leak is suspected in the fuel tank contact JLG Service Department Engine Inspect the fuel tank thoroughly for any cracks slices leaks or other damage 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
29. 1 WH LOQHLS AAZATWNW IOWLNOO uodn Buipuedep eq jou sueeJos ejou esee d sueaJos Jez eue e qissod swous eu 270N pue ypa LAZEE 18497 sseooy 1deoxe 0 sseooe pue S sseooy sBumes 10 Ajunoes NUAN A97 sseooy eu G6 42A G9 43A G10 43A 9 28 Electrical System a Personality Settings MENU MIN MAX DEFAULT Fork Tilt ACCEL UP x xS 0 0 5 0 0 1 DECEL UP x xS 0 0 5 0 0 3 ACCEL DOWN x xS 0 0 5 0 0 1 DECEL DOWN x xS 0 0 5 0 0 3 MIN UP xxxmA 100 1000 300 MAX UP xxxmA 500 1700 1100 MIN DOWN xxxmA 100 1000 300 MAX DOWN xxxmA 500 1700 1100 AUX FUNCTION ACCEL COILA x xS 0 0 5 0 0 1 DECEL COILA x xS 0 0 5 0 0 3 ACCEL COILB x xS 0 0 5 0 0 1 DECEL COILB x xS 0 0 5 0 0 3 MIN COILB xxxmA 100 1000 300 MAX COILA xxxmA 500 1700 1100 MIN COILB xxxmA 100 1000 300 MAX COILB xxxmA 500 1700 1100 G6 42A G9 43A G10 43A 9 29 Electrical System b Tilt Auxiliary Calibration Menu Aux Hydraulic MENU SUB MENU COMMENT Cal Fork Tilt The technician will press the ENTER key
30. 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 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 service brake Refer to Section 8 4 1 Hydraulic Pressures 8 7 4 Steering Orbitrol Valve 20370 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 8 7 5 Steer Select Valve MY0350 The machine can be used in the front wheel four wheel
31. G6 42A G9 43A G10 43A 7 6 2 Air Cleaner Assembly Installation ULS Note Apply Loctite 2427 the capscrew threads before installation Install the air cleaner assembly 3 to mounting bracket 6 with previously removed hardware 7 Install mounting bracket onto cab with previously removed hardware 5 Place loosened clamp 1 over air intake elbow 2 and install elbow on air cleaner assembly Adjust and tighten the clamp Connect sensor 4 Properly connect the battery Close and secure the engine cover Remove Do Not Operate Tags from both ignition key switch and steering wheel 7 13 Engine 7 6 3 1 Air Cleaner Assembly Removal LS Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in N NEUTRAL position engage parking brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel Open engine cover Allow system fluids to cool Properly disconnect battery MY8190 Remove clamp 8 securing air intake elbow 9 to air cleaner assembly 10 Remove two capscrews 11 securing mounting bracket 12 to cab Remove air cleaner assembly Remove capscrews 13 securing mounting bracket to air cleaner assembly Remove mounting bracket 7 14 7 6 4 Air Cleaner Assembly Installation LS Note Apply Loctite 2427
32. SPARE BATTERY POR ENGINE ECU BAT PHA FIG 10 STEERISWAY 5 PLUGGED Fr iux AXE riz isa KEY BATTERY PLUGGED Eris oPtions rowers MAST Fu 208 OPTIONS FOWER Y SIDESHIFT ris 2 OPTIONS FORER T Fig 20 OPTIONS POWER AUX ELEC GND SWING EXTRA RED YEL BLU ORG vov 040 MY7910 G6 42A G9 43A G10 43A 9 11 9 5 5 Engine Schematic if equipped for ULS Electrical System moreno presune PUMP DISPLACEMENT MODULE 3 emu 1 TO CHASSIS 5 _ Pini SNP Bu E 22 2 2 BEES 8 SERA 3 Ta UR EERE Bk m d H Po HE OE E ERE a OBS D FER EE B EE BEE FEE 5 a i 8 8 23 H act ii i5 B WO3 le ASA
33. 13 Properly connect battery 14 Run engine to operating temperature Visually check for leaks with engine running Check coolant level in overflow bottle and fill or drain as necessary 15 Close and secure engine cover 16 Remove Do Not Operate Tags from both ignition key switch and steering wheel 7 3 ENGINE ELECTRICAL SYSTEM The engine electrical system including the starter alternator and primary wiring is described in Section 9 5 Electrical System Schematics 7 4 FUEL SYSTEM 7 4 1 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 Diesel Fuel 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 exce
34. 3 Open engine cover Allow system fluids to cool 4 Properly disconnect battery 5 Remove the cover over the outrigger valve 10070 6 Label disconnect and cap the hydraulic hoses connected to the outrigger control valve 5 Cap all fittings to keep dirt amp debris from entering the hydraulic system G6 42A G9 43A G10 43A Hydraulic System n Remove the bolts holding the outrigger control valve to the frame Outrigger Valve Installation 1 Install the outrigger valve onto the machine frame Uncap and connect the previously labeled hydraulic hoses to the outrigger valve 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 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 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 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel
35. 3 9 QUICK SWITCH ASSEMBLY 3 9 1 Hydraulic Quick Switch Removal 12 MY7390 1 Remove hardware securing cylinder cover 15 and remove cylinder cover 2 Remove clamp hardware 16 securing cylinder cover to hydraulic hoses 17 3 Label and disconnect hydraulic hoses 17 attached to quick switch assembly 10 Drain fluid into suitable container 4 Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system G6 42A G9 43A G10 43A Remove lock bolt 8 holding tilt cylinder rod end pin 9 to quick switch assembly 10 Remove tilt cylinder rod end pin Support quick switch assembly 10 Remove capscrew 11 and locknut 12 securing head pin 13 to boom head 14 Remove the head pin 13 and the quick switch assembly 10 Inspect above pins for nicks or surface corrosion Use fine emery cloth to fix minor nicks or corrosion If damaged or if it cannot be repaired pin must be replaced Hydraulic Quick Switch Installation Assemble quick switch assembly 10 to boom head 14 Line up quick switch between mounts on boom head The quick switch should be centered in the boom head Coat head pin 13 with an anti seize compound Insert head pin through quick switch and boom head Secure with capscrew 11 and locknut 12 Align quick switch with tilt cylinder rod end and insert tilt cylinder rod end pin 9 Align tilt cylinder rod end pin and scre
36. 4 3 COMPONENTS 4 3 1 Steering Column and Orbitrol Valve a Orbitrol Valve Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL position engage parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover Allow the system fluids to cool 4 Properly disconnect the battery Note It may be necessary to remove the main dash panel to gain access to the appropriate hydraulic hoses Refer to Section 9 12 1 Gauges 5 Label disconnect and cap four hoses from side of steering valve 1 Cap fittings on steering valve Label disconnect and plug load sense hose at front of steering valve Cap fitting on steering valve 6 Remove the steering wheel 2 7 Disconnect and remove the transmission control lever 3 8 Remove the steering assembly through dash panel opening G6 42A G9 43A G10 43A Cab and Covers a 9 Support the steering valve and remove the four hex head capscrews and four lockwashers 4 Note DO NOT disassemble the orbitrol valve The orbitrol valve is not serviceable and must be replaced in its entirety if defective b Orbitrol Valve Installation 1 Secure steering valve to steering column with four hex flange capscrews and four lockwashers 2 Install steering column through dash p
37. A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury G6 42A G9 43A G10 43A Safety Practices 1 6 SAFETY INSTRUCTIONS Following are general safety statements to consider BEFORE performing maintenance procedures on the telehandler Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs For all safety messages carefully read understand and follow the instructions BEFORE proceeding 1 6 1 Personal Hazards PERSONAL SAFETY GEAR Wear all the protective clothing and personal safety gear necessary to perform the job safely This might include heavy gloves safety glasses or goggles filter mask or respirator safety shoes or a hard hat LIFTING NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards LIFTING OF EQUIPMENT Before using any lifting equipment chains slings brackets hooks etc verify that itis 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 hoist jack or jack stands only to support equipment Always support equi
38. 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 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 NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover system fluids to cool 4 Properly disconnect battery MY8110 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 20 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
39. lt e X 9 lt Y Electrical System 9 5 4 Chassis Schematic POSITIVE CABLE TO BATTERY PWR BUSSBAR 8 E uruw EVA SHETER GND OPT PWR 2 F SP BAT OPTPWAT GAGE GNO TH ith A i BAT GND ENG GND Der home TS STEER SWAY OPT PWR KEY BAT PWR ECU BAT POS E zz M pn CURE TRO TRIS O3 21510 H3MOd UOTIS NEUSS lt lt OAT WOR Xm rmm x xls lt lt TO ENGINE HARNESS UND IT TEmo UNO HIS TONS EVO aS EEEE 55 USES TIT RYTIDOS sa FNI NIO TAS NOSE H KEY BAT PWR KEYIGN KEY AC KEY START DASH GND GAGE THORN PWR ETEERISWAY STRAW STR ORE HORN FULL TEANS IME SW STRY PEERK SOL FA
40. 11 UE 8 i pe MH6460 1 Inspect forks 1 for cracks paying special attention to heel 2 and mounting tubes 3 2 Inspect forks for broken or bent tips 4 and twisted blades 5 and shanks 6 Yearly Inspection 1 Straightness of the upper face of blade 5b and the front face of shank 6 should not exceed 0 5 percent of the length of blade or height of shank 2 Angle 7 between upper face of blade and front face of shank should not exceed 93 degrees 3 Thickness of blade 8 and shank 9 should not be reduced to 90 percent of original thickness Note Contact local JLG Distributor with fork part number to find manufactured dimensions of fork blade 4 Ensure the fork length 10 is adequate for the intended loads 5 Fork markings should be legible re stamp if needed 6 Compare fork tips 11 when mounted on a carriage Maximum difference in height of fork tips is 3 percent of the length of the blade 10 G6 42A G9 43A G10 43A 3 13 EMERGENCY BOOM LOWERING PROCEDURE A WARNING To avoid instability of the machine the extend retract cylinder MUST BE fully retracted prior to retracting the lift cylinder If circumstances prevent retraction of the extend retract cylinder first lower the lift cylinder the minimum amount necessary and resume retraction of the extend retract cylinder as soon as possible in accordance with the machines load chart A WARNING P
41. 20 Install tail pipe 18 and secure with clamp 17 Adjust the muffler exhaust and tail pipes for proper clearance then tighten all clamps Properly connect the battery Start engine and check for exhaust leaks at all exhaust connections Adjust as needed Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G6 42A G9 43A G10 43A Engine 7 6 AIR CLEANER ASSEMBLY WARNING NEVER run the engine with only the inner safety element installed Note Refer to appropriate Operation amp Safety Manual for your machine for correct element change procedure 7 6 1 1 Air Cleaner Assembly Removal ULS Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel Open engine cover Allow system fluids to cool Properly disconnect battery MY8180 Loosen clamp 1 securing air intake elbow 2 to the air cleaner assembly 3 Pull air intake elbow off air the cleaner Disconnect sensor 4 Remove the screws 5 securing mounting bracket 6 to the cab Remove capscrews and nuts 7 securing air cleaner assembly 3 to mounting bracket 6 Remove air cleaner assembly
42. 20 Install the optional fender assembly 21 Close and secure the engine cover 22 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Note The service brake and parking brake circuits will need to bled after axle installation Refer to Section 8 7 4 Service Brake Bleeding hs Axles Drive Shafts Wheels and Tires 5 4 3 Axle Assembly and Drive Shaft Troubleshooting Problem Cause Remedy 1 Excessive axle 1 Oil level too low 1 Fill oil to correct level Refer to Section noise while 2 5 Fluid and Lubricant Capacities driving 2 Axle and or wheel end housings 2 Drain axle and or wheel end housings filled with incorrect oil or oil level low and fill to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities 3 Incorrect alignment of ring and 3 Correct alignment by adding or pinion gears removing shims as needed 4 Incorrect pinion input shaft 4 Correct bearing preload by adding or bearing preload removing shims as needed 5 Worn or damaged bearings 5 Replace bearings as needed 6 Worn or broken gear teeth 6 Replace gears as needed 7 Contamination in the axle 7 Drain axle and or wheel end housings and fill to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities 8 Axle housing damaged 8 Replace damaged parts 2 Intermittent noise 1 Universal joint s worn or
43. 6 10 Install the guide bar 7 and chain retainer 8 to the front of the push beam with the previously removed hardware 9 11 Properly connect the battery 12 Start the machine and SLOWLY retract the extend retract cylinder until the push beam assembly bores can be aligned with boom sections access bores 13 Properly disconnect the battery G6 42A G9 43A G10 43A MAL1290 14 Install both push beam pins 10 being careful to align the pin mounting bolt holes Note Disconnecting one or both extend retract hydraulic tubes 11 may be required to gain access to the hose guide mounting bolts After installing both hose guides re connect one or both extend retract hydraulic tubes BEFORE preceding 15 Install tilt cylinder hose guide 12 and auxiliary hose guide from rear of third second section
44. 7 12 7 6 Air Cleaner 7 13 7 6 1 Air Cleaner Assembly 016 7 13 7 6 2 Air Cleaner Assembly Installation 16 7 13 7 6 3 Air Cleaner Assembly 15 7 14 7 6 4 Air Cleaner Assembly 16 7 14 7 7 Engine 7 15 7 7 1 Engine 7 15 7 7 2 Engine 2 7 16 G6 42A G9 43A G10 43A 7 1 Engine 7 1 gt INTRODUCTION CUMMINS WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual WARNING Engine fuel lines are pressurized DO NOT attempt repairs unless specific training has been completed 7 1 1 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 Disclaimer and Scope Note Detailed engine service instructions covering disassembly inspe
45. 9 24 9 11 2 Ignition Key Switch a Ignition Switch Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery MY8270 5 Remove the screws securing the dash panel 13 6 Remove hex nut securing ignition key switch 14 to the dash 7 Label and disconnect the ignition switch wires and remove the switch from the machine G6 42A G9 43A G10 43A Electrical System b Disassembly DO NOT disassemble the ignition switch Replace a defective switch with a new part To determine proper operation of ignition key switch test terminals on back of switch for continuity with ohmmeter Inspection and Replacement 0830 Test ignition key switch for continuity by checking from BAT terminal 15 to each of remaining terminals in their corresponding switch position If all terminals do not show proper continuity replace the ignition switch d 1 Ignition Switch Installation Connect the ignition key switch to the previously labeled wires Align the ignition switch in the dash so
46. Hydraulic System 8 1 2 G9 43A amp G10 43A Components EXTEND RETRACT CYLINDER INSIDE BOOM COMPENSATION CYLINDER LIFT LOWER CYLINDER HYDRAULIC FLUID RESERVOIR TILT CYLINDER PRIORITY VALVE FRAME LEVEL CYLINDER MAIN CONTROL VALVE OUTRIGGER CONTROL VALVE G10 43A OUTRIGGER CYLINDER G10 43A MY8080 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 Hesidual pressure may remain in hydraulic cylinders hoses valve bodies components etc I
47. Lg 1 OUTLET pu T gl MEE Ir 9 Ep Es 1 1 1 COMPENSATING a CYLINDER 216 8 i m Ec ol 211 9 L T 1 E 1 i 1 1 Es l j MEE 2 LL 1 1 Ligne EREE S ue MEE UO CIT pev 1 1 1 1 1 1 2 eee i eed c Ly t 7 d 1 1 1 1 Eg 1 3 1 25 1 PS Ss 5S me 1 E T l conTROL 1 P el VALVE sy miren a a g Ee A t 9 9 5 Us BENE ex 6 5 1 dU com 2600 PSI HYDRAULIC K 1 gt OL COOLER RV1 Jmm 1 gt k z 18 75 5 OR 5 1 Rv2 i 1 LEG END 120 4soPSI i PRB m sv av 7 PRIORITYIBRAKE i MAIN PRESSURE amp RETURN LINES 1 1 1 Udo IMPLEMENT PUMP 1 PILOT LINES 1 97 CU IN REV 1 1 DRAIN LINES G6 42A G9 43A G10 43A 8 10 n Hydraulic System Hydraulic Schematic G6 42A Options 8 4 5
48. Route a sling with a minimum lifting capacity of 1000 Ibs 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 Enclosed Cab Install two lifting eye bolts 14 in threaded holes on roof of cab above B pillars 16 G6 42A G9 43A G10 43A Cab and Covers a 26 27 17 OO 18 18 4170 Remove two cab side mount bolts cab 17 Remove the four cab to frame bolts flat washers and nuts 18 Remove the mirrors and all other cab components as needed if not previously removed Carefully begin to lift the cab Stop and check that all wiring hydraulic hoses and fasteners are disconnected or removed 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 When cab is completely clear of machine carefully lower it to ground Block up or support the cab so that it does not move or fall Assure that no personnel enter cab while it is being removed from the machine Inspect condition of fittings clamps hydraulic hoses etc Replace parts as indicated by their co
49. or Section 8 4 3 Pressure Specifications G9 43A amp 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 Hydraulic System n 8 4 2 Pressure Specifications G6 42A Hydraulic Test Procedure Adjustment Pressure Nominal Circuit Port Location Range Pressure Pressure Connect gauge to BV port Reducing JS Run engine at high idle 1 PR 13052317 Ban 450 psi Cartridge Lock steering i Relief Connect gauge to CF1 port 2600 psi B Run engine at high idle 2 RV1 Lock steering Main Connect gauge to EF1 port Relief EF1 Run engine at high idle 3 4000 psi Valve Stall boom retract Connect gauge to EF1 port Boom 3650 3950 1 Run engine at high idle N A 252 272 Ba
50. 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 11 Display Gauge and Dash Switches 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 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery 5 Label disconnect and cap hydraulic hoses and electrical plugs connected to steering select valve 6 Remove the bolts holding the steer select valve to the mounting plate on the frame 7 Remove steer select manifold with attached steer select valve from machine Wipe up any hydraulic fluid spillage in on near and around the machine 8 21 Hydraulic System n b Steer Select Manifold and Valve Disassembly Cleaning Inspection and As
51. section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information 3 14 17 18 19 20 21 22 23 24 25 26 27 28 29 Install previously removed wear pad and spacer 13 on top of second boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information G6 42A 19 G9 43A G10 43A MAL2660 Install the previously removed strong back 16 with the existing hardware Torque as required Install extend retract cylinder pin 17 through strong back 16 Secure pin with retaining rings Apply thread lubricant to extend chain clevis rod threads 18 Install extend chain clevis rod into strong back 16 Install belleville washers 19 as previously removed cupped washer facing strong back Install adjustment nut and lock nut Snug but Do Not tighten at this time Remove the caps and plugs from the extend retract cylinder fittings and the
52. the capscrew threads before installation 1 o o Install the air cleaner assembly 10 to mounting bracket 12 and secure with previously removed hardware 13 Install mounting bracket onto cab with previously removed hardware 11 Secure the air intake elbow 9 to air cleaner assembly 10 with clamp 8 Adjust and tighten the clamp Properly connect the battery Close and secure the engine cover Remove Do Not Operate Tags from both ignition key switch and steering wheel G6 42A G9 43A G10 43A Engine 7 7 REPLACEMENT 7 7 1 Note The radiator and oil cooler integrated with the cooling package must be removed from the machine before engine removal Refer to Section 7 2 Engine Cooling System Several additional components must be removed before engine removal They will be addressed in the following procedures Engine Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and shut engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect and remove battery Remove engine cover Mark position of cover to help with cover adjustment when being reinstalled 5 Remove the oil pan cover underneath the engine compartment 6 Drain
53. 12 1 1250 0 8560 77000 1225 1665 1155 1570 1085 1475 11 4 7 1 2500 0 9690 87200 1545 2100 1455 1980 1365 1855 12 1 2500 1 0730 96600 1710 2325 1610 2190 1510 2055 13 8 6 1 3750 1 1550 104000 2025 2755 1905 2590 1785 2430 12 1 3750 1 3150 118100 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 12 1 5000 1 5800 142200 3020 4105 2845 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED G6 42A G9 43A G10 43A General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Ref 4150707 SOCKET HEAD CAP SCREWS Torque Torque Sis TPI Bolt Dia__ Tensile Stress Load Torque Loctite amp 242 or 271 or Loctite amp 262 or Area See Note 4 Dry 0 17 Vibra TITE 111 or 140 or Vibra TITE 131 Precoat 85 0 16 0 15 Sq In LB IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 48 0 1120 0 00
54. 13 2 Lowering Procedure a Retract the boom as follows 1 If equipped with Personal Work Platform rescue occupants prior to performing procedure 2 Properly support the boom before attempting to proceed with the emergency boom lowering procedure 3 Place a Do Not Operate Tag on both the ignition key switch and steering wheel 4 Properly support the boom as required 5 Place a suitable receptacle under the tube hose connections 6 Remove the plastic cover from the main control valve WARNING Loss of hydraulic is limited to the amount trapped within each tube hose Slowly loosen each hydraulic tube hose fitting to release any possible hydraulic oil pressure that may be trapped between the main control valve and the counterbalance valve of the extend retract cylinder or the lift lower cylinder T MY8620 MY8630 If access is required loosen and remove any clamps securing the lift lower cylinder 1 amp 2 and extend retract cylinder tubes 3 amp 4 to the frame Disconnect the extend retract cylinder tubes from the extend retract cylinder hoses 3 amp 4 Install caps or plugs in tubes to prevent fluid loss and to keep dirt and debris from entering the hydraulic system G6 42A G9 43A G10 43A O k P is 10 11 12 13 Using the hoses and fittings specified connect the hoses between the auxiliary hyd
55. 17 17 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 Wait for the engine to cool and check the coolant level Add coolant to the overflow bottle as required eso to bring the coolant to the proper level 18 Install the mirrors and all other cab components as LOS MATO needed if removed 19 Close and secure the engine cover 18 18 20 Unblock the wheels 6 Install the four cab to frame mount bolts washers and 21 Remove the Do Not Operate Tags from both the nuts 18 Torque to 280 305 Ib ft 379 414 Nm ignition key switch and the steering wheel 7 Install the two cab side mount bolts washers and nuts 17 Torque to 680 720 Ib ft 922 976 Nm 8 Install the engine air filter and hydraulic oil reservoir breather to their brackets at the top of the cab 9 Pull all the hydraulic hoses and electrical wires through the cab 10 Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations 11 Reconnect the previously labeled electrical connections to their appropriate locations 12 For machines equipped with the heater option reconnect the heater hoses to the
56. 18 275 i 1 H al LEGEND Medi MAIN PRESSURE amp RETURN LINES STABILIZEROPTION UE RESERVOIR DRAIN LINES G6 42A G9 43A G10 43A Hydraulic Schematic G9 43A amp G10 43A Hydraulic System 8 4 6 ry MY8070 7 7 3 T FTT 1 4 1 1 1 1 1 1 1 1 HM ee aS L AE 1 mH Har f 1 1 1 Sees HS SS SSS ERNEUT i eee seg 1 5 1 bla 5 spi ct 1 15 md 3AVA 1 1 1 I 1 1 1 1 1 1 1 1 1 G6 42A G9 43A G10 43A NOISS3HdWOO3G XNV x i 1 irp H tF 1 24 h 7 Vs e
57. 3225 12 1 5000 1 5800 142200 3020 4105 2845 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED 2 8 G6 42A G9 43A G10 43A General Information and Specifications 2 3 2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC HEX SOCKET HEAD BOLTS CLASS 8 METRIC NUTS Torque Torque i Torque Loctite 262 or i TM Sizo Pitch 263 Toraue 2711 or mis Mic Vibra TITE 131 111 or 141 mm KN N m N m N m 3 0 5 5 03 2 19 1 8 1 0 12 14 3 5 0 6 6 78 2 95 2 1 1 6 1 9 2 3 4 0 7 8 78 3 82 34 2 3 2 8 3 4 5 0 8 14 20 618 6 2 4 6 5 6 6 8 6 1 20 10 8 74 11 7 9 9 4 12 7 1 28 90 12 6 18 13 16 19 8 1 25 36 60 15 9 26 19 23 28 10 1 5 58 00 25 2 50 38 45 55 12 1 75 84 30 36 7 88 66 79 97 14 2 115 50 0 140 105 126 154 16 2 157 68 3 219 164 197 241 18 2 5 192 83 5 301 226 271 331 20 2 5 245 106 5 426 320 383 469 22 2 5 303 132 0 581 436 523 639 24 3 353 158
58. 5 737 553 663 811 27 3 459 199 5 1080 810 970 1130 30 8 5 561 244 0 1460 1100 1320 1530 33 8 5 694 302 0 1990 1490 1790 2090 36 4 817 355 5 2560 1920 2300 2690 42 4 5 1120 487 0 4090 3070 3680 4290 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED G6 42A G9 43A G10 43A General Information and Specifications 2 3 2 Metric Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC HEX HEAD BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M3 M5 Torque DEC que dlorque TM Size Pitch Stress eee Dry or Loctite 26 3 242 or 271 26 rea Solara K 0 20 Vibra TITE 111 or 140 131 K 0 18 N m N m N m 3 0 5 5 03 3 13 3 5 0 6 6 78 4 22 4 0 7 8 78 5 47 5 0 8 14 20 8 85 6 1 20 10 12 5 7 1 28 90 18 0 25 23 19 8 1 25 36 60 22 8 37 33 27 10 1 5 58 00 36 1 70 65 55 12 1 75 84 30 52 5 125 115 95 14 2 115 71 6 200 180 150 16 2 157 97 8 315 280 235 18 2
59. 8 Disconnect electrical connectors 9 Remove the joystick b Joystick Installation 1 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations Connect the electrical connectors Install the bolts securing the joystick to the cab Properly connect the battery a amp nm Test the complete range of joystick functions per control decals in cab or appropriate Operator and Safety Manual Note Check the controls of the auxiliary attachments See the appropriate Operation amp 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 G6 42A G9 43A G10 43A Frame Level Attachment Tilt Auxiliary Hydraulics and G10 43A Outrigger Joysticks 4 3 5 a Joystick Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL position engage parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover Allow the system fluids to cool 4 Properly disconnect the battery If Equipped MY8120 If Equipped Ps Cab and Covers 5 Remove knob on end of joystick 12 if necessary 6 Remove screws 13 securing dash panel to cab Rem
60. Cleanliness is of extreme importance Before attempting to remove transmission thoroughly clean exterior of transmission to help prevent dirt from entering during replacement process Avoid spraying water or cleaning solution onto or near transmission shift solenoids and other electrical components 6 4 1 Transmission Removal A 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 Ib 454 kg 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in N NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel 3 Open the engine cover Allow the system fluids to cool 4 Remove engine cover Mark position of cover to help with cover adjustment when being reinstalled 5 Drain the hydraulic oil reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 6 Properly disconnect the battery 7 Thoroughly clean the transmission and surrounding area including all the hoses and fittings before proceeding Transmission 10 11 NS SN Y VS 800 Place suitable receptacle under transmission drain hose 2 Open transmission drain valve and allow transmission oil to drain into receptacle
61. Cylinder Nut 800 1000 Ib ft 1085 1355 Nm 8 26 G6 42A G9 43A G10 43A n Hydraulic System 8 8 5 a Extend Retract Cylinder Cylinder Torque Specifications G9 43A amp G10 43A Head Nut Valve 300 400 Ib ft 407 542 Nm Apply Loctite 271 745 825 lb ft 1010 1119 Nm 105 115 Ib ft 142 156 Nm b Tilt Cylinder Nut Valve 1125 1375 Ib ft 1525 1864 Nm 44 Ib ft 60 Nm c Compensation Cylinder Nut 1125 1375 Ib ft 1525 1864 Nm d Frame Level Cylinder Head Nut Set Screws 300 400 Ib ft 407 542 Nm 720 800 Ib ft 976 1085 Nm Apply Loctite 271 4 lb ft 5 Nm Apply Loctite 243 e Outrigger Cylinder G10 43A Piston Head Set Screws Check Valve 2350 2600 Ib ft 3186 3525 Nm Apply Loctite 271 300 400 Ib ft 407 542 Nm 4 Ib ft 5 Nm Apply Loctite 243 30 35 Ib ft 41 47 Nm G6 42A G9 43A G10 43A 8 27 Hydraulic System This Page Intentionally Left Blank 8 28 G6 42A G9 43A G10 43A Section 9 Electrical System Contents PARAGRAPH TITLE PAGE 9 1 Electrical Component 9 3 9 1 1 General 9 3 9 2 Specifications 5 1 el Ie ue ape ee eae nls
62. G6 42A G9 43A G10 43A 8 8 HYDRAULIC CYLINDERS 8 8 1 General Cylinder Removal Instructions 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 NEUTRAL engage the park brake shut the engine OFF and chock wheels Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open the engine cover Allow the system fluids to cool Label disconnect and cap or plug hydraulic hoses in relation to the cylinder Attach a suitable sling to an appropriate lifting device and to the cylinder Make sure the device used can actually support the cylinder Remove the lock bolt and or any retaining clips securing the cylinder pins Remove the cylinder pins 7 Remove the cylinder Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools General Cylinder Disassembly 20400 Clean the cylinder with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holding equipment if possible 8 23 Hydraulic System A WARNING Significant pressure may be tra
63. G6 42A G9 43A G10 43A 31200792 SECTION CONTENTS Section Subject Page Section 1 Safety Practices Heise eura Ke OR E JR Gc 1 1 1 1 Introduction Melee ae a en RI Rn EE des 1 2 1 2 Disclaimer 1 2 1 3 Operation amp Safety 1 2 1 4 Do Not Operate Tags 5 Pes 1 2 1 5 Safety Information RR i OUR ERRE NLT Te REN UST 1 2 1 6 Safety 1 3 1 7 Safety 1 4 Section 2 General Information and Specifications 2 1 2 1 Replacement Parts and Warranty 2 2 2 2 Thread Locking 2 2 2 3 Torque Charts RI RR DA NE xd det mas 2 3 2 4 Specifications crees preasa a Deed weg ds 2 14 2 5 Fluid and Lubricant 2 18 2 6 Service and Maintenance Schedule 1 2 21 2 7 Lubrication 2 24 Section 3 EAR UE Roni wed
64. G6 42A G9 43A G10 43A 9 27 Electrical System Analyzer Joystick Software Version P1 2 9 12 2 e TI 1 e VE rii quod N3dO WS95INL 2 MOILSAOL 8 1 1 E 1 lt gt TIOO NIW NMOG NIW io M MG aie INOIIVHEITUO INOIIVHEITUO avo 1 1 1 1 i INIdWOO WUXXX VIIOO XWW WUXXX NWXXXX UIVOLOV AXX X NOIIWNEITVO NOIIVNHITVO NOILONDS UTIL SOITOVHGAH XDV A 1 1 1 1 HHINZO WAINI VIIOO 45019 VAXXXX vxov GAH MATION LIIL XWO4 NOIZONAZ i i i i 1 OL ATA OL ATA SX X SX X TIOTA V NO INANI XOY MATION GAH XAY MATION LTIL SROISSINSNWHE ayo i i i i i UAIN WHINSO SX X T320V SX X NMOG
65. Ib ft 271 291 Nm Note Raising boom up or down with sling my be necessary so boom compensation and lift lower cylinder bores can be aligned for easier pin installation Note Grease the boom pivot bore compensation cylinder rod end lift lower cylinder rod end and pins before installing 4 Uncap and reconnect the previously labeled hydraulic hoses to the extend retract cylinder Uncap and connect and remaining hydraulic fittings to their appropriate locations Recheck wear pad gaps to ensure they meet the minimum gap requirement Shim if necessary Ensure that the boom chains are properly adjusted Refer to Section 3 8 Boom Adjustments 8 Properly connect the battery 9 Install the quick switch assembly Refer to Section 10 11 12 13 14 3 9 Quick Switch Assembly Start engine and operate all boom functions several times Check for leaks and check hydraulic fluid level in reservoir add fluid if required Clean up all debris hydraulic fluid etc in on near and around the machine Close and secure the engine cover Remove Do Not Operate Tags from both ignition key switch and the steering wheel Install the previously removed attachment to the quick switch assembly
66. Section 2 5 Fluid and Lubricant Capacities 13 Loosen the hose clamps label and disconnect the 8 Reinstall surge tank cap heater hoses 16 Cap or plug the hoses to prevent 9 Properly connect the battery debris from entering the heater system Note When the engine is initially started run it briefly at low idle and check the machine for any visual sign of 15 Remove the bolts securing the heater assembly to fluid leakage STOP the engine immediately if any the cab Remove the heater assembly leakage is noted and make any necessary repairs before continuing 14 Label and disconnect any electrical connections 10 Wait for engine to cool and check the coolant level Add coolant as required to bring the coolant to the proper level 11 Close and secure the engine cover 12 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G6 42A G9 43A G10 43A 4 9 Cab and Covers a 4 4 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 an
67. See Rd Ro 9 5 9 3 Safety 9 5 9 4 2 22 4 4 9 5 9 4 1 Engine 9 5 9 4 2 ri dhe dowd aiu identit s duda aoro 9 5 9 4 3 Power Distribution Unit 9 6 9 4 4 Optional Power Distribution Unit VEC 9 7 9 5 Electrical System 9 8 9 5 1 Cab 1 9 8 9 5 2 Options 9 9 9 5 3 Accessory Module Schematic G9 43A amp G10 43A 9 10 9 5 4 Chassis 9 11 9 5 5 Engine Schematic if equipped for 15 9 12 9 5 6 Engine Schematic if equipped for 16 9 13 9 6 Engine Start 9 14 9 6 1 iig IDEE ne Mee eee es 9 14 9 7 Charging Circuit eta enti erent eee eee 9 15 9 7 1 15 9 15 9 7 2 16 9 16 G6 42A G9 43A G10 43A 9 1 Electrical
68. and Tires 5 10 5 6 1 Wheel and Tire Assembly 5 10 5 6 2 Wheel and Tire Assembly 5 11 5 7 Brakes hc choad yale ede 5 11 5 8 Towing a Disabled 5 12 5 8 1 Manually Releasing the Park 5 12 5 8 2 Manually Resetting the Park Brake 5 12 G6 42A G9 43A G10 43A 5 1 Es 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 5 1 1 G6 42A Components REAR STEERING CYLINDER TRANSMISSION DROP BOX REAR AXLE ASSEMBLY REAR XLE REAR WHEEL HUBS 2 DRIVE SHAFT FRONT STEERING CYLINDER FRONT AXLE ASSEMBLY FRONT AXLE WHEEL HUBS 2 MY7740 5 2 G6 42A G9 43A G10 43A hs Axles Drive Shafts Wheels and Tires G9 43A amp G10 43A Components 5 1 2 REAR AXLE WHEEL HUBS 2 REAR ST
69. and remove the radiator assembly Refer to Section 7 2 3 Radiator Assembly and Replacement 7 Remove the heater hoses attached to the engine if equipped Note Engine harness is routed and attached to engine using hold down clamps and plastic wire ties at various places on engine Before removing engine ensure that harness has been completely separated disconnected from engine Move harness clear of engine and with help of an observer ensure that engine clears harness during removal 8 Label and disconnect all electrical wire connections on the engine 9 Disconnect and cap fuel inlet line 10 Disconnect and cap fuel return line from engine 11 Remove exhaust pipe from the exhaust manifold Refer to Section 7 5 Engine Exhaust System 12 Loosen clamps on sleeve reducer at engine and on air suction pipe 13 Remove air cleaner tube from turbo charger 14 Remove access plug from bottom of engine bell housing This will allow access to remove bolts holding the torque convertor diaphragm to the engine flywheel G6 42A G9 43A G10 43A 15 16 17 18 19 20 Turn engine over slowly by hand and align each of four torque convertor diaphragm bolts to be accessed Remove them one at a time Secure the engine with a lifting strap or chain from the appropriate lifting points 1 Use a suitable hoist or overhead crane Place a support or jack under transmission to hold transmission in place whi
70. are not met G6 42A G9 43A G10 43A 3 8 2 Chain Tension Adjustment G6 42A MAL2571 C 1 Remove the extend chain lock nut 1 and loosen adjustment nut 2 until the belleville washers 3 are free to turn on the extend rod 2 Verify the belleville washers 3 are in the correct order as shown Remove the extend chain adjustment nut 2 and correct if required A o N B MAL2551 g 3 Remove lock nut 4 from retract chain clevis 5 4 Setthe retract chain adjustment nut face 6 flush with the end of the retract clevis 5 Verify the belleville washers 7 are in the correct order as shown Remove the retract chain adjustment nut 6 and correct if required Note Belleville washers are shown in the un compressed state 3 21 MAL2561 6 If dimension is greater than 11 625 in 295 2 mm push the third section boom IN until dimension A is less than 11 625 in 295 2 mm MAL2571 7 With dimension A less than 11 625 in 295 2 mm verify the extend rod Belleville washers 3 and the retract chain Belleville washers loose Tighten the extend chain rod adjusting nut 2 until dimension A is 12 063 12 188 in 306 4 309 5 mm 8 Install and temporari
71. both the ignition key switch and the steering wheel Engine 7 5 3 1 7 12 Exhaust System Removal LS Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel Open engine cover Allow system fluids and exhaust system to cool Properly disconnect the battery 25 MY7820 Loosen and remove clamp 17 securing tail pipe 18 to muffler 19 Remove tail pipe Loosen and remove clamp 20 securing muffler 19 Remove muffler Loosen and remove clamp 21 securing exhaust pipe 22 Remove exhaust tail pipe Loosen and remove clamps 23 securing exhaust pipe 24 Remove exhaust pipe Loosen and remove clamps 25 securing exhaust outlet pipe 26 to turbo charger 27 Remove exhaust outlet pipe and flex pipe 28 7 5 4 Exhaust System Installation LS Note Keep all clamps loosened until entire exhaust system is in place 1 10 11 Install exhaust outlet pipe 26 to turbo charger 27 and secure with clamp 25 Install flex pipe 28 and secure with clamp 25 Install exhaust pipe 24 and secure with clamps 23 Install exhaust pipe 22 and secure with clamp 21 Install muffler 19 and secure with clamp
72. 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 4 12 G6 42A G9 43A G10 43A Section 5 Axles Drive Shafts Wheels and Tires Contents PARAGRAPH TITLE PAGE 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 1 1 G6 42A Components 5 2 5 1 2 G9 43A amp G10 43A 5 3 5 2 Axle Serial 5 4 5 3 Axle Specifications And Maintenance 5 4 5 4 Axle 2 2 22 2 5 4 5 4 1 Axle 5 4 5 4 2 Axle Installation i uu eintreten cere dena ed sean 5 5 5 4 3 Axle Assembly and Drive Shaft Troubleshooting 5 6 5 5 Drive Shafts cesa endinn net e ll do Ie uude ram eu da 5 9 5 5 1 Drive Shaft Inspection and Service 5 9 5 5 2 Drive Shaft Maintenance 5 9 5 5 3 Drive Shaft 5 9 5 5 4 Drive Shaft Cleaning and Drying 5 9 5 5 5 Drive Shaft 5 9 5 6 Wheels
73. chain 15 from anchor rod 16 and lay flat on bottom of third boom section Remove anchor rod 16 from front of boom Note It may be necessary to lift the extend retract cylinder through the access holes in the sides of the third boom section to remove the chain retainer 14 20 17 MAL1290 17 At rear of boom remove both retaining clips 17 from extend retract cylinder pin 18 Remove extend retract cylinder pin from strong back 19 18 Loosen and remove eight bolts 20 from the strong back 19 Remove strong back 19 Remove both extend retract cylinder hydraulic tubes Plug tube ends and cap the fittings to prevent dirt and debris from entering hydraulic system 3 18 20 Place sling around push beam extend retract cylinder assembly Lift and slowly pull push beam extend retract cylinder assembly approximately half way out the front of boom assembly 21 Lower push beam onto a suitable support Guide the push beam extend retract cylinder assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components 22 Relocate sling or using two slings for better stability balance push beam extend retract cylinder assembly and slowly pull push beam extend retract cylinder assembly out towards the front of boom assembly 23 Lower the push beam extend retract cylinder assemb
74. clevis rod Do not tighten at this time 13 Uncap and connect the extend retract cylinder hydraulic tubes to their appropriate locations 14 Adjust the chain as needed Refer to Section 3 8 Boom Adjustments 15 Install the cover on the rear of the boom 16 Properly connect the battery 17 Close and secure the engine cover 18 Remove Do Not Operate Tags from both ignition key switch and steering wheel 3 16 3 7 PUSH BEAM EXTEND RETRACT CYLINDER REMOVAL INSTALLATION A CAUTION The complete push beam extend retract cylinder assembly weighs over 1 200 Ib 545 kg This section explains removal of push beam extend retract cylinder through front of boom assembly without removing or disassembling boom assembly Push Beam Extend Retract Cylinder Removal 3 7 1 1 Park machine on a hard level surface level machine fully retract boom level boom place transmission control lever in N NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover Allow system fluids to cool 4 Remove cover from rear of first boom section 2 MAL1310 5 Disconnect both tilt hoses 1 and both auxiliary hoses not shown from the hose retainer brackets 2 at the bottom front inside the boom Plug the hose ends to prevent dirt and d
75. damaged 1 Repair or replace universal joints when traveling as needed 2 Differential ring and or pinion 2 Determine cause and repair as needed gears damaged 3 Vibration or 1 Drive shaft universal joint 1 Tighten capscrews to correct torque intermittent noise assembly ies incorrectly tightened when traveling uu m 2 Drive shaft universal joint s worn 2 Repair or replace universal joints or damaged as needed 3 Drive shaft s damaged unbalanced 3 Replace drive shaft s as needed 5 6 G6 42A G9 43A G10 43A Axles Drive Shafts Wheels and Tires hs Problem Cause Remedy 4 Oil leaking from axle differential housing and or 1 Drain and or inspection plugs loose and or o rings damaged or missing 1 Replace o rings as needed and tighten plugs to 96 Ib ft 130 Nm axle housings 2 Hose fittings loose 2 Tighten fittings 3 Axle shaft seal damaged or missing 3 Replace seal and or joint coupling fork and or worn or damaged shaft shaft axle shaft sealing surfaces 4 Input shaft multi seal ring damaged 4 Replace multi seal ring and or input or missing and or worn or damaged shaft Adjust ring and pinion alignment pinion input shaft sealing surfaces and bearing preload as described in the Engine Repair Manual 5 Axle casing to brake housing and or 5 Replace o rings and seals brake housing to differential assembly o rings and or seals
76. desired current is and the digital output driver s diagnostic feedback is low Normal operation will resume when the issue is resolved Yes 33428 Anti Stall Valve Short to Ground The anti stall digital output was shorted to ground This fault may be caused by improper wiring or a control module issue The actual current is greater than 200mA PWM is 95 and the digital output driver s diagnostic feedback is low Normal operation will resume when issue is resolved Yes 441 Battery Voltage Too Low System Shutdown Battery voltage is less than 8 0V The control module may be unable to regulate proper output current The CM will continue to regulate the Anti Stall Valve but higher currents may not be possible No 442 Battery Voltage Too High System Shutdown Battery voltage is greater than 16 0V The CM will continue operation but extended periods of time above this threshold may cause thermal shutdown of the CM s primary regulator Yes 998 EEPROM Failure The control module detected an issue with the non volatile memory used to adjustments Verify all settings using the JLG Analyzer Since no critical settings are maintained in EEPROM the CM will continue operation Yes G6 42A G9 43A G10 43A 9 37 Electrical System 9 13 SAE DIAGNOSTIC TROUBLE AND FAULT CODES 9 13 1 Fault Code Displa
77. equipped 4 8 4 4 Cab Removal 2 3 Ro on m m ee e 4 10 4 5 Cab Installation saaie m RR eR ER IRE REA ERR ERR n 4 11 G6 42A G9 43A G10 43A 4 1 Cab and Covers a 41 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers The following illustration identifies the components that are referred to throughout this section 4 1 1 General Overview G6 42A G9 43A FRAME LEVEL INDICATOR STEERING WHEEL INSTRUMENT PANEL ff TRANSMISSION I gt CONTROL LEVER AUXILIARY HYDRAULIC 14 JOYSTICK G6 42A 15 NC 9 IGNITION SWITCH SERVICE BRAKE PEDAL ACCELERATOR PEDAL DECOMPRESSION VALVE G9 43A IF EQUIPPED JA P ACCESSORY CONTROL LEVER IF EQUIPPED RIGHT HAND PANEL BOOM CONTROL JOYSTICK FRAME LEVEL JOYSTICK AND ATTACHMENT TILT IF EQUIPPED AUXILARY HYDRAULIC JOYSTICK G9 43A MY7700 G6 42A G9 43A G10 43A Cab and Covers 4 1 2 General Overview G10 43A RIGHT HAND FRAME LEVEL PANEL ACCESSORY INDICATOR CONTROL LEVER STEERING WHEEL BOOM CONTROL JOYSTICK FRAME LEVEL INSTRUMENT f JOYSTICK ff IF EQUIPPED TRANSMISSION Y f CO
78. 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 2123 Joystick Trigger Switch De Clutch functionality prevented transmission No Active At Power Up always engaged The trigger for de clutch should be open released when the control system is energized or is ignored until it momentarily opens 2125 Joystick Left Roller Not In Fork Tilt Up amp Down prevented No Th i The left roller must be in the neutral position P established by Calibration when the control system is energized or it is ignored until is momentarily returns to neutral 2126 Joystick Right Roller Not In Auxiliary Hydraulic A amp B prevented No The Neuital Frost The right roller must be in the neutral position Power Up established by Calibration when the control system is energized or it is ignored until is momentarily returns to neutral 2356 Auxiliary Hydraulic Joystick Auxiliary Hydraulic A amp B prevented Yes G6 42A G9 43A G10 43A 9 31 Electrical System DTC Event Comment Latched 2357 Auxiliary Hydraulic Joystick Auxiliary Hydraulic A amp B prevented Yes Out Of Range High 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 contr
79. extend retract tubes 20 Install both extend retract tubes 20 and torque as required Uncap and reconnect the previously labeled hydraulic hoses to the extend retract cylinder Uncap and connect and remaining hydraulic fittings to their appropriate locations Recheck wear pad gaps to ensure they meet the minimum gap requirement Shim if necessary Ensure that the boom chains are properly adjusted Refer to Section 3 8 Boom Adjustments Properly connect the battery G6 42A G9 43A G10 43A 30 31 32 33 3 6 3 6 1 The following section explains the removal of the extend Start engine and operate all boom functions several times Check for leaks and check hydraulic fluid level in reservoir add fluid if required Clean up all debris hydraulic fluid etc in on near and around the machine Close and secure the engine cover Remove Do Not Operate Tags from both ignition key switch and steering wheel EXTEND RETRACT CHAIN REMOVAL INSTALLATION Extend Retract Chain Removal retract chains without removing or disassembling the boo 1 m assembly Park machine on a hard level surface level machine fully retract boom level boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open engine cover Allow system fluids
80. fluids to cool Properly disconnect battery Using a suitable sling or hoist support the boom Label disconnect and cap the hydraulic hoses at the rear of the boom Cap all fittings to keep dirt and debris from entering the hydraulic system Label and disconnect any electrical cables if equipped at the rear of the boom 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 Remove the pin from the rod end of the lift lower cylinder Lower the cylinder onto the frame rails MY1520 Confirm that boom assembly is balanced with sling and remove the boom assembly pivot pin 1 Lift boom assembly from machine and lower onto suitable supports G6 42A G9 43A G10 43A 3 4 2 1 Complete Boom Installation Using suitable slings balance the boom assembly lift and carefully guide the boom into place Align the frame pivot bore with the boom assembly pivot bore Install the boom pivot pin 1 With the sling still in place install the compensation cylinder pins and bolts Apply Loctite 242 and torque lock bolt to 100 110 Ib ft 135 149 Nm 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
81. 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 24 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 pr
82. 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 6 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF 8 22 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 pressure check of 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
83. i 6 250 EE gt 3 0 gt 0 50 a 3 0 A36 STEEL RECOMMENDED ALL WELDS SHALL CONFORM TO AWS D1 1 ALL DIMENSIONS ARE IN INCHES G6 42A G9 43A G10 43A 4100 3 37 3 38 This Page Intentionally Left Blank G6 42A G9 43A G10 43A Section 4 Cab and Covers Contents PARAGRAPH TITLE PAGE 4 1 Operator Cab and Covers Component Terminology 4 2 4 1 1 General 6 42 09 4 4 2 4 1 2 General Overview G10 43A 4 3 4 2 Operator Cab club ee ox RUE cR oe 4 4 4 2 1 Cab Safety iod kc sed doa cuta a pd e hd eR baer doe enacted 4 4 4 2 2 Serial Number 4 4 4 3 Cab 4 4 4 4 3 1 Steering Column and Orbitrol 4 4 4 3 2 Service Brake 4 5 4 3 3 Accelerator Pedal ikke 4 6 4 3 4 Boom Joystick 4 7 4 3 5 Frame Level Attachment Tilt Auxiliary Hydraulics and G10 43A Outrigger JOVSIICKS i qoute caia Re ole CI ne RR 4 7 4 3 6 Windshield Wiper 4 8 4 3 7 Heater Air Conditioning System if
84. leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area Fuel Tank Installation Setfuel 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 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 5 Fluid and Lubricant Capacities Check fuel tank for leaks Properly connect the battery Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 4 8 After Fuel System Service Drain and flush the fuel tank if it was contaminated Vent air from the fuel system in accordance with the instructions found in the appropriate Operation amp Safety Manual Fill the fuel tank with fresh clean diesel fuel as required 7 10 G6 42A G9 43A G10 43A Engine 7 5 7 5 1 1 96 4 ENGINE EXHAUST SYSTEM Exhaust System Removal ULS Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and shut engine OFF Place a Do Not Operate Tag on both the ig
85. of the third boom section being careful not to damage any components 940 11 Install tilt cylinder hoses and if equipped auxiliary hoses through front of third boom section Note Verify tilt cylinder hoses and if equipped auxiliary hoses are routed UNDER hose guide 12 at rear of third boom section at retract chain clevis bracket 12 Snug the Temporary Extend Chain Bracket 9 930 5 Install the push beam wear pad 4 to the previously removed chain retainer b using two bolts and two washers Torque as required 6 Lift the push beam assembly 6 with pry bars using the access holes on each side of the third boom section and install the guide bar 7 and chain retainer 5 using the previously removed hardware 13 8 Torque to 25 30 Ib ft 34 41 Nm O _ MY3900 l 13 Install the hose retainer assembly 13 using existing hardware Torque as required 14 Remove caps from the hose retainer fittings and plugs from the tilt cylinder hoses and if equipped the auxiliary hoses o P m 15 Connect tilt cylinder hoses and if equipped the auxiliary hoses to their proper locations Torque 10 11 as required 7 Loosen the Temporary Extend Chain Bracket 9 8 Apply thread lubricant to clevis mounting pin 10 9 Lift push beam and ins
86. operate operating properly Circuits 10 Excessive chain wear 1 Improper chain adjustment 1 Adjust to correct tension Refer to Section 3 8 Boom Adjustments Replace chains as needed 2 Chain sheave s not properly 2 Lubricate chain sheave Refer lubricated to Section 2 6 Service and Maintenance Schedule 3 Chain sheave s not rotating 3 Lubricate chain sheave Refer freely to Section 2 6 Service and Maintenance Schedule Repair or replace chain sheave s as needed 4 Improper chain lubrication 4 Lubricate at regular intervals Refer to Section 2 6 Service and Maintenance Schedule Replace chains as needed 3 36 G6 42A G9 43A G10 43A N 3 15 PUS H BEAM TEMPORARY BRACKETS Note The drawings below are only suggested and can be subject to individual interpretation Temporary Extend Chain Bracket 5 00 3 1 25 Tube 1 0 1 3125in O D 2 0in 0 1875 0 2504 x 4 0 0 875 2 0 SEE gt TS K 1 3125 4 6 875 gt 7 00 1 50 L zl ane X NOTE A WELD FROM X Y ONLY 2 1875 a lt 4 0 Temporary Retract Chain Bracket 5 00 1 50 3 125 0 1 id ra 1 10 gt 3 16 N ee 2 0 45 0 875 0 50 4 150 2 0 Drill 0 3125 Thru Y 71 1 Y
87. or Shorted to Low Source Temp intake Intake Manifold Air Temperature High Data 155 105 0 Red Valid but Above Normal Operational Range Most Manifold 1 Severe Level 5 Volts Sensor Supply Voltage 2 Circuit Voltage Below 187 a910 Ambet DC Supply Normal or Shorted to Low Source Coolant Level Sensor Circuit Voltage Above 195 WT Amig Normal Shorted to High Source Coolant Level Sensor Circuit Voltage Above 136 4 Amber Normal or Shorted to High Source 197 111 18 Amber Coolant Level Coolant Level Data Valid but Below Normal Opera tional Range Moderately Severe Level G6 42A G9 43A G10 43A 9 39 Electrical System Fault SPN FMI Lamp SPN Codes Codes Codes Color Description mnm Barometric Pressure Sensor Circuit Voltage Above el 108 3 Anne Pressure Normal or Shorted to High Source Barometric Barometric Pressure Sensor Circuit Voltage Below 222 4 Ambar Pressure Normal or Shorted to Low Source 5 Volts Sensor Supply Voltage 2 Circuit Voltage Above xd 9910 3 Ambar DC Supply Normal or Shorted to High Source Engine Speed High Data Valid but Above Normal ao ue 0 Red Engines speed Operational Range Most Severe Level Coolant Level Low Data Valid but Below Normal 299 IM 1 i Operational Range Most Severe Level 237 644 2 Amber External Speed External Speed
88. slowly pull push beam assembly out the front of third boom section 12 Lower push beam assembly onto suitable supports 13 Remove all remaining brackets clevises hoses wear pads shims backing plates and hardware from the second and third boom sections Label all parts and hardware being removed from each section Note Inspect all chains hoses and sheaves for wear and or damage and replace as needed 3 5 4 Push Beam Extend Retract Cylinder Installation and Third Boom Section Assembly Note Inspect the wear pad surfaces of the second and third boom sections Verify all areas are clean and free of any weld spatter paint etc before beginning the re assembly procedure Note Inspect and lubricate all extend and retract chains before re assembly Refer to Section 3 11 Boom Extend and Retract Chains for detailed information 1 Place the third boom section onto suitable supports 2 Clean and lubricate the bottom and sides of third boom section where push beam guide bar travels 3 Place a sling or using two slings for better stability lift and slowly push the push beam assembly approximately half way into the third boom section Lower the push beam onto a suitable support c Boom 4 Relocate the sling and slowly insert the push beam assembly into the front of the third boom section Guide the push beam extend retract cylinder assembly over the top of the retract chain anchor at the rear
89. terminal will not have flexed as frequently if at all as the middle of chains It is best to measure in 12 pin increments from pin center to pin center For example if links are one inch from pin center to pin center distance should be 12 in 305 mm If links are 3 4 in 9 5 mm apart Examine pin head rivets to determine if VEE flats distance after 12 pins should be 9 in 229 mm are still in correct alignment 6 Chain with rotated displaced heads 7 or abnormal pin protrusion 8 should be replaced immediately MZ1465 DO NOT attempt to repair chain by welding or driving pin s back into chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system This condition damages the chain as well as increases frictional loading and should be corrected MY1360 If distance measured 3 is 3 greater than normal length 4 discard and replace chain G6 42A G9 43A G10 43A 3 29 ote Cracked Plates Inspect chains very carefully front and back as well as side to side for any evidence of cracked plates If any one crack is discovered the chain should be replaced in its entirety It is important however to determine the cause of the crack before installing a new chain s
90. 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 Install dash panel with previously used hardware Properly connect the battery Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Note lf further information is needed refer to Section 9 5 Electrical System Schematics G6 42A G9 43A G10 43A 9 11 3 Dash Switches Switch Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Open engine cover Allow system fluids to cool 4 Properly disconnect the battery 8280 5 Each switch 16 is mounted in dash panel 17 6 Pull switch out of dash panel and disconnect harness connector to switch in question Disassembly DO NOT disassemble dash panel switch Replace a defective switch with a new part 9 25 Electrical System 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 1 2 Switch Installation Connect the swit
91. to cool 4 Properly disconnect battery 5 Remove cover from the rear of first boom section 0580 Remove extend retract cylinder hydraulic tubes 4 Plug tube ends and cap the fittings to keep dirt amp debris from entering hydraulic system Remove extend retract cylinder mounting pin 5 from strong back Remove extend chain adjustment nut and lock nut 6 from strong back G6 42A G9 43A G10 43A 10 11 12 13 14 15 16 17 18 3 6 2 Remove the retract chain adjustment and lock nuts 7 from the front of the first boom section Remove the strong back mounting bolts and remove the strong back from the boom Remove push beam mounting pins from rear of second boom section Place chain clevis rod to one side of push beam Lift the push beam to gain access to the chain clevis at the rear of the third boom section Reaching inside the rear of the boom at the chain anchor bracket remove the cotter pin and pin from the retract chain clevis Remove the cotter pin and pin from the extend chain Connect wire or rope approximately 30 ft 9 1 m to the end of the extend chain Lower push beam Center chain clevis rod on push beam to aid in removal Pull push beam extend chain from rear of boom Disconnect wire or rope from extend chain Pull the retract chain from the rear of the boom Extend Retract Chain Installation The following section explains the in
92. to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links To prepare the chain for lubrication the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces All surplus lubricant should be wiped away from the external surfaces DO NOT use a solvent for this wiping operation Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration It is important that a reputable lubrication specialist a local JLG Distributor or the vehicle distributor be consulted for guidance G6 42A G9 43A G10 43A N 3 12 5 Forks should be cleaned and inspected prior to being attached to carriage If the following criteria is not met forks must be removed from service immediately Daily Inspection
93. transmission control lever in the N NEUTRAL position engage the parking brake and shut the engine OFF Note In order to remove engine drive plates engine and 2 3 4 5 6 6 transmission must be separated Refer to Section 6 4 1 Transmission Removal or Section 7 7 1 Engine Removal 1120 Remove four bolts holding diaphragms to flywheel With drive plates and torque converter removed loosen and remove four bolts 7 and eight lock washers holding the two diaphragms 8 to the torque converter 9 Replace both diaphragms if damaged 2 Torque Convertor Diaphragm Installation Install two new diaphragms on torque converter and install the four bolts with lock washers Mount the diaphragm converter assembly to the transmission Refer to Section 6 4 3 Transmission Installation or Section 7 7 2 Engine Installation for the remainder of the installation G6 42A G9 43A G10 43A 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 local distributor if internal transmission The transmission should be checked serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features repair is required during the warranty period Problem Ca
94. 0 40 Boom Chain Lubricant Schaffer 2005 Silver Streak Engine Coolant Ethylene Glycol 50 50 Mix Standard g and Water 60 40 Mix Cold Weather 2 Diesel Standard B5 Biodiesel Low Sulfur 2d Fuel Blend 1 diesel and 2 diesel fuels S 500 mg winterized 2 kg Cold Weather B5 Biodiesel with Winter Conditioner Note Friction Modifier may be added to front axle differentials see Section 2 5 3 Capacities G6 42A G9 43A G10 43A 2 19 amp General Information and Specifications 2 5 8 Capacities Engine Crankcase Oil Capacity with Filter Change 8 0 quarts 7 6 liters Fuel Tank Capacity 38 gallons 144 liters Cooling System System Capacity 15 quarts 14 2 liters Hydraulic System System Capacity G6 42A 43 gallons 163 liters G9 43A amp G10 43A 44 gallons 168 liters Reservoir Capacity to Middle of Sight Gage 24 5 gallons 93 liters Auxiliary Hydraulic Circuit Max Flow Not Available at Publication Transmission Capacity with Filter Change 16 quarts 15 1 liters Transfer Case Capacity 2 1 quarts 2 0 liters Axles Differential Housing Capacity G6 42A 8 5 quarts 8 liters Friction Modifier Front differential only 13 6 ounces 402 2 milliliter G9 43A amp G10 43A Front 8 2 quarts 7 8 liters Rear 13 quarts 12 3 lit
95. 10 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 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 JLG France SAS 241 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493
96. 14 2 115 50 0 119 110 105 16 2 157 68 3 186 175 165 18 2 5 192 83 5 256 240 225 20 2 5 245 106 5 362 340 320 22 2 5 303 132 0 494 465 435 24 3 353 153 5 627 590 555 27 3 459 199 5 916 860 810 30 3 5 561 244 0 1245 1170 1100 33 3 5 694 302 0 1694 1595 1495 36 4 817 355 5 2176 2050 1920 42 4 5 1120 487 0 3477 3275 3070 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED G6 42A G9 43A G10 43A General Information and Specifications 2 3 2 Metric Fastener Torque Chart Continued Values for Magni Coated Fasteners Ref 4150701 CLASS 10 9 METRIC HEX HEAD BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE Torque DAD qe TM Size Pitch Miei Stress pues See Dry or Loctite 26 3 242 or 271 26 0 17 Vibra TITE 111 or 140 M TR 131 K 0 18 Su Sq mm KN N m N m N m 3 0 5 5 03 3 13 3 5 0 6 6 78 4 22 4 0 7 8 78 5 47 5 0 8 14 20 8 85 6 1 20 10 12 5 13 12 11 7 1 28 90 18 0 21 20 19 8 1 25 36 60 2
97. 2 1 Boom System 3 4 3 3 Boom Assembly 3 4 3 4 Complete Boom 3 5 3 4 1 Complete Boom 3 5 3 4 2 Complete Boom Installation 3 5 3 5 Boom Section Removal Installation 3 6 3 5 1 Second and Third Boom Section 3 6 3 5 2 Third Boom Section 3 7 3 5 3 Push Beam Extend Retract Cylinder 3 9 3 5 4 Push Beam Extend Retract Cylinder Installation and Third Boom Section Assembly 1 uote doy oe SX br D ence Got tow BAD Mee RW 3 9 3 5 5 Third Boom Section Installation 3 11 3 5 6 Second and Third Boom Section Installation 3 13 3 6 Extend Retract Chain Removal Installation 3 15 3 6 1 Extend Retract Chain 3 15 3 6 2 Extend Retract Chain 3 15 3 7 Push Beam Extend Retract Cylinder Removal Installation 3 16 3 7 1 Push Beam Extend Retract Cylinder 3 16 3 7 2 Push Beam Extend Retract Cylinder Installation
98. 2 8 31 29 27 10 1 5 58 00 36 1 61 58 55 12 1 75 84 30 52 5 105 100 95 14 2 115 71 6 170 160 150 16 2 157 97 8 265 250 235 18 2 5 192 119 5 365 345 325 20 2 5 245 152 5 520 490 460 22 2 5 303 189 0 705 665 625 24 3 353 222 0 905 850 800 27 3 459 286 0 1315 1235 1160 30 3 5 561 349 5 1780 1680 1575 33 3 5 694 432 5 2425 2285 2140 36 4 817 509 0 3115 2930 2750 42 4 5 1120 698 0 4985 4690 4395 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED G6 42A G9 43A G10 43A General Information and Specifications 2 3 3 Hydraulic Hose Torque Chart O Ring Face Seal amp JIC Torque Chart Size ORFS JIC Flats Method 4 ds Sm de 1 5 to 1 75 ND Di NE ds 8 En a 1 5 to 1 75 10 e ni isi NS 1 5 to 1 75 12 e Nm N PANER TE Te E 20 e iod 0 75 to 1 0 20000 2054 0780010 32 nee o 0 75 to 1 0 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 appropri
99. 43A General Information and Specifications 4 2 6 3 1000 1500 2000 Change g Change Change Wheel Check Transmission Transfer Case Axle Oil End Oil Air Intake Oil amp Filter Oil System P a oF Lubrication Boom Chains Schedule Hydraulic Hydraulic Tank Fluid amp Filters Breather Change Crankcase Engine Change Vent Filter if Valve Lash Engine Coolant equipped for ULS Adjustment OY3440 G6 42A G9 43A G10 43A 2 23 4 General Information and Specifications 27 LUBRICATION SCHEDULE 2 7 1 50 Hour Oy G10 43A OY2550 2 24 G6 42A G9 43A G10 43A General Information and Specifications 2 7 2 250 Hour p G10 43A OY2560 G6 42A G9 43A G10 43A Ay General Information and Specifications 2 7 3 1000 Hour G10 43A OY2570 2 26 G6 42A G9 43A G10 43A m ey XR Section 3 Boom Contents PARAGRAPH TITLE PAGE 3 1 Boom System Component 3 3 3 2 Boom System Three 3 4 3
100. 5 Remove the screws that secure the main dash panel Pull out the dash panel to gain access to the wiper motor 4 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 wiper assembly for possible reuse on replacement motor housing 9 Remove the motor from the inside of the cab G6 42A G9 43A G10 43A 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
101. 5 1 Cab Schematic 28 le gt 22 CANTERMITOR H sc esum o gt erac Tian voos GREEN SHIELD CAN SHIELD CAN SET a 2 can YELEON SHIELD CAN Ac T L905 GREEN SHIELDED H 904 YELLOW i Ly CABLE n L Dpto 9 Mmm PPP O gt e gt ti Torr Parece 191 TRANS TMP sone 4 gt mew i ENG WARN IT parcem y sna t ssaa gt sm tam lt 4 Pons wero 2 1 1 B B 3 HORN
102. 5 192 119 5 430 385 325 20 2 5 245 152 5 610 550 460 22 2 5 303 189 0 830 750 625 24 3 353 222 0 1065 960 800 27 3 459 286 0 1545 1390 1160 30 3 5 561 349 5 2095 1885 1575 33 3 5 694 432 5 2855 2570 2140 36 4 817 509 0 3665 3300 2750 42 4 5 1120 698 0 5865 5275 4395 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED 2 10 G6 42A G9 43A G10 43A General Information and Specifications 2 3 2 Metric Fastener Torque Chart Continued Values for Magni Coated Fasteners Ref 4150701 CLASS 8 8 METRIC HEX SOCKET HEAD BOLTS CLASS 8 METRIC NUTS Torque Torque Torque Lub or Loctite Dry or ease 2631M 242 271 225 0 17 Vibra TITE 111 or 140 0 15 0 16 Sq KN N m N m N m 3 0 5 5 03 2 19 14 14 1 0 3 5 0 6 6 78 2 95 1 8 17 1 5 4 0 7 8 78 3 82 2 6 24 2 3 5 0 8 14 20 6 18 5 8 4 9 4 6 6 1 20 10 8 74 9 8 4 7 9 7 1 28 90 12 6 15 14 13 8 1 25 36 60 15 9 22 20 19 10 1 5 58 00 25 2 43 40 38 12 1 75 84 30 36 7 75 70 66
103. 55 895 1215 745 1015 11 8 7 1 1250 0 7630 68700 1290 1755 1160 1580 965 1310 12 1 1250 0 8560 77000 1445 1965 1300 1770 1085 1475 11 4 7 1 2500 0 9690 87200 1815 2470 1635 2225 1365 1855 12 1 2500 1 0730 96600 2015 2740 1810 2460 1510 2055 13 8 6 1 3750 1 1550 104000 2385 3245 2145 2915 1785 2430 12 1 3750 1 3150 118100 2705 3680 2435 3310 2030 2760 11 2 6 1 5000 1 4050 126500 3165 4305 2845 3870 2370 3225 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER G6 42A G9 43A G10 43A General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Magni Coating Fasteners Ref 4150701 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Torque SIE T suere Clamp Loctite gogh or 271 or Loctite EM or 017 Vibra TITE 1110r140 Vibra TITE 131 0 16 0 15 Sq In LB IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 380 7 0 8 48 0 1120 0 00661 420 8 0 9 6 32 0 1380 0 00909 580 14 1 5 40 0 1380 0 01015 610 14 1 6 8 32 0 1640 0 01400 900 25 2 8 36 0 1640 0 01474 940 26 2 9 10 24 0 1900 0 01
104. 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 410 280 380 16 0 7500 0 3730 33600 355 485 335 455 315 430 7 8 9 0 8750 0 4620 41600 515 700 485 660 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 12 1 0000 0 6630 59700 845 1150 795 1080 745 1015 11 8 7 1 1250 0 7630 68700 1095 1490 1030 1400 965 1310 12 1 1250 0 8560 77000 1225 1665 1155 1570 1085 1475 114 7 1 2500 0 9690 87200 1545 2100 1455 1980 1365 1855 12 1 2500 1 0730 96600 1710 2325 1610 2190 1510 2055 13 8 6 1 3750 1 1550 104000 2025 2755 1905 2590 1785 2430 12 1 3750 1 3150 118100 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 12 1 5000 1 5800 142200 3020 4105 2845 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 2 6 G6 42A G9 43A G10 43A General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Magni Coating Fasteners Ref 4150701 SOCK
105. 661 6 32 0 1380 0 00909 40 0 1380 0 01015 8 32 0 1640 0 01400 36 0 1640 0 01474 10 24 0 1900 0 01750 32 0 1900 0 02000 1 4 20 0 2500 0 0318 2860 122 14 114 13 28 0 2500 0 0364 3280 139 16 131 15 Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 25 35 20 25 20 25 3 8 16 0 3750 0 0775 7000 35 50 35 50 35 50 24 0 3750 0 0878 7900 40 55 40 55 35 50 7 16 14 0 4375 0 1063 9550 60 80 55 75 50 70 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 13 0 5000 0 1419 12750 90 120 85 115 80 110 20 0 5000 0 1599 14400 100 135 95 130 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315 430 7 8 9 0 8750 0 4620 41600 515 700 485 660 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 12 1 0000 0 6630 59700 845 1150 795 1080 745 1015 11 8 7 1 1250 0 7630 68700 1095 1490 1030 1400 965 1310 12 1 1250 0 8560 77000 1225 1665 1155 1570 1085 1475 11 4 7 1 2500 0 9690 87200 1545 2100 1455 1980 1365 1855 12 1 2500 1 0730 96600 1710 2325 1610 2190 1510 2055 13 8 6 1 3750 1 1550 104000 2025 2755 1905 2590 1785 2430 12 1 3750 1 3150 118100 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370
106. 750 1120 36 4 1 32 0 1900 0 02000 1285 42 4 7 1 4 20 0 2500 0 0318 2020 86 9 7 80 9 28 0 2500 0 0364 2320 99 11 1 95 11 In Sq In LB FT LB N m FT LB N m FT LB N m 5 6 18 0 3125 0 0524 3340 15 20 14 19 15 20 24 0 3125 0 0580 3700 15 20 15 21 15 20 3 8 16 0 3750 0 0775 4940 25 35 25 34 25 34 24 0 3750 0 0878 5600 30 40 28 38 25 34 7 6 14 0 4375 0 1063 6800 40 55 40 54 35 48 20 0 4375 0 1187 7550 45 60 44 60 40 54 1 2 13 0 5000 0 1419 9050 65 90 60 82 55 75 20 0 5000 0 1599 10700 75 100 71 97 65 88 9 16 12 0 5625 0 1820 11600 90 120 87 118 80 109 18 0 5625 0 2030 12950 105 145 97 132 90 122 5 8 11 0 6250 0 2260 14400 130 175 120 163 115 156 18 0 6250 0 2560 16300 145 195 136 185 125 170 3 4 10 0 7500 0 3340 21300 225 305 213 290 200 272 16 0 7500 0 3730 23800 255 345 238 324 225 306 7 8 9 0 8750 0 4620 29400 365 495 343 466 320 435 14 0 8750 0 5090 32400 400 545 378 514 355 483 1 8 1 0000 0 6060 38600 545 740 515 700 480 653 12 1 0000 0 6630 42200 600 815 563 765 530 721 11 8 7 1 1250 0 7630 42300 675 920 635 863 595 809 12 1 1250 0 8560 47500 755 1025 713 969 670 911 11 4 7 1 2500 0 9690 53800 955 1300 897 1219 840 1142 12 1 2500 1 0730 59600 1055 1435 993 1351 930 1265 13 8 6 1 3750 1 1550 64100 1250 1700 1175 1598 1100 1496 12 1 3750 1 3150 73000 1420 1930 1338 1820 1255 1707 11 2 6 1 5000 1 4050 78000 1660 2260 1560 2122 1465 1992 12 1 5000 1 5800 87700 1865 2535 1754 2385 1645 2237 NOTES 1 THESE TORQUE VALUES DO APPLY CADMIU
107. 8 5 8 11 0 6250 0 2260 14400 150 203 110 149 165 224 135 1838 18 0 6250 0 2560 16300 170 230 130 176 190 258 153 207 3 4 10 0 7500 0 3340 21300 260 353 200 271 285 388 240 325 16 0 7500 0 3730 23800 300 407 220 298 330 449 268 363 7 8 9 0 8750 0 4620 29400 430 583 320 434 475 646 386 523 14 0 8750 0 5090 32400 470 637 350 475 520 707 425 576 1 8 1 0000 0 6060 38600 640 868 480 651 675 918 579 785 12 1 0000 0 6680 42200 700 949 530 719 735 1000 633 858 11 8 7 1 1250 0 7630 42300 800 1085 600 813 840 1142 714 968 12 1 1250 0 8560 47500 880 1193 660 895 925 1258 802 1087 11 4 7 1 2500 0 9690 53800 1120 1518 840 1139 1175 1598 1009 1368 12 1 2500 1 0730 59600 1240 1681 920 1247 1300 1768 1118 1516 1 3 8 6 1 3750 1 1550 64100 1460 1979 1100 1491 1525 2074 1322 1792 12 1 3750 1 3150 73000 1680 2278 1260 1708 1750 2380 1506 2042 11 2 6 1 5000 1 4050 78000 1940 2630 1460 1979 2025 2754 1755 2379 12 1 5000 1 5800 87700 2200 2983 1640 2224 2300 3128 1974 2676 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K G6 42A G9 43A G10 43A 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Va
108. AKE OFF 21 Y6 ONLY IF PARK BRAKE OFF al Wi re sowas 6 ONLY IF PARK BRAKE OFF E sese 5 eS Dd A lt WS ONE 2 I pen SR 8 ie ecen ones CD 261 enms 22 2 gt 70 REVERSE 20 REVERSE SOL or erroe soot awe Parama EF STATT PA 4 EE SHETER GND 22 IBANSIMP SW TRANS TMP SW ac SP BAT PWA REY START s Lo REGEN PWR SHIFTER GND TE DIE TT 18 s pepe E BEE lt ge B B soon snemu ewa 2 posueren on F toa ETUR sur ye m p 55 3984 SIDJOYPWE 38583 mmm 208 98 8539723 suse lt 9 3 25392508 PLUGGED 4 lt a MY7940 L G6 42A G9 43A G10 43A Electrical System Options Schematic 9 5 2
109. Amr Controller 1 Injector Power Supply Bad Intelligent Device or Component 5 Volts DC Sup Sensor Supply Voltage 1 Circuit Voltage Below dog a509 4 Amber ply Normal or Shorted to Low Source 5 Volts DC Sup Sensor Supply Voltage 1 Circuit Voltage Above one 4908 3 Amber ply Normal or Shorted to High Source 415 100 1 Red Engine Oil Pressure Low Data Valid but Below Normal Pressure Operational Range Most Severe Level G6 42A G9 43A G10 43A 9 41 Electrical System Fault SPN FMI Lamp SPN um Codes Codes Codes Color Description Cummins 418 97 15 Amber Water in Fuel Water in Fuel Indicator High Data Valid but Above Blinking Indicator Normal Operational Range Least Severe Level 422 111 2 Amber Coolant Level Coolant Level Data Erratic Intermittent or Incorrect Water in Fuel Water in Fuel Sensor Circuit Voltage Above is a Amben Indicator Normal or Shorted to High Source Water in Fuel Water in Fuel Sensor Circuit Voltage Below es id Ambar Indicator Normal or Shorted to Low Source Pedal Low Idle Accelerator Pedal or Lever Idle Validation Circuit 2 208 2 AIDS Switch Data Erratic Intermittent or Incorrect Pedal Low Idle Accelerator Pedal or Lever Idle Validation Circuit ave i Red Switch Out of Calibration 435 100 2 Amber Engine Oil Oil Pressure Sensor Circuit Data Erra
110. BEFORE transmission mounts are removed Place blocks under the transmission to help support it during removal Remove both rear transmission mount bolts and lockwashers securing transmission mount to frame Remove the bolts and washers holding the transmission to the engine Remove capscrews and lockwashers securing rear transmission mount to transmission Carefully remove the transmission from the machine Avoid causing damage to the transmission or surrounding parts 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 Remove any external transmission components as required including the transmission temperature Switch and inlet and outlet cooler hose fittings Cover all transmission openings G6 42A G9 43A G10 43A Transmission 27 28 29 6 4 2 8020 Remove the transmission filter 4 and dispose of properly Clean the filter mounting surface Cover or cap the oil filter mount If transmission oil is suspect to contamination or torque converter is damaged remove the converter and flex plate from the transmission Remove the bolt and washers holding the converter to the flex plate Transmission Inspection and Internal Repair 6 4 3 Transmission Installation A WARNING NEVER lift a transmission alon
111. Codes Codes Color Description Cummine DOCU Engine Oil Pressure Sensor Circuit Voltage Above 155 190 1 Pressure Normal or Shorted to High Source Engine Oil Oil Pressure Sensor Circuit Voltage Below Normal 100 1 Amber Pressure or Shorted to Low Source Engine Oil Oil Pressure Low Data Valid but Below Normal 109 19 Amber Pressure Operational Range Moderately Severe Level Engine Coolant Coolant Temperature Sensor Circuit Voltage 194 ue 3 Amper Temperature Above Normal or Shorted to High Source Engine Coolant Coolant Temperature Sensor Circuit Voltage Below 195 me 4 Temperature Normal or Shorted to Low Source Engine Coolant Coolant Temperature High Data Valid but 146 110 16 Amber 9 Above Normal Operational Range Moderately Temperature Severe Level 147 91 1 Red Accelerator Accelerator Pedal or Lever Position Sensor Circuit Pedal Position Abnormal Frequency Pulse Width or Period 148 91 0 Red Accelerator Accelerator Pedal or Lever Position Sensor Circuit Pedal Position Abnormal Frequency Pulse Width or Period 151 110 0 Red Engine Coolant Coolant Temperature High Data Valid but Above Temperature Normal Operational Range Most Severe Level Temp Intake Intake Manifold Air Temperature Sensor Circuit ns 12 Manifold 1 Voltage Above Normal or Shorted to High Source Intake Manifold Air Temperature Sensor 19 195 5 Manifold 1 Voltage Below Normal
112. Contents PARAGRAPH TITLE PAGE 7 1 7 2 7 14 Disclaimer and 7 2 7 1 2 Engine Serial 7 2 7 1 8 Specifications and Maintenance Information 7 2 7 1 4 Component 7 2 7 2 Engine Cooling System 7 5 7 2 1 Surge Tank Cap 1 7 5 7 2 2 Thermostat 7 5 7 2 8 Radiator Assembly and 7 6 7 3 Engine Electrical 7 8 7 4 lE 7 8 7 4 1 Diesel Fuel ev ERR E xb A NOR EUR 7 8 7 4 2 Fuel Tank 4 c 40400 b A Dade 7 9 7 4 3 After Fuel System 7 10 7 5 Engine Exhaust 7 11 7 5 1 Exhaust System 015 7 11 7 5 2 Exhaust System 016 7 11 7 5 3 Exhaust System 15 7 12 7 5 4 Exhaust System 5
113. EERING CYLINDER REAR AXLE ASSEMBLY DRIVE SHAFT TRANSMISSION DROP BOX FRONT DRIVE SHAFT FRONT STEERING CYLINDER FRONT AXLE ASSEMBLY HEEL HUBS 2 REG MY7750 G6 42A G9 43A G10 43A Axles Drive Shafts Wheels and Tires A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual 5 2 AXLE SERIAL NUMBER Front and rear axle serial number plate is located on a mounting pad on front side of center section of each axle Information on serial number plate is required in correspondence regarding axle Supply information from the axle serial number plate when communicating about an axle assembly or axle components 5 3 AXLE SPECIFICATIONS AND MAINTENANCE INFORMATION For oil specifications and maintenance information refer to Section 2 General Information and Specifications Detailed axle service instructions are provided in the following publications G6 42A Service Manual P N 31200162 Parts Manual P N 31200727 G9 43A and G10 43A Service Manual P N 31200239 Parts Manual P N 31200727 5 4 AXLE REPLACEMENT 5 4 1 Front and rear axle assemblies differ in that front axle assembly is equipped with a parking brake mechanism and a limited slip feature rear axle has neither Following steps outline a typical axle removal procedure suitable for either f
114. ET HEAD CAP SCREWS Torque Torque SEE TPI Tensile Stress Load Torque Loctite 242 or 271 or Loctite 262 or Area See Note 4 Dry K 0 17 Vibra TITE 111 or 140 or Vibra TITE 131 Precoat 85 K 0 16 K 0 15 In Sq In LB IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 48 0 1120 0 00661 6 32 0 1380 0 00909 40 0 1380 0 01015 8 32 0 1640 0 01400 36 0 1640 0 01474 10 24 0 1900 0 01750 32 0 1900 0 02000 1 4 20 0 2500 0 0318 2860 122 14 114 13 28 0 2500 0 0364 3280 139 16 131 15 In Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 25 35 20 25 20 25 3 8 16 0 3750 0 0775 7000 35 50 35 50 35 50 24 0 3750 0 0878 7900 40 55 40 55 35 50 7 16 14 0 4375 0 1063 9550 60 80 55 75 50 70 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 13 0 5000 0 1419 12750 90 120 85 115 80 110 20 0 5000 0 1599 14400 100 135 95 130 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315 430 7 8 9 0 8750 0 4620 41600 515 700 485 660 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 12 1 0000 0 6630 59700 845 1150 795 1080 745 1015 11 8 7 1 1250 0 7630 68700 1095 1490 1030 1400 965 1810
115. Fuse Engine ECU Ignition Power 10 F4 Fuse Gauge Power 10 F5 Fuse Spare Accessory Power 15 F6 Fuse Auxiliary Electric Power 10 F7 Fuse Horn Power 15 F8 Fuse Spare Battery Power 25 F9 Fuse Engine ECU Battery Power 25 F10 Fuse Steer Frame Level Power 10 F11 Fuse Rear Axle Stabilizer Tilt Power 10 F12 Fuse Key Battery Power 15 F13 Fuse Options Power 3 20 F14 Fuse Options Power 4 20 F15 Fuse Options Power 1 20 F16 Fuse Options Power 2 20 IGN1 Relay Ignition 1 IGN 2 Relay Ignition 2 ACCY1 Relay Accessory 1 ACCY2 Relay Accessory 2 G6 42A G9 43A G10 43A Electrical System 9 4 4 Optional Power Distribution Unit VEC F1 R1 R5 F2 F3 R2 R6 F4 R3 Fo R7 F6 R4 E7 R8 F8 1260 Connector Legend No Type Function Amp Rating F1 Fuse Wiper 20 F2 Fuse Roof Wiper 5 F3 Fuse Option 15 F4 Fuse Option 25 F5 Fuse Heater 20 F6 Fuse Lights 30 F7 Fuse Beacon 10 F8 Fuse Dash Fan 10 R1 Relay Wiper R2 Relay Heater Blower R3 Relay Aux Elec 1 R4 Relay Aux Elec 2 R5 Relay Option 15A R6 Relay Option 25A R7 Relay Lights R8 Relay Beacon Fan G6 42A G9 43A G10 43A Electrical System 9 5 ELECTRICAL SYSTEM SCHEMATICS 9
116. G9 43A G10 43A 2 15 General Information and Specifications 2 4 3 Electrical SystemEngine System Battery if equipped for ULS Type Rating 12 BCI Negative Ground Maintenance Free Cold Cranking Amps Q 0 F 18 C 950 Cranking Amps 32 F 18 C 1190 Reserve Capacity Minutes 25 Amps 185 Group Series Group 31 Alternator 12V 120 Amps Battery if equipped for LS Type Rating 12 BCI Negative Ground Maintenance Free Cold Cranking Amps Q 0 F 18 C 700 Cranking Amps 32 F 18 C 840 Reserve Capacity Minutes 25 Amps 180 Group Series Group 31 Alternator 12V 120 Amps Battery Arctic if Equipped 2 Type Rating 12 BCI Negative Ground Maintenance Free Cold Cranking Amps Q 0 F 18 C 750 Cranking Amps 32 F 18 C 1000 Reserve Capacity Minutes 25 Amps 310 2 4 4 Engine Specifications Note Engine manufacturer s maximum high idle setting is lockwired and sealed DO NOT disturb this setting G6 42A G9 43A amp G10 43A Description If Equipped for ULS If Equipped for LS Engine Make Model Cummins QSB3 3 Cummins QSB3 3 Displacement 201 in 3 3 liters 201 in 3 3 liters Low Idle 1000 rpm 1000 rpm High Idle 2600 rpm 2600 rpm Horsepower 100 HP 74 6 kW 2600 rpm 99 HP 74 kW 2600 rpm Peak Torque 306 Ib ft 415 Nm 1600 r
117. GELMEN SHOLINS AXXCX HETION GAH WTION MAOA WOA Daa Wivd ITIL MOILSAOL W i i i i i 1 i XYK OL OL SX X VI SX X MS WEZATIVNV AX XX GAH MATION LIIL MAOA THHZAIVNV TOULNOD WOA MOILSAOL IST ON NIINA STA OSZ ON HHINH SHA sx x WIIOD T320V SX X X Xa SHVMLIOS CXX ERN WHOA TWO NOI SEIL IONLNOO TONINOO ITIL 4 1 1 1 1 1 1 1 1 ITIL WILL 00000 3d02 SNOISUZA WHLSAS SVO MOILSAOL SNOIIVNHITVO SNOIIVNEITVO ISSILITVNOSuSd ISSILITVNOSHS4 559009 8D11SONDVIG Qoo X SSHODV SNIHOVR UAINA nNSR DNSR FONW i 4
118. Input Multiple Unit Synchronization Input Data Erratic Intermittent or Incorrect System code 1 Sensor Supply Voltage 3 Circuit Voltage Below 208 5 Amber Diagnostic Normal or Shorted to Low Source System code 2 Sensor Supply Voltage 3 Circuit Voltage Above an 3 Diagnostic Normal or Shorted to High Source 241 84 2 Amber Wheel based Vehicle Speed Sensor Circuit Data Erratic Vehicle Speed Intermittent or Incorrect Wheel based Vehicle Speed Sensor Circuit tampering has been x zu Arbar Vehicle Speed detected Abnormal Rate of Change Red Stop Lamp Driver Circuit Voltage Below a 9e i Amber Redstop Lamp Normal or Shorted to Low Source Fan Clutch we 245 647 4 Amber Output Device Fan Control Circuit Voltage Below Normal or Shorted to Low Source Driver tae High Fuel Pressure Solenoid Valve Circuit Voltage 271 1347 4 Amber Pressurizing Below Normal or Shorted to Low Source Assembly 1 Fg Pump High Fuel Pressure Solenoid Valve Circuit Voltage 272 1347 3 Amber Pressurizing f Above Normal or Shorted to High Source Assembly 1 285 639 9 Amber Datalink Multiplexing PGN Timeout Error Abnormal Update Rate 286 639 13 Amber Datalink Multiplexing Configuration Error Out of Calibration 9 40 G6 42A G9 43A G10 43A Electrical System Fault SPN FMI Lamp SPN E Codes Codes Codes Color Descri
119. M PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER G6 42A G9 43A G10 43A 2 5 General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Magni Coating Fasteners Ref 4150701 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque Sis TPI Bolt Dia Tensile Stress Clamp Load Dry Pip 263 Loctite amp 242 or 271 or Loctite amp 262 or rea K 0 17 Vibra TITE 1110r140 Vibra TITE 131 K 0 16 K 0 15 In Sq In LB IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 48 0 1120 0 00661 6 32 0 1380 0 00909 40 0 1380 0 01015 8 32 0 1640 0 01400 36 0 1640 0 01474 1320 37 4 10 24 0 1900 0 01750 1580 51 6 32 0 1900 0 02000 1800 58 7 1 4 20 0 2500 0 0318 2860 122 14 114 18 28 0 2500 0 0364 3280 139 16 131 15 Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 25 35 20 25 20 25 3 8 16 0 3750 0 0775 7000 35 50 35 50 35 50 24 0 3750 0 0878 7900 40 55 40 55 35 50 7 16 14 0 4375 0 1063 9550 60 80 55 75 50 70 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 13 0 5000 0 1419 12750 90 120 85 115 80 110 20 0 5000 0 1599 14400 100 135 95 130 90 120 9 16 12 0
120. NNECTOR EE GND GRIDHEATER RELAY MY7930 DIAGNOSTIC 9 13 G6 42A G9 43A G10 43A Electrical System 9 6 ENGINE START CIRCUIT Starter X A NS 2264 34 S N N Y 057 wes 52 Testing the Starter on the Engine If starter 1 does not engage when ignition key switch is turned check following 1 The main fuse may be blown requiring replacement Check for cause of blown fuse 2 There may be a defect in ignition key switch ignition wiring or starter solenoid 3 Check battery condition Clean battery posts and connectors at each end of battery cables 4 Check for broken wiring and damaged insulation on wiring Replace all broken or damaged wiring 5 Check all connections at starter solenoid key switch and wiring harness plugs Clean and tighten all connections 6 If starter still does not operate after these checks have been performed check starting circuit b Starter Circuit Checks 1 Check wires and connections for looseness corrosion damage etc 2 If a whirring noise is heard but engine does not turn over starter is spinning but not engaging flywheel The starter drive or solenoid that pushes drive forward to engage flywheel may be defective Missing or damaged teeth on flywheel can also prevent starter from cranking engine 9 14 10
121. NTROL LEVER D M XN Q J 2552295 AUXILIARY 1 ASI HYDRAULIC Lo M 4 2 2 OUTRIGGER JOYSTICKs JOYSTICK IGNITION SWITCH SS SERVICE BRAKE PEDAL ACCELERATOR PEDAL DECOMPRESSION VALVE G6 42A G9 43A G10 43A Cab and Covers A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual 4 2 OPERATOR CAB 4 2 1 Cab Safety WARNING The protection offered by this ROPS FOPS will be impaired if subjected to any modification or structural damage at which time replacement is necessary ROPS FOPS must be properly installed using fasteners of correct size and grade and torqued to their specified value WARNING DO NOT weld grind drill repair or modify the cab any way Any modification or damage to cab structural components requires cab replacement Refer to the Operation amp Safety Manual To help ensure optimum safety protection and performance replace the cab if itis damaged Refer to the appropriate parts manual for ordering information 4 2 2 The cab serial number decal is located on left side of cab behind seat Information specified on serial number plate includes cab model number cab serial number and other data Write this information down in a convenient location to use in cab correspondence Serial Number Decal
122. OL IRANS TMP SIGNAL PWR AR NAT SIGNAL T m F LH WE Kev acc TOR LYS Pw lt EXTRA SWING ete eZ lt OPT FWA OPT PWAE GND CPT PWR GG GNOT OPT PWR AOX ELEC GND SIDESHIFT MAST asmi 1 HOLO3NNOO SS3NHYH OL AC CLUTCH sum e SPACCYPWH m POUT SIGNAL pepe SIGNAL PWR SIGNALRIN ED SIGNAL gt LUGGED TOS MURA 1 a ECTS SCZ lt TS GC PWRE AUK ELEC GNE TENDE ELEKE PLUGGED YY E PLUGGED ania HoLmoad NOISSWsiwaL lt vvv POWER DISTRIBUTION FUSE BREAKER LEGEND Fi Tia TEANSEARKERKEWR Fr sa ALTERNATOR EXCITE ENGINE ECU IGN Fa ik GAGE NST PANEL PW FS SPARE ACCESSORY PWR Fe AUX ELECTRIC Fr iss HORN wn FE
123. OLENOIDS OIL DRAIN PLUG OIL FILLER PLUG e TRANSFER CASE F BREATHER OIL FILL TUBE AND DIPSTICK TRANSMISSION FILTER SHIFT SOLENOIDS OIL DRAIN VALVE OIL DRAIN HOSE MY8000 6 2 G6 42A G9 43A G10 43A Transmission A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Note These instructions cover only the routine maintenance removal installation and troubleshooting of transmission Refer to local distributor and applicable Transmission Service Manual for assistance with comprehensive transmission diagnosis repair and component replacement 6 2 TRANSMISSION SERIAL NUMBER MY8010 Transmission serial number plate 1 is located on front of transmission case behind oil dipstick Information on the serial number plate is required in correspondence regarding the transmission 6 3 TRANSMISSION SPECIFICATIONS AND MAINTENANCE INFORMATION For transmission oil specifications and maintenance information refer to Section 2 5 Fluid and Lubricant Capacities Detailed transmission service instructions are provided in the following publications Service Manual P N 31200241 Parts Manual P N 31200727 G6 42A G9 43A G10 43A 6 4 TRANSMISSION REPLACEMENT Note Contact local distributor if internal transmission repair is required during the warranty period
124. Ply Foam Approximately 720 Ib 327 kg Pneumatic 76 psi 5 2 bar 400 75 28 DuraForce 14 Ply Foam Approximately 570 Ib 259 kg G6 42A G9 43A G10 43A 2 17 amp General Information and Specifications 2 5 FLUID AND LUBRICANT CAPACITIES 2 5 1 Fluids if Equipped for ULS Ambient Temperature MS Compartment or System Type and Classification Viscosities oF Min min X x SAE 15W 40 5 120 15 49 Engine Crankcase API CJ 4 Plus SAE 07720 1 401 0 1 401 20 Transmission and Transfer Mobilfluid 424 10W 30 0 104 20 40 Case Mobilfluid LT 75W 80 40 0 40 20 Mobilfluid 424 10W 30 0 104 20 40 Mobilfluid LT 75W 80 40 0 40 20 SAE140 50 122 10 50 GL4 with gon 14 122 10 50 Axle Differential and Wheel LS Additives 90 GLS with 82 1000 0 LS Additives D 4 104 20 40 75W 90 40 104 40 40 75W 40 50 40 10 Mobilfluid 424 10W 30 0 104 20 40 Exxon Univis HVI 40 0 40 20 Boom Wear Pad Grease Mystik Tetrimoly Grade 2 4 104 20 40 Cylinder and Axle Grease Multipurpose Grease Grade 2 22 104 30 40 Boom Chain Lubricant Schaffer 200S Silver Streak B5 Biodiesel with Winter Conditioner Engine Coo
125. Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Feed the tilt cylinder hoses and if equipped auxiliary hoses through the access holes at the rear of the second boom section Push the third boom section the remainder of the way into the second boom section Feed the retract chain through the access holes at the rear of the second boom section Connect the retract chain to the chain clevis at the rear of the second boom section using the existing pin and retaining clips Secure the retract chain tilt cylinder hoses and if equipped auxiliary hoses to the bottom of the boom head with rope or wire Note Keep the retract extend chain free of any dirt and or contaminates 15 Remove the Temporary Extend Chain Bracket MY3960 16 Install previously removed pin 6 chain roller 7 tilt hose sheave 8 and if equipped auxiliary hose sheave assemblies at rear of the second boom section with existing hardware and shim as required 970 9 9 9 9 17 Thrust washers 9 are to be used as required to shim the hose sheave and retract chain sheave within 0 0625 in 1 6 mm of a tight fit At least one thrust washer 9 is required at each noted location 18 Center the retract chain sheave 10 between
126. Repeat drain procedure with the drop box 3 Transfer used transmission oil into a suitable covered container and label container as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the transmission drain plug Remove the transmission to axle drive shafts Refer to Section 5 5 3 Drive Shaft Removal Remove exhaust components from turbo to exhaust pipe Refer to Section 7 5 Engine Exhaust System 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Remove the implement pump Refer to Section 8 6 1 Implement Pump Replacement Label and disconnect transmission temperature switch connector and shift solenoid wiring harness connectors Label disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission Remove access cover from bottom of engine bell housing This will allow access to remove four bolts holding the torque convertor diaphragm to the engine flywheel Turn the engine over slowly by hand and align each of the four torque convertor diaphragm bolts to be accessed Remove them one at a time Wipe up any spilled hydraulic and transmission oil Connect a lifting strap or chain to lifting eye at top of transmission and to a suitable hoist or overhead crane Operate hoist or crane to remove slack from chain but DO NOT raise transmission at this time Place blocks under rear of engine for support
127. Section Subject Page iv G6 42A G9 43A G10 43A Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1 1 introduction orse eii eee Rl Ill I ed iR t 3E LER 1 2 1 2 J idriulgee SEARE ERS 1 2 1 3 Operation amp Safety 1 2 1 4 Do Not Operate 6 1 2 1 5 Safety 1 2 1 5 1 Safety Alert System and Signal 1 2 1 6 Safety Instructions ocu EI mc RR Ee E Eos 1 3 1 6 1 Personal Hazards sisse eee ave eek e e Reed 1 3 1 6 2 Equipment 1 3 1 6 3 General 1 3 1 6 4 Operational 1 4 1 7 Safety 2 5222 Re RR 1 4 G6 42A G9 43A G10 43A 1 1 Safety Practices 11 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures Following the procedures in this manual will help assure safety and equipment reliability Read understand and follow the information in this manual and obey all locally approved safety practices procedures rules codes
128. System 9 8 9 9 9 10 9 11 9 12 9 13 Window Wiper Washer Windshield Wiper 9 17 9 8 1 Windshield Wiper 9 17 9 8 2 Windshield Rear Window Washer Reservoir 9 18 Cab Heater and 9 19 9 9 1 Cab Heater 9 19 Solenoids Sensors and Senders 9 20 9 10 1 Park Brake Solenoid 9 20 9 10 2 Transmission Solenoid Valve 9 21 9 10 3 Transmission Temperature 9 21 9 10 4 Engine Coolant Temperature 9 22 9 10 5 Fuel Level 9 22 Display Gauge and Dash 9 24 9 11 1 Display 1 9 24 9 11 2 Ignition Key 9 24 9 11 3 Dash Switches 9 25 Hand Held Analyzer G9 43A and 110 4 9 27 9 12 1 Analyzer 9 27 9 12 2 Analyzer Joystick Software Version 1 2 9 28 9 12 3 Analyzer Pump Software
129. The wear pads on this machine are flat rectangular wear pads with metal inserts A total of 30 wear pads are installed on the boom sections of the G6 42A G9 43A and G10 43A machines 3 10 1 Wear Pad Inspection 1 1 NS A Ma2070 Inspect all wear pads for wear If angle indicators 1 on ends of wear pads are visible wear pads can be reused If the pads show uneven wear front to back they should be replaced Replace pads as a set if worn or damaged 3 10 2 Note Inspect all wear pads Replace as necessary Wear Pad Installation and Lubrication The following wear pad procedure must be followed to insure the proper wear pad installation 1 Wear pad inserts and mounting bolts MUST be clean from any grease oil or other contaminates before applying Loctite 2427 installing mounting bolts 2 Apply Loctite 2427 all wear pad mounting bolts 1390 3 A spacer 2 with holes must be used before shim 3 is used 4 A shim 3 must be inserted between spacer 2 and wear pad support plate block or boom section 4 5 The number of shims can vary at each shim point G6 42A G9 43A G10 43A C x is 6 The bottom wear pads must be shimmed equally on each side T 15 16 MY5510 Maintain a total boom section clearance 5 of 0 070 0 130 in 1 78 3 30 mm both the horizontal and ve
130. ULT AXA EEN TATTO SAT ENG WAANT Enc stop ir TRANBEKEWE GND True TCT ON DGLUTCH PLUGGED CANUAOS L MOD GND VV XIGWASSV 8V2 OL mu START LT ENG WARN IT 1 ECU BATIO22 stan SS3NHYH 13NYd OL M C v ud 124254444242 A M AM CARE CAN woos SHIELD CANT ENG GND SHLD CANT CABLE tpans REVERSE SOL TRANS SOL YS TRANS SOL TRANS SOLYE TRANS SOL Ye REY START SHTPWRT SHETPWRE REVERSE TRANBEK SHIFTER GND lt THRSGNSIS TER RNET SP BAT PWR EP ACCY PWE REGEN FORCE SW BEGEN INH SW TEGEN DIS LAMP lt FEST LAMP TEANS TNE SW AC CLUTCH SBT TUT UP TTL ON SPAT TRANS SOLYI REVERSE SOL TRANS SOL YS TRANS SOL TRANS SOLVE ECU TRANS BRK SOL 55454145 HQLO3NNOO ARMAF SIGNAL SIGNAL ETN HOLOSNNOO SS3NHYH OL ZHOLO3NNOO MM SS3NHUVH SISSVHO 10H1NOO
131. USE AND RELAY MODULE G6 42A G9 43A G10 43A Electrical System 9 2 SPECIFICATIONS Electrical system specifications are listed in Section 2 General Information and Specifications 9 3 SAFETY INFORMATION A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual 9 4 FUSES AND RELAYS 9 4 1 Engine Compartment MY7980 Starter Lockout Relay 1 Glow Plug Fuse 2 Starter Relay 3 VEC Fuse 4 and VEC control module 5 are located in engine compartment G6 42A G9 43A G10 43A C MY7420 The optional power distribution unit is located in the cab For access remove the screws securing the load chart panel 4 to the dash Electrical System 9 4 3 Power Distribution Unit VEC F8 F3 IGN1 F15 F4 F16 F14 Fis F9 F7 Pee IGN3 F10 Ld En ACCY1 F12 F 2 F6 MY4610 Connector Legend No Type Function Amp Rating F1 Fuse Trans Park Brake Power 15 F2 Fuse Alternator Excite 5 F3
132. Version 1 2 9 36 SAE Diagnostic Trouble and Fault 9 38 9 13 1 Gauge Fault Code 9 38 9132 Fault CodeS sceon oriak urade aea ne RR e 9 38 G6 42A G9 43A G10 43A Electrical System 91 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 IF EQUIPPED FOR ULS 3IN 1 GAUGE DASH SWITCHES 4351 IGNITION SWITCH ALTERNATOR FUSE AND RELAY MODULE G6 42A G9 43A G10 43A ACCESORY POWER DISTRIBUTION UNIT behind dash panel OPTIONAL HEATER AC CONTROLS IF EQUIPPED ENGINE CONTROL MODULE ECM STARTER VEC CONTROL MODULE MY8220 9 3 Electrical System IF EQUIPPED FOR LS DASH SWITCHES 3IN 1 GAUGE DISTRIBUTION UNIT behind dash panel tc gt a o lt OPTIONAL HEATER AC CONTROLS IF EQUIPPED IGNITION SWITCH ENGINE CONTROL MODULE ECM ALTERNATOR STARTER VEC CONTROL MODULE 8230 F
133. WR HORN EUR E 22 HORN HORN E E E gt 3 D QB spp z 9o EO dui m gt pacar so 2 pric pax sou Qi Qr stone smon 2 gt 5 2 STR AW gt ewe 1 DEUAN P t 5 R m 8 i Penna 5 f 8 PRETT i i Wc i 5 i 9 i i 3 sesenroncesw lt m DPF SoorLAMPTS 0 8 gt E gt lt 5 8 gt mEENEWRIS 2 1 gt A m gt Um 8 EBER m gt gt gt gt gt 1 o 2 8 zzgl B 5 2 9 vin 21822 21282 su 5 9 5 3 z 1 E gt os gt E TRANSMISSION LEGEND ZF E E 5 5 s 3 BAD GEAR ACTIVATED TRANS SOLENOIDS 2 gis 5 8 3 2 82 Fi Yi Y3 Y4 Y6 3 i F2 Yi Y3 Y5 Y6 F8 1 8 3 F4 vive RI Y2 Y3 Y4 Y6 el cune Jz 4 R2 Y2 Y3 Y5 Y6 e row PI zewssovi fy Y2 Y3 Y6 sso 12 T gt gt Q TRANS SOL 22 ils R4 Y2 Ye fela xErsws E E 2 ems gt Y6 ONLY IF PARK BRAKE OFF 2 Y6 ONLY IF PARK BR
134. ace a Do Not Operate Tag on both the ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery 5 Slowly turn surge tank cap and allow any pressure to escape Remove surge tank cap 6 Place a suitable container beneath radiator drain 7 11 12 13 Place funnel at base of the radiator to channel drained coolant into a container Loosen draincock 1 to allow coolant to drain Transfer coolant into a properly labeled container Dispose of properly if the coolant needs to be replaced Tighten the radiator draincock Label remove and cap the fuel cooler 2 fuel lines Remove drip shield plate 3 Loosen and remove the nuts and washers from two isolator mounts at the bottom of the radiator 4 Place a suitable container beneath the hydraulic oil cooler fittings Transfer any hydraulic oil into a properly labeled container Dispose of properly Label disconnect and cap the hydraulic cooler hoses 5 Cap all fittings and openings to prevent dirt and debris from entering hydraulic system Loosen and remove the nut and washer 6 from top of radiator IF EQUIPPED FOR ULS 11 SIDA 10 MY7770 G6 42A G9 43A G10 43A Engine IF EQUIPPED FOR LS 7 SP 2
135. aken Read understand and follow these instructions During service of the boom perform the following 1 Check wear pads Refer to Section 3 10 Boom Wear Pads 2 Check hose sheaves and chain rollers 3 Apply grease at all lubrication points grease fittings Refer to Section 2 6 Lubrication Schedules 4 Check for the proper operation by operating all the boom functions through their full ranges of motion several times Note Depending on your particular circumstance the following procedures explain the removal installation of individual boom sections or removal installation of the complete boom WARNING NEVER weld or drill the boom unless approved writing by the manufacturer The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling G6 42A G9 43A G10 43A iC M is 3 4 COMPLETE BOOM REMOVAL INSTALLATION 3 4 1 Complete Boom Removal 10 11 12 13 Remove any attachment from quick switch assembly Remove the quick switch assembly Refer to Section 3 9 Quick Switch Assembly Park machine on a hard level surface level machine fully retract boom level boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open engine cover Allow system
136. an repair and or replace suction pipe Replace central shaft Repair or replace pump assembly G6 42A G9 43A G10 43A Transmission Problem Cause Remedy 3 Low clutch 1 Incorrect oil level 1 Fill transmission to correct level with pressure hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities 2 Main pressure valve stuck open 2 Clean the valve spool and housing 3 Broken or worn coupling shaft or 3 Replace coupling and or o rings piston o rings 4 Pressure reducing valve stuck open 4 Clean the valve spool and housing 4 Lack of power 1 Park or service brake dragging 1 Refer to Section 8 4 Hydraulic Circuits 2 Low engine rpm causes 2 Adjust the engine rpm to specifications converter stall Refer to Engine Service Manual 3 Pump output pressure is low 3 Refer to Problem 2 Low or no pump flow or pressure 4 Clutch discs worn or damaged 4 Replace clutch discs 5 Transmission overheating 5 Refer to Problem 5 Transmission overheating oil above 248 F 120 C 5 Transmission 1 Low oil level 1 Fill transmission to correct level with overheating oil above 248 F 120 C A Clogged radiator Transmission filled with incorrect oil or oil contaminated Excessive roading Restriction in oil cooler hoses Pump worn or damaged Thermal by pass valve damaged or flow restrict
137. anel opening Position steering valve to its original orientation in the cab 3 Install travel select lever connect the instrument panel harness connector install the steering wheel assembly Torque the steering wheel nut to 29 34 Ib 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 11 Display Gauge and Dash Switches 7 Properly connect the battery 8 Carefully examine all connections one last time before engine start up Rectify any faulty conditions 9 Start engine and check operation of steering system Check for hydraulic fluid leaks Check hydraulic fluid level in tank and add fluid as required 10 Close and secure the engine cover 11 Remove Do Not Operate Tags from both ignition key switch and steering wheel 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 G6 42A G9 43A G10 43A 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 Valv
138. ate 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 Ib ft 4 Nm 3 Use the double wrench method while tightening to avoid hose twist 4 Torque wrench must be held at the center of the grip Apply constant force until it clicks 5 After connection has been properly tightened mark a straight line across connecting parts indicating that connection has been properly tightened G6 42A G9 43A G10 43A 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 Ib ft 4 Nm Mark a dot on one of swivel nut flats and another dot in line on hex of adapter it s connecting to Use double wrench method while tightening to avoid hose twist After connection has been properly tightened mark a straight line across the connecting parts not covering dots indicating that connection has been properly tightened 2 13 General Information and Specifications 2 4 SPECIFICATIONS 2 4 1 Travel Speeds G6 42A G9 43A amp G10 43A Gear ULS LS ULS LS First 3 8 mph 6 1 km h 3 4 mph 6 1 km h 3 4 mph 5 5 km h 3 5 mph 5 6 km h Second 6 8 mph 12 9 km h 6 8 mph 10 9
139. attery Open surge tank cap and fill system completely to full cold level with coolant Replace and tighten surge tank cap Add coolant to overflow bottle until bottle is 1 4 to 1 2 full This overfilling will compensate for any air trapped in cooling system 6 Run engine to operating temperature Visually check for leaks with engine running Check coolant level in overflow bottle and fill or drain as necessary 7 Close and secure engine cover 8 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 2 3 Radiator Assembly and Replacement 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 f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position f 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 Assembly Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and shut engine OFF 2 Pl
140. aulic System 43A amp G10 43A Hydraulic Schematic Manual Controls G9 8 4 7 SERVICE BRAKE VALVE PARK BRAKES FRONT STEER CYLINDER STEER MODE SELECT VALVE dE STEER ORBITAL LU YR TELESCOPE TILT CYLINDER E 8160 QUICK ATTACH CIRCUIT oso pst E 1 Ls ANTHSTALUT 7 VALVE PUMP SIDE VALVE ANTI STALL 4K 5K VALVE VERSION 65 PSI COOLER 25 PSI BREATHER S RESERVOIR _ f CONTROL VALVE STD CAB CONTROLS OPTIONAL ON G9 43A ONLY SEE SHEET 2 FOR ADD L CONTROL VALVE OPTIONS 1 8 13 G6 42A G9 43A G10 43A Anti Stall System Hydraulic System 8 4 8 n
141. ber Engine Turbocharger Wastegate Actuator Condition Exists 9 48 G6 42A G9 43A G10 43A 31200792 An Oshkosh Corporation Company JLG Industries Inc 1 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 2 65811111 Fax 61 2 65813058 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG Latino Americana Ltda Rua Antonia Martins Luiz 580 Distrito Industrial Jo o Narezzi 13347 404 Indaiatuba SP Brazil Phone 55 19 3936 8870 Fax 455 19 3935 2312 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 4852 2639 5797 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 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 22 200
142. 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 it s 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 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 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 re
143. bolts also hold the push pin beams in place 2 Loosen and remove all retract chain sheave components 2 and the hydraulic hose rollers and components Note Offset the extend chain rod to the left or right of the push beam assembly allowing the push beam to be raised enough to allow the removal of the chain and hose sheaves 4070 3 Attach the Temporary Extend Chain Retention Bracket 3 between the extend chain rod 4 and the push beam tube 5 Snug in place Do Not tighten Note Refer to Section 3 15 Push Beam Temporary Brackets for Temporary Extend Chain Bracket diagram 4 Atthe rear of the boom remove the retract chain 6 from the chain clevis 3 7 3 8 vi Lr N Mi m 11 11 8 7 12 11 11 E ce e Ceol F MY4110 c Loosen and remove the tilt hoses and if equipped auxiliary hoses from the hose retainers 7 amp 8 at the front of the third boom section Loosen and remove tilt hose and auxiliary hose retainers 7 amp 8 from front of third boom section 10 L 10 E 9
144. boom place transmission control lever in N NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect 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 MY7110 8 Remove the four bolts and lockwashers 2 securing the pump to the transmission top bolts shown only Remove the o ring located between the transmission and the pump Wipe up any hydraulic oil spillage G6 42A G9 43A G10 43A Hydraulic System n 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 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 to the previously removed bolts 4 Secure the pump to the transmissio
145. boom section The boom sections are connected by extend and retract chains These chains are routed around sheaves on the front of the push beam and the rear of the second boom section As the extend retract cylinder is forced out hydraulically the second boom section is pulled out by the push beam and third boom section is pulled out by the extend chain As hydraulic pressure is applied to the retract port on the extend retract cylinder the retract chain pulls the third boom section and the push beam pulls the second boom section back into the first boom section The mechanical linkage formed by the chains and supporting hardware extend and retracts the second and third boom sections at the same rate The boom section lifts and lowers via action of the lift lower cylinder 3 4 3 3 BOOM ASSEMBLY MAINTENANCE These instructions provide the complete boom assembly removal and installation or the second and third boom sections removal and installation Before beginning conduct a visual inspection of machine and work area and review task about to be undertaken Read understand and follow these instructions Boom assembly consists of first second and third section booms and supporting hardware Note Before removing the boom or boom section the carriage or any other attachment must be removed from the quick switch Before beginning conduct a visual inspection of machine and work area and review task about to be undert
146. ccess b Radiator Assembly Installation 1 Install radiator fan shroud 12 with previously removed hardware ER 11520 4 4 2 Place radiator assembly in engine compartment and secure using previously used hardware 4 Note Install engine fan if previously removed 3 Install previously removed fan guard 11 4 Uncap and connect both transmission cooler hoses at radiator 10 5 Uncap and install both radiator hoses 9 to the radiator and tighten clamps 6 Uncap and install both charge air cooler tubes 8 to radiator and tighten clamps 7 Install coolant surge tank 7 and mounting plate Uncap and connect previously removed coolant surge tank hoses Engine 7791 8 Install previously removed nut and washer 6 to isolator mount at top of radiator Note Verify proper clearance between the fan and the fan shroud 12 9 Uncap and connect the previously labeled hydraulic oil cooler hoses to the hydraulic oil cooler fittings 5 10 Uncap and connect the previously labeled fuel cooler hoses to the fuel cooler fittings 2 11 Install previously removed drip shield plate 3 12 Open surge tank cap and fill radiator completely with coolant Replace and tighten surge tank cap Refer to Section 2 5 Fluid and Lubricant Capacities for proper capacities
147. ceeding 9 Raise machine using a suitable jack or hoist Place suitable supports under both sides of frame and lower machine onto supports Ensure that machine will remain in place during axle removal 10 Support the axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 11 Remove both wheel and tire assemblies from axle being removed Refer to Section 5 6 1 Wheel and Tire Assembly Removal Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 12 Remove the drive shaft assembly Refer to Section 5 5 3 Drive Shaft Removal 13 On the front axle remove the capscrew and locknuts securing the lower position cylinder mount pin to the front cylinder Tap the cylinder mount pin out and move the cylinder to prevent it from interfering with axle removal 14 Remove bolts and locknuts securing axle to frame G6 42A G9 43A G10 43A Axles Drive Shafts Wheels and Tires hs 15 Remove axles from machine using jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise disturb machine while removing axle Balance axle and prevent it from tipping turning or falling while removing it from beneath machine Place axle on a suitable support or holding stand 5 4 2 Axle Installation 1 Before proceeding ensu
148. ch to the cab harness connector Position the switch over the rectangular opening in the dash and snap into position Properly connect the battery Start the machine and check the replaced switch for proper function Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 26 G6 42A G9 43A G10 43A Electrical System 9 12 HAND HELD ANALYZER 9 12 1 Analyzer Usage G9 43A AND G10 43A Help messages can be viewed using the Analyzer P N 2901443 Help messages can be accessed by The hand held analyzer can be used in place of the cab pressing the ENTER key while viewing the current Help display panel message The Help message shall be EVERYTHING OK when no fault is present The Analyzer cable plugs into the joystick tilt accessory module connector under the dash 7 MY8200 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 MY8210 The Analyzer cable plugs into Pump Module connector at engine above fuel filter 8 For more information contact the local JLG Distributor
149. ch 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 ZF Powershift Transmission 4WG 92 98 TSC Repair Manual JLG P N 31200241 and can be obtained by calling your local JLG dealer or ZF Service Center 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 Contact the JLG Service Department if internal transmission repair is required during warranty period G6 42A G9 43A G10 43A 9 10 3 Transmission Temperature Sender Transmission Temperature Sender Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Open engine cover Allow system fluids to cool 4 Properly disconnect the battery Unplug transmission temperature sender connector 10 from the wiring harness connector The sender is threaded into the transmission housing Remove the sender Transmission Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or fault
150. ct the battery 3 20 25 Adjust the chain as needed Refer to Section 3 8 Boom Adjustments 26 Install the cover on the rear of the boom 27 Close and secure the engine cover 28 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 3 8 BOOM ADJUSTMENTS 3 8 1 1 Park machine on level ground Place transmission control lever in N NEUTRAL engage parking brake and level boom Chain Tension Inspection G6 42A 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Extend the boom 4 5 ft 1 2 1 5 m then fully retract the boom Verify boom is level 4 Measure the following three dimensions A B amp C MAL2561 5 At the boom head verify dimension is between 11 500 11 812 in 292 1 300 0 mm G6 42A G9 43A G10 43A A 7 J Lp Hl B MAL2601 6 At the bottom front of the boom verify dimension B 0 712 0 725 in 18 1 18 4 mm of the washer stack on the retract chain clevis A MAL2611 7 the back of the boom verify dimension is not less than 2 850 in 72 4 mm on the extend chain clevis Note Belleville washers are shown in the un compressed state 8 Boom adjustment will be required if the above dimensions
151. ction internal repair assembly adjustment and troubleshooting information are provided in appropriate engine service manual 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 7 1 2 The engine serial number Is stamped on top of engine Information contained in serial number is required in correspondence with engine manufacturer Engine Serial Number 7 1 3 Specifications and Maintenance Information For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Note Refer to Section 9 13 1 Gauge Fault Code Display for error codes and troubleshooting 7 1 4 To understand safety operation and maintenance information presented in this section it is necessary that operator mechanic be familiar with names and locations of engine components The following illustration identifies components that are referred to throughout this section Component Terminology G6 42A G9 43A G10 43A Engine Oil FILTER FUEL FILTER PRIMARY tc 6 y AA a lt 25
152. ctite 243 to all mounting bolts 3 Install two straps and four new bolts 1 securing front axle 3 bearing crosses to transmission Torque bolts to 55 60 Ib ft 75 81 Nm Axles Drive Shafts Wheels and Tires hs 4 Install two straps and four new bolts 2 securing front axle 3 bearing crosses to axle Torque bolts to 55 60 Ib ft 75 81 Nm 5 Install two straps and four new bolts 7 securing rear axle 9 bearing crosses to axle Torque bolts to 55 60 Ib ft 75 81 Nm 6 Install previously removed bolts nuts and washers 8 and secure the carrier bearing to frame Torque to 55 Ib ft 75 Nm 7 Install two straps and four new bolts 4 securing the rear axle 6 bearing crosses to the transmission Torque bolts to 55 60 Ib ft 75 81 Nm 8 Install two straps and four new bolts 4 securing the rear axle 6 bearing crosses to the rear axle 9 at the carrier bearing Torque bolts to 55 60 Ib ft 75 81 Nm 9 Properly connect the battery 10 Close and secure the engine cover 11 Unblock the wheels 12 Remove Do Not Operate Tags from both ignition key switch and steering wheel 5 10 5 6 WHEELS AND TIRES WARNING Mismatched tire sizes ply ratings or mixing of tire types radial tires with bias ply tires may compromise machine stability and may cause machine to tip over It is recommended that a replacement tire to be same size ply and brand as originally installed Refe
153. d mounts If modification damage a cracked weld and or fatigued metal is discovered replace the cab Contact the local distributor with any questions about the suitability or condition of a cab Note Remove and label cab components as needed before removing the cab from the machine Label disconnect and cap hydraulic hoses Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine 1 Park machine on a firm level surface Allow sufficient overhead and side clearance for cab removal Level the machine fully retract boom lower boom place travel select lever in N NEUTRAL position engage park brake and shut engine OFF 2 Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab removal 3 Open engine cover Allow the system fluids to cool 4 Properly disconnect battery 5 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain petcock and allow the coolant to drain 6 Transfer the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility 7 Tighten the radiator drain petcock 8 Disconnect cab heater hoses Refer to Section 4 3 7 Heater Air Conditioning System if equipped 9 Remove necessary dash panels to gain access to electrical wiring connections Label a
154. dL Service Manual Models 6 42 G9 43A amp G10 43A G6 42A S N 0160048658 amp After G9 43A amp G10 43A S N 0160048671 amp After excluding 0160048773 31200792 Revised October 13 2014 JL An Oshkosh Corporation Company EFFECTIVITY PAGE February 15 2013 A Original Issue Of Manual July 15 2014 B Revise page ii Added 3 32 3 33 4 8 Revised Pages 2 2 thru 2 12 3 20 thru 3 23 4 8 6 2 6 4 8 5 9 8 9 4 9 19 October 13 2014 C Revise pages 1 4 2 16 2 17 7 2 31200792 G6 42A G9 43A G10 43A READ THIS FIRST Modifications Modifications to this machine may affect compliance with Industry Standards and or Governmental Regulations Any modification must be approved by JLG Machine Configuration Two configurations of each machine are included in this manual Determine if machine is equipped with Ultra Low Sulfur Fuel Decal 1 as indicated below f equipped with the Ultra Low Sulfur decal all specific references to this machine configuration will be referred to as Ultra Low Sulfur ULS from this point forward f not equipped with the Ultra Low Sulfur decal all specific references to this machine configuration will be referred to as Low Sulfur LS from this point forward ULTRA LOW SULFUR DIESEL FUEL ONLY lt 15 mg kg 2700 REAR VIEW
155. ded AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information G6 42A G9 43A G10 43A N 24 25 26 27 3 5 6 17 16 15 15 MY3880 Install previously removed wear pad and spacer 15 on the bottom rear of the second boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Install the previously removed wear pad and spacer 16 on the left or right side of the second boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Install the previously removed counterbalance valve 17 Torque to 44 Ib ft 59 7 Nm Torque all wear pad mounting bolts as required Second and Third Boom Section Installation Note Using a straight bar approximately 20 in 508 mm long will aid in the installation of the wear pads located on the inside front of each boom section 1 Lubricate the bottom of the second boom section where the wear pads of the first boom section contact the second boom section Place the sling or two slings for better stability around the third boom section and slowly insert the second and third boom section into the first boom section be
156. e for installation information Service Brake Pedal Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL position engage parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover Allow the system fluids to cool Properly disconnect the battery MY8110 5 Remove the bolt and lockwasher 1 securing the service brake pedal pivot pin 2 6 Pull pivot pin from service brake pedal bracket 3 7 Remove service brake pedal from cab Ps Cab and Covers Service Brake Pedal Installation Position the service brake pedal in its mounting location within the cab Secure the brake pedal into position with the pivot pin Be sure the brake pedal has the correct range of motion Secure pivot pin with bolt and lockwasher Properly connect the battery Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 4 3 3 Accelerator Pedal Accelerator Pedal Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in N NEUTRAL position engage parking brake and turn the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open e
157. e enlist the help of at least one assistant or use a Suitable hoist or overhead crane and sling If replacing entire transmission transfer transmission temperature switch to replacement transmission Gear shift solenoids are included with a new transmission G6 42A G9 43A G10 43A 1 Install two guide studs near the top of the bell housing holes 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 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 Ib ft 72 Nm Remove the two alignment studs and install and torque the last two transmission mounting bolts Install capscrews and lockwashers securing rear transmission mount to transmission Torque capscrews to 125 140 Ib ft 170 190 Nm Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers Apply Loctite 24 the transmission mount bolts and torque to 125 140 Ib ft 169 190 Nm Turn the engine over slowly by hand and align each of the four torque convertor diaphragm 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 Ib ft 35 59 Nm Replace access plug Remove the hoist or overhead cran
158. e OFF 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery 5 Loosen hardware 3 securing alternator to support bracket on engine 6 Slide alternator toward engine to relieve tension on fan belt Remove fan belt Note Hecord how the alternator is installed to ensure correct installation later 7 Label and disconnect the wire leads attached to the alternator assembly 8 Remove lower mounting hardware securing alternator to lower mounting hole on engine 9 While supporting alternator with one hand remove upper mounting hardware from upper alternator mount Remove alternator from machine 9 16 G6 42A G9 43A G10 43A Electrical System 98 WINDOW WIPER WASHER WINDSHIELD WIPER MOTOR 9 8 1 Windshield Wiper Motor a Removal Note It 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 machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery 0440
159. e and sling Connect the transmission temperature switch connector and the shift solenoid wiring harness connectors 9 Secure wiring harness to transmission housing 11 12 13 14 Connect the transmission oil cooler inlet and outlet hoses at the transmission Install the hydraulic pump Refer to Section 8 6 1 Implement Pump Replacement Install the transmission to axle drive shafts Refer to Section 5 5 5 Drive Shaft Installation Install exhaust components from turbo to exhaust pipe Refer to Section 7 5 Engine Exhaust System Clean the transmission oil filter mounting surface Transmission 15 Apply a thin film of clean hydraulic oil to the new transmission filter gasket Install the new filter and torque to 20 25 Ib ft 27 34 Nm 16 Fill the transmission Refer to Section 2 5 Fluids and Lubricant Capacities for proper capacity 17 Transmission oil may be added through the dipstick tube 5 Remove the dipstick and add hydraulic oil Check the fluid level by taking intermittent dipstick readings as outlined in the appropriate Operation amp Safety Manual DO NOT overfill Reinstall the dipstick when finished 18 Transmission transfer case fluid may be added through the fill plug 6 Install fill plug and tighten when filled to appropriate level 19 Properly connect the battery Note Check transmission oil level with engine at idle and transmission o
160. e issue Active when Machine Setup s AUX HYDRAULIC is set to ENABLED 33199 Auxiliary Function desired current is greater than 250 but the Yes B Valve Open Circuit actual current is less then 75 The auxiliary hydraulic B digital output was open circuit This fault may be caused by improper wiring or a control module issue Active when Machine Setup s AUX HYDRAULIC is set to ENABLED 33200 Auxiliary Function The actual current is greater than 200mA PWM is Yes B Valve Short To Ground 95 and the digital output driver s 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 Setup s AUX HYDRAULIC is set to ENABLED 441 Battery Voltage Too Low Fork Tilt Up amp Down Auxiliary Hydraulics amp De No System Shutdown Clutch functionality prevented Battery voltage is less than 8 0V so the control module has prevented associated functionality 442 Battery Voltage Too High Fork Tilt Up amp Down Auxiliary Hydraulics amp De Yes System Shutdown Clutch functionality prevented Battery voltage is greater than 8 0V so the control module has prevented associated functionality Low Side Fault Relay de energized 447 Reference Voltage Out Of Fork Tilt Up amp Down Auxiliary Hydraulics amp De Yes Range Clutch functionality prevented
161. e 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 2 2 THREAD LOCKING COMPOUND JLG P N Loctite ND Industries Description 0100011 2421 Vibra TITE 121 Medium Strength Blue 1001095650 243 Vibra TITE 22 Medium Strength Blue 0100019 2711 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium High Strength Red Loctite 243 be substituted in place of Loctite 242 Vibra TITE 122 can be substituted in place of Vibra TITE 121 G6 42A G9 43A G10 43A General Information and Specifications
162. e machine until the Operation amp 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 amp 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 amp Safety Manual is missing consult the local JLG Distributor before proceeding 1 2 1 4 DO NOT OPERATE TAGS Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance Remove key and disconnect battery leads 1 5 SAFETY INFORMATION To avoid possible death or injury carefully read understand and comply with all safety messages In the event of an accident know where to obtain medical assistance and how to use a first aid kit and fire extinguisher fire suppression system Keep emergency telephone numbers fire department ambulance rescue squad paramedics police department etc nearby If working alone check with another person routinely to help assure personal safety 1 5 1 Safety Alert System and Signal Words A 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
163. ebris from entering the hydraulic system 6 Remove both hose retainer brackets 2 G6 42A G9 43A G10 43A M is G6 42A 1 G9 43A G10 43A MAL2670 7 Loosen and remove the lock nut adjustment nut 3 and belleville washers 4 from the retract chain 5 at the bottom front of the first boom section Note Note position of belleville washers for reassembly 8 Secure a rope or wire to the retract chain 5 NI m zn G6 42A Sz Er 225 g Ul Go I p Heo G9 43A Tj H n G10 43A 5 9 Loosen and remove the lock nut adjustment nut 6 and belleville washers 7 from the extend chain anchor 8 at the rear of the first boom section MAL2660 Note Note position of belleville washer for reassembly G6 42A G9 43A G10 43A
164. ed hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities Remove debris from the radiator Drain transmission and fill to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities Stop and idle the engine Replace cooler hoses Repair or replace pump assembly Replace thermal by pass valve cartridge Refer to Section 6 5 Transmission Cooler Thermal By Pass Valve 6 10 G6 42A G9 43A G10 43A Transmission 3 Incorrect clutch engagement 4 Internal damage 5 Broken diaphragm torque convertor 6 Loose diaphragm torque convertor mounting capscrews Problem Cause Remedy 6 Grinding or 1 Oil level too low 1 Fill oil to correct level Refer to Section clunking 2 5 Fluid and Lubricant Capacities noise from 2 Repair or replace parts as needed transmission 2 Transmission filled with incorrect oil 3 Drain transmission and fill to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities Refer to Section 9 9 2 Transmission Solenoid Valves Repair or replace parts as needed Replace diaphragm torque convertor Refer to Section 6 4 1 Transmission Removal Tighten capscrews G6 42A G9 43A G10 43A 6 Transmission Problem Cause Remedy 7 Oil leaking from 1 O
165. ed to a secure location reactivate parking brake Carefully follow procedures from start to finish Contact local JLG Distributor if you are unsure about any part of the procedure or for specific instructions concerning your particular situation 5 8 2 Manually Resetting the Park Brake Note Block the wheels of the machine BEFORE attempting to reset the machine s park brake Once the park brake is released the machine s park brake AND service brakes are inoperable MZ1020 1 Loosen each release screw 5 only 1 4 turn ata time in sequence until each screw has lost contact with the guide pin 2 Remove screws along with nuts and seals Replace seals lubricate screws with a silicone based grease and re install screws along with nuts 3 Adjust the nut of the screw heads in relation to the arm by 1 18 in 30 mm 4 Repeat steps 1 thru 3 for other side of differential 5 After repairs to machine have been made start machine and check park brake and service brakes for proper function Refer to Section 8 7 4 Service Brake Bleeding Section 8 7 5 Service Brake Test and Section 8 7 6 Steering Orbitrol Valve G6 42A G9 43A G10 43A Section 6 Transmission Contents PARAGRAPH TITLE PAGE 6 1 Transmission Assembly Component 6 2 6 2 Transmission Serial 6 3 6 3 Transmission Specificatio
166. efore leaving the machine TIRES Always keep tires inflated to the proper pressure to help prevent tipover DO NOT over inflate tires NEVER use mismatched tire types sizes or ply ratings Always use matched sets according to machine specifications MAJOR COMPONENTS Never alter remove or substitute any items such as counterweights tires batteries or other items that may reduce or affect the overall weight or stability of the machine BATTERY DO NOT charge a frozen battery Charging a frozen battery may cause it to explode Allow the battery to thaw before jump starting or connecting a battery charger 1 7 SAFETY DECALS Check that all safety decals are present and readable on the machine Refer to the Operation amp Safety Manual supplied with machine for information G6 42A G9 43A G10 43A Section 2 General Information and Specifications Contents PARAGRAPH TITLE PAGE 2 1 Replacement Parts and Warranty 2 2 2 2 Thread Locking 2 2 2 3 Torque Charts 2c x Rest ene RUE 2 3 2 3 1 SAE Fastener Torque 2 3 2 3 2 Metric Fastener Torque 2 9 2 3 8 Hydraulic Hose Torque 2 13 2 4 Specifications x evi Hele rer eee e
167. 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 4nd 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 amp G10 43A 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 Section 8 8 5 Cylinder Torque Specifications G9 43A G10 43A for torque specifications for the head gland 8 If applicable install new counter balance valve into
168. er control from dash panel Remove control from panel b Disassembly DO NOT disassemble cab heater and fan controls The controls are not serviceable Replace controls if found to be defective G6 42A G9 43A G10 43A Installation and Testing Check that the variable speed fan control is in the OFF position Install the heater controls to the dash panel with the previously used hardware Connect the cab electrical harness connector to the controls Install the control knobs Install screws securing dash panel to cab Properly connect the battery Turn ignition key to ON position and check fan speeds If further repair is needed refer to Section 9 5 Electrical System Schematics Start the machine and allow engine to warm to operating temperature Check heat control at different levels Close and secure the engine cover Remove Do Not Operate Tags from both ignition key switch and steering wheel 9 19 Electrical System 9 10 SOLENOIDS SENSORS AND SENDERS 9 10 1 Park Brake Solenoid Valve a Park Brake Solenoid Valve Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Pro
169. er in fuel tank may also prevent fuel level indicator from moving Refer to Section 9 5 Electrical System Schematics for further information G6 42A G9 43A G10 43A 9 23 Electrical System 9 11 DISPLAY GAUGE AND DASH SWITCHES 9 11 1 Display Gauge 12 fk 7 b MY8260 Gauge Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Open engine cover Allow system fluids to cool Properly disconnect the battery Remove the screws 11 securing the dash panel Label and disconnect the wires from the gauge 12 remove the gauge bracket Pull the gauge out of dash panel 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 into the dash panel Install gauge bracket 2 Connect previously labeled wires to the gauge 3 Install panel with previously used hardware 11 4 Properly connect the battery 5 Turn ignition to ON position to check gauge values 6 Close and secure the engine cover 7 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel
170. ers Friction Modifier Front differential only 13 12 ounces 372 7 milliliter Wheel End Capacity G6 42A 1 7 quarts 1 6 liters G9 43A amp G10 43A 1 75 quarts 1 65 liters Air Conditioning System if equipped System Capacity 2 5 Ib 1134 9 2 20 G6 42A G9 43A G10 43A General Information and Specifications 4 2 6 SERVICE AND MAINTENANCE SCHEDULE 2 6 1 10 1st 50 amp 50 Hour EVERY 10 ba fe fa Check Fuel Air Filter Check enone Check Hydraulic Check Tire Level Restriction Oil Level Oil Level Condition amp Indicator Pressure Transmission Oil Level Check Wheel Lug Nut Torque Drain Fuel Check Engine Check Washer Lubrication Water Coolant Level Battery Fluid Level Schedule Separator if equipped MY7680 G6 42A G9 43A G10 43A 2 21 General Information and Specifications 2 6 2 2 22 1st 250 250 amp 500 Hour Change Axle Oil Change Engine Oil and Filter Check Boom Wear Pads Change Fuel Filters Change Wheel End Oil Check Axle Oil Level Check Transfer Case Oil Level Check Wheel Lug Nut Torque Transmission Oil amp Filter Check Wheel End Oil Levels Rear Axle Stabilization Transfer Case Oil Air Filter Vacuator Valve P a Lubrication Schedule OY3430 G6 42A G9 43A G10
171. es to reservoir Connect the cab wiring harness connectors to the reservoir connectors Install reservoir tank onto mounting bracket Install lock washers and nuts and secure Fill the washer fluid reservoir with washer fluid Properly connect the battery Turn ignition key switch to RUN position and press washer switch Verify that fluid is sprayed on both windshield and rear glass Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G6 42A G9 43A G10 43A Electrical System 9 9 HEATER AND FAN 9 9 1 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 Cab Heater Controls a Cab Heater Controls Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery MY4351 5 Remove screws securing right cab dash panel 6 6 Pull out panel to gain access to heater control electrical connections Disconnect harnesses 7 Remove heater control knobs 8 Remove necessary hardware securing heat
172. f the hyaraulic 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 c
173. facility Clean and reinstall the transmission drain plug Label disconnect and cap the transmission oil cooler hoses 10 Cap all fittings and openings to prevent dirt and debris from entering Loosen and remove thermal by pass valve 11 Plug the opening to prevent dirt and debris from entering the system G6 42A G9 43A G10 43A 6 5 2 Thermal By Pass Valve Cartridge Installation 1 Remove plug and install new thermal by pass valve 11 4 Uncap and connect previously labeled transmission oil cooler hoses 10 Fill the transmission Refer to Section 2 5 Fluids and Lubricant Capacities for proper capacity Properly connect battery Note Check transmission oil level with engine at idle and transmission oil at normal operating temperature 5 Apply park brake shift transmission control lever to N NEUTRAL position and lower the forks or attachment to ground Open engine cover Remove transmission dipstick b and check oil level Oil level should be at MAX line Add oil as required Replace transmission dipstick Close and secure engine cover Recheck all drain plugs lines connections etc for leaks and tighten where necessary 6 Transmission 6 6 TORQUE CONVERTOR DIAPHRAGM 6 6 1 Torque Convertor Diaphragm Removal Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the
174. ge 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 Ib ft 43 Nm for the G6 42A and to 42 Ib 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 bol
175. heck 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 Checkthe 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 8 4 1 Hydraulic Pressures 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 machine run engine and follow procedures in Section 8 4 2 Pressure Specifications G6 42A
176. heels gt The drive shaft assembly is a balanced assembly Mark yoke and axle transmission and shaft and slip yoke so that these components can be returned to their original positions when reinstalled Yokes at both ends of drive shaft must be in same plane to help prevent excessive vibration G6 42A G9 43A G10 43A MY8140 7 Remove four bolts and two straps 1 securing bearing cross to the transmission output shaft flange Discard bolts 8 Remove four bolts and two straps 2 securing bearing crosses to the axle Discard bolts 9 Remove front drive shaft assembly 3 10 Remove four bolts and two straps 4 securing bearing cross to transmission output shaft flange Discard bolts 11 Remove four bolts and two straps 5 securing bearing cross to rear axle Discard bolts 12 Remove rear drive shaft assembly 6 5 5 4 1 Disassemble and clean all parts using an approved cleaning fluid Allow to dry Drive Shaft Cleaning and Drying 2 Remove and burrs or rough spots from all machined surfaces Re clean and dry as required 5 5 5 1 Raise drive shaft assembly into position Slip yoke end of drive shaft mounts toward axle If reinstalling a drive shaft previously removed align flange yokes according to alignment marks made during removal Drive Shaft Installation Note The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration 2 Apply Lo
177. il at normal operating temperature 20 Apply park brake shift transmission control lever to the N NEUTRAL position and lower the forks or attachment to the ground 21 Remove the transmission dipstick 5 and check the fluid level The level should be at the MAX line 22 If fluid is low add fluid as required and recheck level 23 Replace the transmission dipstick when finished 24 Install the engine cover 25 Close and secure engine cover 26 Recheck all drain plugs lines connections etc for leaks and tighten where necessary Close and secure the engine cover 27 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6 4 4 After Transmission Service or Replacement In general 1 Check transmission oil level and add oil as required 2 Disconnect and clean all transmission cooler hoses When possible remove transmission lines from the machine for cleaning 3 Drain and flush entire transmission cooling system 4 Thoroughly clean transmission filter screens and cases and replace transmission filter elements Note Check transmission oil level with engine at idle and oil at normal operating temperature 5 Reassemble all components and fill the transmission with clean fresh hydraulic oil through the dipstick tube opening 5 Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation amp Safety Manual DO NOT overfill Reinstal
178. il leaking from vent high oil level transmission 2 Drain plug loose and or o rings damaged or missing 3 Hose fittings loose 4 Oilleaking 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 Oil escaping from breather at shut down 10 Housing damaged 1 Remove drain plug and drain oil as needed until oil is at correct level Refer to Section 2 5 Fluid and Lubricant Capacities Replace o rings as needed and tighten plugs to 96 Ib ft 130 Nm Replace o rings as needed and tighten plug to 26 Ib ft 35 Nm Tighten fittings Replace gaskets and or tighten capscrews to 7 lb ft 9 5 Nm Tighten capscrews to 34 Ib ft 46 Nm Replace o rings and or tighten capscrews to 85 Ib ft 115 Nm Replace converter and or input shaft seal Replace output shaft seal Transmission may be under full Ensure transmission is at operating temperature 185 F 85 C and fill to upper mark on transmission dip stick Replace housing as needed 6 12 G6 42A G9 43A G10 43A Section 7 Engine
179. inders for general tilt cylinder removal 11 1 Remove the access cover from the rear of the first boom section 9 7 06 42 ET 10 1 a i o M 5 8 H 860 T v ze 10 Loosen and remove the four bolts 8 securing the ATs G9 43A retract chain anchor plate 9 A G10 43A 2 fil f 2 11 Between bottom front of first and second boom 6 1 Im sections feed a rope or wire to retract chain anchor E a T 6 plate and secure to second or third boom section 12 Disconnect both tilt tubes 10 and if equipped both auxiliary tubes from fittings on hose retainer brackets 11 at bottom front inside the boom Plug the tube LJ LJ ends to prevent dirt and debris from entering the hydraulic system 79 14 Disconnect both tilt hoses not shown and if 2 Remove the locknut adjustment nut and six equipped bath auxiliary noses torm hose retainer belleville washers 1 from the extend chain clevis bonom inside ihe Boom Plug 1058 rear of the boon ends to prevent dirt and debris from entering the hydraulic system 14 Loosen remove the hose retainer brackets 11 tubes 2 from rear of boom Cap and or plug all open hoses tubes and or fittings to prevent dirt and debris from entering the hydraulic system 3 6 and if equipped both auxiliary take up brackets G6 42A G9 43A G10 43A
180. ine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open engine cover Allow system fluids to cool Properly disconnect the battery Remove the main control valve protective cover 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 8 17 Hydraulic System b Main Control Valve Disassembly G6 42A inm Oy OF O AWO a anoqy 7 G9 43A amp G10 43A SUN 2 gt 3 UN 2 O MA C 3 i N 2 MY0340 G6 42A G9 43A G10 43A 8 18 Hydraulic System n 1 To disassemble the individual sections of the main control valve
181. ing careful not to damage hoses chains and or surrounding components Lower the second and third boom section onto a suitable support relocate one sling and insert the second and third boom section assembly allowing access for the installation of the bottom plate wear pads spacers and shims at the front of the first boom section G6 42A G9 43A G10 43A Remove any rope or wire securing the retract chain and tilt hoses and if equipped auxiliary hoses as the second and third boom sections are installed into the first boom section H4 LI Us 1 840 Install previously removed mounting plate 1 at the bottom front of the first boom section Torque as required Install the previously removed wear pads spacers and shims at the bottom front of the first boom section 2 Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Install previously removed mounting plate 3 at top front of first boom section Torque as required Install previously removed wear pads Spacers 4 P N 298 1729 and shims at top front of first boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Install p
182. ion 4 3 30 FOKS ceo eee ee eee ee eee a 3 31 Emergency Boom Lowering Procedure 3 31 3 13 1 Equipment and Supplies 3 31 3 13 2 Lowering 3 32 Troubleshooting ices ae oi Sete dw mE ERE weed cen evens arse 3 34 Push Beam Temporary 3 37 G6 42A G9 43A G10 43A 31 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section SECOND BOOM SECTION EXTEND CHAIN INSIDE BOOM THIRD BOOM SECTION FIRST BOOM SECTION g NO eA NS RETRACT CHAIN N c INSIDE SGN TILT EXTEND RETRACT CYLINDER CYLINDER INSIDE PUSH BEAM STRONG BACK MY7730 PIVOT PIN G6 42A G9 43A G10 43A 3 3 Cy 3 2 BOOM SYSTEM THREE SECTION 3 2 1 The three section boom consists of the first second and third assemblies with a single extend chain and a single retract chain Boom System Operation 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
183. ion and insert tilt cylinder hoses and if equipped auxiliary hoses into second boom section followed slowly by third boom section being careful not to damage any surrounding components Lower the third boom section onto a suitable support relocate one sling and insert the third boom section assembly approximately 75 into the second boom section G6 42A G9 43A G10 43A 3 47 5 5 1 T j 4 EL MY3870 Install the previously removed wear pad mounting plate 1 with existing hardware at the bottom front of the second boom section Torque as required Install previously removed wear pads shims and spacers 2 with existing hardware at bottom front of second boom section Torque as required Install wear pad mounting plate 3 with existing hardware at inside top front of the second boom section Torque as required Install previously removed wear pads spacers and shims on each side at front of the second boom section 4 Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Install wear pads spacer 5 using bolts and washers at top front of the second boom section Snug mounting bolts Shim as needed AFTER boom section is installed
184. ircuit also Refer to Section 9 5 Electrical System Schematics in this manual G6 42A G9 43A G10 43A Hydraulic System n 8 3 HYDRAULIC PRESSURE DIAGNOSIS JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting the JLG 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 Contact local JLG Distributor for ordering information Part Description Approximate Price and Number Weight Availability 70000652 Hydraulic Pressure Test 10 Ibs Consult Factory Kit 70000101 Digital Hydraulic 7 lbs Consult Factory Pressure Test Kit G6 42A G9 43A G10 43A 8 3 1 When diagnosing trouble in hydraulic system use hydraulic testing information in Section 8 4 1 Hydraulic Pressures Pressure Checks and Adjustments In general follow steps below whenever conducting pressure checks and performing adjustments 1 Park machine on a firm level surface Engage park brake place travel select lever in NEUTRAL level boom and turn engine OFF 2 Test port is located at top right corner of main control valve Install a pressure gauge capable of measuring at least 1096 more pressure than that which circuit being checked operates unde
185. issue Yes 259 Model Change Hydraulics Suspended Cycle Ems Fork Tilt Up amp Down Auxiliary Hydraulics amp De Clutch functionality prevented The user changed the Model Selection using a JLG Analyzer All functions are being prevented until the EMS is cycled Machine Setup s MODEL was changed via JLG Analyzer Yes G6 42A G9 43A G10 43A 9 35 Electrical System Analyzer Pump Software Version P1 2 9 12 3 speeds biol senijeuosjeg senijeuosjeg peeds Senieuosjed MS Jez jeuy uez Apeuy e npo N Add Janes dnjes 8250 senijeuosjag 00000 sseooy SUOISJOA sonsouDeiq AX XX VUXXX enjoy e1S huy VUIXXX ranbioy euiBu3 XXXX peeds Seues 5 dnjeg 255000006566 X sseoov sonsouBeiq
186. km h 6 1 mph 9 8 km h 6 3 mph 10 1 km h Third 15 5 mph 25 9 km h 15 1 mph 24 3 km h 13 9 mph 22 4 km h 14 2 mph 22 9 km h Fourth 23 2 mph 32 9 km h 22 2 mph 35 7 km h 19 8 mph 31 9 km h 18 3 mph 29 5 km h 2 4 2 Hydraulic Cylinder Performance Note Machine with no attachment or load engine at full throttle hydraulic oil above 130 F 54 C minimum engine at operating temperature a G6 42A Approximate Times seconds Function ULS LS Min Time Max Time Min Time Max Time Boom Extend Boom Level 13 6 14 7 14 0 14 8 Boom Retract 7 41 14 8 12 3 13 1 Boom Lift 11 9 12 8 12 6 13 4 Boom Lower 8 8 9 0 9 2 10 0 Attachment Tilt Forward 3 8 3 8 3 4 3 9 Attachment Tilt Rearward 3 2 3 2 3 9 4 4 Frame Level Full Right to Left 7 4 7 4 6 3 6 9 Frame Level Full Left to Right 5 8 5 8 8 6 9 6 G6 42A G9 43A G10 43A General Information and Specifications b G9 43A amp G10 43A Approximate Times seconds Function ULS LS Min Time Max Time Min Time Max Time Boom Extend Boom Level 14 4 16 5 14 4 15 9 Boom Retract 11 0 20 0 16 8 18 6 Boom Lift 10 2 12 4 11 3 12 5 Boom Lower 9 3 14 0 9 2 10 2 Attachment Tilt Forward 6 0 8 5 7 2 8 0 Attachment Tilt Rearward 6 0 9 0 6 8 7 5 Frame Level Full Right to Left 10 5 13 0 11 9 13 1 Frame Level Full Left to Right 10 9 12 1 11 0 12 1 G6 42A
187. l and add coolant if required Replace pressure cap 23 Check for leaks from 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 engine rpm at full throttle 25 Purge hydraulic system of air by operating all boom functions through their entire range of motion several times Check hydraulic oil level 26 Check for proper operation of all components 27 Turn the engine OFF 28 Install oil pan cover underneath engine compartment 29 Close and secure the engine cover 30 Remove Do Not Operate Tags from both ignition key switch and steering wheel G6 42A G9 43A G10 43A Section 8 Hydraulic System Contents PARAGRAPH TITLE PAGE 8 1 Hydraulic Component 8 2 8 1 1 G6 42A Components 8 2 8 1 2 G9 43A amp G10 43A 8 3 8 2 Safety 8 4 8 3 Hydraulic Pressure 8 5 8 3 1 Pressure Check
188. l Coolant Level Data Valid But Below Normal ing Operating Range Least Severe Level Engine Crankshaft Speed Position Data Valid But 2468 190 0 Above Normal Operating Range Moderately Severe Level 2554 1209 2 Aber Not Available Exhaust Gas Pressure Data Erratic Intermittent or Incorrect 9 46 G6 42A G9 43A G10 43A Electrical System Fault SPN FMI Lamp SPN Codes Codes Codes Color Description Cummine Inlet Air Heater Intake Air Heater 1 Circuit Voltage Above Normal 2989 Driver 1 or Shorted to High Source Inlet Air Heater Intake Air Heater 1 Circuit Voltage Below Normal 6520 Amber Driver 1 or Shorted to Low Source 2646 110 31 Amber Not Available Engine Coolant Temperature Condition Exists 2765 2797 13 None NotAvailabie Engine Injector Bank T Barcodes Out of Calibration Engine Intake Exhaust Gas Recirculation EGR Temperature 2961 412 15 None Valve Data Valid But Above Normal Operating Range Actuator 12 Least Severe Level Boost Intake Manifold Pressure Sensor Circuit Data 2973 102 2 Amber Pressure Erratic Intermittent or Incorrect Circuit Voltage Below Normal or Shorted to Low Source 3139 3667 3 Amb r Engine Air Shutoff Circuit Voltage above normal or shorted to high source 3141 3667 4 Amber Engine Air Shutoff Circuit Voltage below normal or shorted to
189. l indicator needle on the operator s instrument cluster The reading must be at the FULL mark Turn the ignition key switch to the OFF position The fuel level indicator needle should return to the EMPTY position G6 42A G9 43A G10 43A Electrical System b Fuel Level Circuit Tests If the fuel level sender 8 is suspected of giving a false reading perform the following checks If the fuel level indicator needle does not move check the fuel tank for fuel Check for loose or defective wiring faulty ground connections and corrosion on the fuel tank sender and wiring lead If fuel level indicator needle does not move after ignition key switch is turned to the RUN position use a test lamp to determine whether current is flowing from ignition switch to fuel level sender If 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 Checkthat ignition terminal has current and that fuse in fuse panel is not blown 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 fuel tank through wiring in cab Check fuel level sender A defective fuel level send
190. l output driver s 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 desired current is greater than 250 but the actual current is less then 75 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 Valve Short To Battery Fork Tilt Up amp 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 Setup s AUX HYDRAULIC is set to ENABLED The desired current is OmA and the digital output driver s diagnostic feedback is low Low Side Fault Relay de energized Yes G6 42A G9 43A G10 43A 9 33 Electrical System DTC Event Comment Latched 33198 Auxiliary Function The actual current is greater than 200mA PWM is Yes A Valve Short To Ground 95 and the digital output driver s 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 modul
191. l the dipstick when finished 6 Transmission transfer case fluid may be added through the fill plug 6 Install fill plug and tighten 7 Apply park brake shift transmission control lever to the N NEUTRAL position and lower the forks or attachment to the ground 8 Remove the transmission dipstick 5 and check the oil level The oil level should be at the MAX line 9 If oil is low add oil as required and recheck level 10 Replace the transmission dipstick when finished 11 Close and secure engine cover 12 Recheck all drain plugs lines connections etc for leaks and tighten where necessary G6 42A G9 43A G10 43A Transmission 65 TRANSMISSION COOLER THERMAL BY PASS VALVE 6 5 1 Thermal ByPass Valve 1 Cartridge Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and shut engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery MAL2180 Place a suitable receptacle under transmission oil cooler hose 10 Allow the transmission oil to drain into receptacle Transfer used transmission oil into a suitable covered container and label container as Used Oil Dispose of used oil at an approved recycling
192. lant Ethylene Glycol 50 50 Mix Standard g and Water 60 40 Mix Cold Weather 2 Diesel t B5 Biodiesel id Fuel Blend 1 diesel and 2 diesel fuels S lt 15 mg winterized 2 kg Cold Weather Note Friction Modifier may be added to front axle differentials see Section 2 5 3 Capacities 2 18 G6 42A G9 43A G10 43A General Information and Specifications 2 5 2 Fluids if Equipped for LS Ambient Temperature JE aP Range Compartment or System Type and Classification Viscosities oF Min min 7 SAE 15W 40 5 120 15 49 4 Multigrade SAEOW 40 40 0 1 401 20 Transmission and Transfer Mobilfluid 424 10W 30 104 20 40 Case Mobilfluid LT 75W 80 40 0 40 20 Mobilfluid 424 10W 30 0 104 20 40 Mobilfluid LT 75W 80 40 0 40 20 SAE140 50 122 10 50 API GL4 with 2 14 122 10 50 Axle Differential and Wheel LS Additives 90 32 104 0 40 GL5 with SAE90LS LS Additives 80W 90 85W 90 4 104 20 40 75W 90 40 104 40 40 75W 40 50 40 10 CN Mobilfluid 424 10W 30 0 104 20 40 Exxon Univis 40 0 40 20 Boom Wear Pad Grease Mystik Tetrimoly Grade 2 4 104 20 40 Cylinder and Axle Grease Multipurpose Grease Grade 2 22 104 3
193. le engine is being removed Remove bolts and washer securing engine mounts Remove bolts holding transmission to engine Slightly lift and pull engine out of machine Have an assistant ensure that engine clears all frame components during removal Place engine on a flat level surface 7 15 Engine 7 7 2 1 Secure engine with a lifting strap or chain from the appropriate lifting points 1 Use a suitable hoist or overhead crane Engine Installation Note Apply Loctite 242 o engine mount bracket capscrew threads before installation 2 Install two guide studs in bell housing holes 3 Lift engine and slowly push and lower into engine bay Have an assistant ensure that engine clears frame hose and harness components during engine installation Position engine brackets over the front frame mounts 4 Push 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 Ib ft 72 79 Nm 6 Remove support from under transmission and lower engine remainder of way onto frame Align motor mount holes and install bolts Apply Loctite 242 to motor mount bolts and torque to 125 140 Ib ft 169 190 Nm 7 Turn engine over slowly by hand and align each
194. 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 Wheel and Tire Assembly Removal 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel 3 Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed G6 42A G9 43A G10 43A Axles Drive Shafts Wheels and Tires ES 4 Place a suitable jack under axle pad closest to wheel being removed Raise machine and position a suitable support beneath axle Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly 5 Lower the machine onto the support 6 Remove lug nuts and lug washers in an alternating pattern 7 Remove wheel and tire assembly from machine 5 6 2 Wheel and Tire Assembly Installation Note If the machine is equipped with directional tire assemblies the wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel 5 Note Verify valve stems face outward on all wheel and tire assemblies 1 Position wheel onto studs on wheel end of axle 2 Install wheel lug washers 3 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts G6 42A G9 43A G10 43A M 474 5 4 Tighten lug nuts an a
195. leville washers 7 become fully compress to distance of B 1 500 1 512 in 38 1 38 4 mm Do Not Overtighten pen MAL2591 Install and temporarily tighten the retract chain lock nut 4 Start the machine and at low idle fully extend and retract the boom three times Verify boom is fully retracted and level Shut machine Off Recheck the Belleville washers 7 to verify they are fully compressed to dimension B 1 500 1 512 in 38 1 38 4 mm If required re tighten the retract chain adjustment nut 6 until dimension is obtained Note If dimension requires adjustment continue to step 13 If dimension does NOT require adjustment continue to step 14 G6 42A G9 43A G10 43A C x pe 13 Start the machine and at low idle fully extend and retract the boom three times Verify boom is fully retracted and level Shut machine Off 14 Verify dimension A 17 000 17 312 in 421 8 439 7 mm Verify dimension C is not less than 3 069 in 77 9 mm Note Re adjust boom if dimensions amp C are not met Contact the local JLG Distributor if the procedure cannot be obtained 15 Loosen the retract chain lock nut and the extend chain lock nut and apply Loctite 2427 16 Torque the retract chain lock nut 5 and extend chain lock nut 1 without adding any additional spring load Torque each lock nut to 100 Ib ft 135 Nm
196. lief counter clockwise one half turn Re check the main relief setting and adjust if necessary 8 8 3 Steering Cylinders STEERING CYLINDER a PA Coe MZ d hte AXLE CENTER SECTION The steer cylinder is attached to each axle center housing The steer cylinder assembly can be found in Section 5 3 Axle Specifications And Maintenance Information The steer cylinder is covered in the appropriate manufacturer s axle literature 8 25 n Hydraulic System 8 8 4 Lift Lower Cylinder Cylinder Torque Specifications G6 42A Piston Head Valve Internal Set Screw 1623 Ib ft 2200 Nm Apply thread lock 295 lb ft 400 Nm 44 Ib ft 60 Nm 7 Ib ft 10 Nm Apply thread lock Note The capscrews for the bolt plate need to be torqued in sequence in an alternating pattern starting at 35 Ib ft to 75 Ib ft to 95 Ib ft Check the final torque in a circular pattern a minimum of two times b Extend Retract Cylinder Piston Head Valve External Set Screw Internal Set Screw 461 Ib ft 625 Nm Apply thread lock 295 lb ft 400 Nm 44 Ib ft 60 Nm 4 Ib ft 5 Nm Apply thread lock 4 Ib ft 5 Nm Apply thread lock c Tilt Cylinder Nut Valve 1125 1375 Ib ft 1525 1864 Nm 44 Ib ft 60 Nm d Compensation Cylinder Nut 990 1210 Ib ft 1342 1640 Nm e Frame Level
197. low source 3186 1623 9 Amb r Tachograph Output Shaft Speed Abnormal update rate 3213 1623 2 Amis Tachograph Output Shaft Speed Received Net work Data In Error 3222 520435 12 Amar Glow Plug Module Bad intelligent device or component Multiplexed Accelerator Pedal or Lever Sensor 3328 ius System Abnormal update rate 3328 191 9 Amor Transmission Output Shaft Speed Abnormal update rate High Pressure Common Rail Fuel Pressure Relief 3727 5571 7 NA Valve Mechanical system not responding or out of adjustment 3737 1675 11 NA Engine Starter Mode Overcrank Protection Condition Exists 3918 5421 13 Amber Engine Turbocharger Wastegate Actuator Out of Calibration G6 42A G9 43A G10 43A 9 47 Electrical System Fault SPN FMI Lamp SPN um Codes Codes Codes Color Description Engine Turbocharger Wastegate Actuator 3921 5421 7 Amber Mechanical system not responding or out of adjustment 3922 5421 5 Amber Engine Turbocharger Wastegate Actuator Current below normal or open circuit 3923 5421 6 Engine Turbocharger Wastegate Actuator Current above normal or grounded circuit 3924 520553 11 Amber Utility Reverse kW Fault Condition Exists 3925 1188 2 Amber Engine Turbocharger Wastegate Actuator 1 Position Data erratic intermittent or incorrect 3927 5421 T Engine Turbocharger Wastegate Actuator Root Cause Not Known 3928 5421 T Am
198. lternating pattern as indicated in figure Torque to 350 400 Ib ft 475 542 Nm 5 Remove machine from supports s 7 9 10 V 2 4200 6 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 5 7 BRAKES Check the brake disks for wear every 1 000 hours of operation or yearly For more information on brake disk inspection refer to the Axle Repair Manual P N 31200240 5 11 Axles Drive Shafts Wheels and Tires hs 5 8 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort after exhausting all other options Make every effort to repair the machine and move it under its own power before using the emergency towing procedures outlined below Note Block the wheels of the machine BEFORE attempting to release the park brake Once the park brake is released the machine s park brake AND service brakes are inoperable 5 8 1 Manually Releasing the Park Brake MZ1020 1 Loosen the nuts of the screws 5 for the manual release of the braking units Draw the nuts back approximately 6 mm 2 Tighten the screws until they are gently seated on the driving plate 3 Carefully tighten each release screw a 1 4 turn ata time in sequence until all have been turned on full turn 360 4 Repeat steps 1 thru 3 for other side of differential Note After machine has been tow
199. lues for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque Size TPI Bolt Dia as Stress Clamp Load Dry ES Loctite 242 271 or Loctite 262 rea K 0 20 Vibra TITE 411 or 140 Vibra TITE 131 K 0 18 K 0 15 In Sq In LB IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 48 0 1120 0 00661 6 32 0 1380 0 00909 40 0 1380 0 01015 8 32 0 1640 0 01400 36 0 1640 0 01474 1320 43 5 10 24 0 1900 0 01750 1580 60 7 32 0 1900 0 02000 1800 68 8 1 4 20 0 2500 0 0318 2860 143 16 129 15 28 0 2500 0 0364 3280 164 19 148 17 In Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 25 35 20 25 20 25 24 0 3125 0 0580 5220 25 35 25 35 20 25 3 8 16 0 3750 0 0775 7000 45 60 40 55 35 50 24 0 3750 0 0878 7900 50 70 45 60 35 50 7 16 14 0 4375 0 1063 9550 70 95 65 90 50 70 20 0 4375 0 1187 10700 80 110 70 95 60 80 1 2 13 0 5000 0 1419 12750 105 145 95 130 80 110 20 0 5000 0 1599 14400 120 165 110 150 90 120 9 16 12 0 5625 0 1820 16400 155 210 140 190 115 155 18 0 5625 0 2030 18250 170 230 155 210 130 175 5 8 11 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 23000 240 325 215 290 180 245 3 4 10 0 7500 0 3340 30100 375 510 340 460 280 380 16 0 7500 0 3730 33600 420 570 380 515 815 430 7 8 9 0 8750 0 4620 41600 605 825 545 740 455 620 14 0 8750 0 5090 45800 670 910 600 815 500 680 1 8 1 0000 0 6060 51500 860 1170 770 1045 645 875 12 1 0000 0 6630 59700 995 13
200. ly onto suitable supports 24 Remove the extend retract cylinder as required 3 7 2 Push Beam Extend Retract Cylinder Installation 1 Clean and lubricate bottom and sides of third boom section where push beam guide bar travels 2 Place a sling or using two slings for better stability lift and slowly push the push beam extend retract cylinder assembly approximately half way into the front of the boom assembly 3 Lower the push beam onto a suitable support 4 Relocate the sling and slowly insert the push beam extend retract cylinder assembly into the front of the boom assembly Guide the push beam extend retract cylinder assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components 5 Remove the plugs and caps from extend retract cylinder hydraulic tubes Install both extend retract cylinder hydraulic tubes G6 42A G9 43A G10 43A MAL1290 6 Install the strong back 1 with the previously removed hardware 2 and torque as required 7 Align the extend retract cylinder bore with the strong back bores and install the extend retract cylinder pin 8 and secure with the retaining clips 4 8 Install anchor rod through front of boom assembly MY3930 9 Connect the extend chain 5 to the anchor rod
201. ly tighten the extend chain lock nut 1 3 22 6 TE B MAL2551 9 Tighten the retract chain adjustment nut 6 until the belleville washers 7 become fully compressed to dimension 0 712 0 725 in 18 1 18 4 mm Do Not Overtighten 10 Install and temporarily tighten the retract chain lock nut 4 11 Start the machine and at low idle fully extend and retract the boom three times Verify boom is fully retracted and level Shut machine Off 12 Recheck the Belleville washers 7 to verify they are fully compressed to dimension B 0 712 0 725 in 18 1 18 4 mm If required re tighten the retract chain adjustment nut 6 until dimension B is obtained Note If dimension requires adjustment continue to step 13 If dimension does NOT require adjustment continue to step 14 13 Start the machine and at low idle fully extend and retract the boom three times Verify boom is fully retracted and level Shut machine Off 14 Verify dimension A 11 500 11 812 in 292 1 300 0 mm Verify dimension C is not less than 2 850 in 72 4 mm Note Re adjust boom if dimensions amp are not met Contact the local JLG Distributor if the procedure cannot be obtained 15 Loosen the retract chain lock nut and the extend chain lock nut and apply Loctite 2427 16 Torque each retract chain lock
202. mples of dynamic shock loading RETRACT CHAINS which can impose abnormal loads above the endurance limit of a leaf chain 3 11 1 Boom Chain Inspection High velocity movement of load followed by A WARNING Worn pins stretched or cracked links or corrosive environments can cause chain failure A chain failure could result in uncontrolled boom movement loss of load or machine instability Under normal operating conditions the boom extend retract chains will need to be exposed and inspected every 1000 hours of operation Environmental conditions and dynamic impulse shock loads can drastically affect normal operating conditions and require more frequent inspection intervals Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit Some effects can be as follows Moisture Corrosive rusting reduces chain strength by pitting and cracking Temperature Low temperature reduces chain strength by embrittlement Going in and out of cold storage results in moisture from condensation Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an exte
203. mt 3SV8 HOS 310N Le lt lt lt lt 1 2 soar NV J NIHOLMOG NOILO3S 8V2 335 um INANI 3N3038 252 55 x finaino mw a naino LINSNVEL XL Hu Uu Wwid3s MO1Sh8Nv9 067 NYO 0r 209170 WISI 9 JAVA GAH 8xnv 0 wies HolHsnanvo vweHN o 6 linauno V3AWAQAHXWV 6 SOWNY 8 IVNOIS GAH XN 8515 Xnv 8 ndino SATWANMOG 8 sosru 3mwanni annu 5 A39 17 109170 GNNOHD 90 VNV OND 9 AfldNI 21037138 d3T10H 73s 9 vosxw s INANI 4 5 Hamoa SOVETOANOUWLIOXa SONNY S xnvoxas INANI linaino amod awnouoSoww anon 6 9 91 1930 HOS 39181 YOLLSAOP ET inant DOWNY vwosnux3 vos z ANANI 0 FINON Adossaoov GND 2 linaino amod 3OVIIOANOUMIOX3SOTNVS 1 ANANI 3dAL NOILdO 055392 lt e T 9
204. n a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engine OFF 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool G6 42A G9 43A G10 43A 4 Properly disconnect the battery Install a drive ratchet into the square hole in the serpentine belt tensioner bracket 2 6 While lifting the automatic belt tensioner away from the belt remove the fan serpentine belt how the alternator is installed to ensure correct installation later 7 Label and disconnect the wire leads attached to the alternator assembly 8 Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine 9 While supporting alternator with one hand remove upper longer mounting hardware from upper alternator mount Remove alternator from machine b Alternator Installation 1 Position alternator and align with upper alternator mount on engine bracket Insert upper longer mounting hardware through alternator mount Thread longer capscrew into alternator front mount DO NOT tighten completely at this time 2 Align lower alternator mount hole with lower mounting bracket on engine and insert lower mounting capscrew Tighten lower capscrew and upper capscrew securely 3 Place a drive ratchet into square hole on ser
205. n with the four 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 tube and hose clamps must be tight 9 Properly connect the battery 10 Inspect for leaks and check all fluid levels The hydraulic reservoir oil level must be to the middle of the sight gauge c Pump Test d Referto Section 8 3 1 Pressure Checks and Adjustments G6 42A G9 43A G10 43A 8 7 CONTROL VALVES 8 7 1 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 NEUTRAL engage the park brake and shut the eng
206. nd disconnect harnesses Push harness connectors through the opening cab 4 10 10 11 12 13 14 15 16 17 18 19 Remove boom joystick from is mounting position Refer to Section 4 3 4 Boom Joystick Assembly Label disconnect and cap all hydraulic hoses attached to boom joystick Cap all fittings and openings to keep dirt and debris from entering hydraulic system Remove frame level and attachment tilt and auxiliary control joystick Refer to Section 4 3 5 Frame Level Attachment Tilt Auxiliary Hydraulics and G10 43A Outrigger Joysticks Label disconnect and cap all hydraulic hoses attached to the joystick Cap all fittings and openings to keep dirt and debris from entering hydraulic system Label disconnect and cap all hydraulic hoses attached to steering orbital valve Cap all fittings and openings to keep dirt and debris from entering hydraulic system 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 Push all hydraulic hoses through opening in cab Disconnect engine air filter and hydraulic oil reservoir breather from their brackets at top of cab Move air filter and breather clear from cab so they do not become damaged during cab removal Remove the fuel tank from the cab Refer to Section 7 6 2 Fuel Tank 5 0610 Open Cab
207. nded 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 3 28 sudden abrupt stops Carrying loads in suspension over irregular surfaces such as railroad tracks potholes and rough terrain Attempting to inch loads which are beyond the rated capacity of the vehicle The above load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct frequent inspections until replacement life can be predicted The boom chain s normal life expectancy can be expressed as a maximum percent of elongation This is generally 3 As the chain flexes back and forth over the sheave the bearing joints pins and inside link plates gradually incur wear due to articulation 3 11 2 The extend retract chains are only partially visible through the rear of the boom with all the sections retracted It is possible to see a section of the retract chain as the boom is slowly extended If there is ANY question that extend retract chains are damaged the chains should be removed and inspected Refer to Section 3 6 Extend Retract Chain Removal Installation for detailed information Replace chains if necessary Expose Chain
208. ndition Inspect and replace machine parts that are exposed with cab removed Repair or replace as required G6 42A G9 43A G10 43A CAB INSTALLATION 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 0610 Open Cab Route a sling with minimum lifting capacity of 1000 Ibs 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 Enclosed Cab Install two lifting eye bolts 14 in threaded holes on roof of cab above B pillars 16 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 position of sling as needed to help balance cab during installation 4 11 Ps Cab and Covers 14 Fill the cooling system completely with coolant allowing time for the coolant to fill the engine block The cooling system capacity is listed in Section 2 5 Fluid and Lubricant Capacities d 15 Properly connect the battery 16 Startthe engine and check the operation of all controls Check for hydraulic fluid leaks Check the hydraulic
209. ne External Auxiliary Commanded Dual Output Shutdown Protection Input Special Instructions 649 1378 Amber Engine Oil Change Lubricating Oil and Filter Condition Exists Blinking Change Interval G6 42A G9 43A G10 43A 9 43 Electrical System Fault SPN FMI Lamp SPN ume Codes Codes Codes Color Description mnm Tuiboch rder Turbocharger 1 Speed Low Data Valid but 687 103 18 Amber 9 Below Normal Operational Range Moderately 1 Speed Severe Level 689 190 2 Amber Engine Speed Primary Engine Speed Sensor Error Data Erratic Intermittent or Incorrect Turbocharger 1 Compressor Inlet Temperature 691 1172 3 Amber iios Circuit Voltage Above Normal or Shorted to High Source Temperature Sensor Circuit ECM Internal Temperature Sensor Circuit Voltage 687 mee a Amber Voltage Above Normal or Shorted to High Source Sensor Circuit ECM Internal Temperature Sensor Circuit Voltage ANDET Voltage Below Normal or Shorted to Low Source Engine Speed Mechanical Misalignment Between Camshaft and 731 723 7 Amber 2 Crankshaft Sensors Mechanical System Not Responding Properly or Out of Adjustment 952 524286 31 Amber Not Available Reserved for temporary use Condition Exists 953 524286 31 Amber Not Available Reserved for temporary use Condition Exists 1117 627 2 None Power Supply Power Lost With Igni
210. ng Rail Severe Level ECU Power Output Supply Voltage 1 Data Valid 1938 3597 18 Amber Not Available But Below Normal Operating Range Moderately Severe Level ECU Power Output Supply Voltage 1 Voltage 1943 Amber NotAvailable Above Normal or Shorted to High Source 1941 3597 4 Amber Not Available ECU Power Output Supply Voltage 1 Voltage Below Normal or Shorted to Low Source 1942 101 2 Amber Not Available Crankcase Pressure Data Erratic Intermittent or Incorrect Amber 1974 101 15 Blink Not Available Crankcase Pressure Data Valid But Above Normal ing Operating Range Least Severe Level 2185 3512 3 Sensor Supply 4 Circuit Voltage above normal or shorted to high source 2186 611 4 Amb r System code 1 Sensor Supply 4 Circuit Voltage Below Normal or Diagnostic Shorted to Low Source 2195 703 14 Auxiliary Equipment Sensor Input 3 Engine Protection Critical Special Instructions Injector Injector Metering Rail 1 Pressure Data Valid 2249 157 1 Amber Metering Rail but Below Normal Operational Range Most 1 Pressure Severe Level 2272 27 4 Amber Not Available EGR Valve Position Circuit Voltage Below Normal or Shorted to Low Source 2288 103 15 None Not Available Turbocharger 1 Speed Data Valid But Above Normal Operating Range Least Severe Level 2311 633 31 Amber Fueling Actuator 1 Circuit Error Condition Exists G6 42A G9 43A G10 43A 9 45 Electrical System
211. ng brake and shut engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel 3 Open engine cover Allow system fluids to cool 4 Properly disconnect the battery 5 Slowly turn surge tank cap to allow any pressure to escape Remove surge tank cap 6 Place a funnel at the base of the radiator to channel drained coolant into container Loosen draincock and slowly remove to allow the coolant to drain Transfer coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Replace radiator draincock 7 Loosen and remove the top radiator hose from the thermostat housing G6 42A G9 43A G10 43A TYPICAL THERMOSTAT Disconnect the engine water temperature sender 1 if connected to the thermostat housing Remove the two capscrews 2 securing the thermostat housing 3 to the engine 10 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 b Thermostat Installation 1 Install engine thermostat thermostat gasket and thermostat housing Secure with two capscrews and torque as required Connect the engine water temperature sender if connected to the thermostat housing Properly connect the b
212. ng s and lubricate at regular intervals Refer to Section 2 7 Lubrication Schedule 4 Excessive Compensation 1 Insufficient lubrication 1 Lubricate at regular intervals cylinder pivot pin noise and Refer to Section 2 7 or wear Lubrication Schedule Replace worn pins as needed 2 Worn bushing s 2 Replace bushing s and lubricate at regular intervals 3 34 G6 42A G9 43A G10 43A 1 V pe Problem Cause Remedy 5 Drooping chain or jerky 1 Chain s tension not properly 1 Adjust chain s boom extend or retract adjusted functions 2 Chain s stretched or binding 2 Replace chains as needed Refer to Section 3 8 Boom Adjustments 3 Wear pads loose contaminated 3 Replace wear pad Refer to excessively worn or damaged Section 3 10 Boom Wear Pads 4 Contaminated corroded or 4 Remove contamination and or rusted wear pad sliding corrosion from wear pad sliding surfaces surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s 5 Extend Retracthydraulic system 5 Refer to Section 8 4 Hydraulic not operating properly Circuits 6 Damaged boom section 6 Replace the damaged boom section Refer to Section 3 3 Boom Assembly Maintenance 6 Boom will not raise or lower 1 Broken hydraulic hoses ortubes 1 Locate break replace hose s and or connection leaks or tube s tighten c
213. ngine cover Allow the system fluids to cool Properly disconnect the battery MAL1000 5 Disconnect the electrical harness connector 8 6 Remove the bolts 9 securing the accelerator pedal to accelerator pedal bracket 10 Remove accelerator pedal assembly from cab OD Accelerator Pedal Installation Position the accelerator pedal in its mounting location within the cab Secure accelerator pedal into position with pivot pin Install pedal ball joint to accelerator pedal Properly connect the battery Verify proper accelerator pedal operation Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G6 42A G9 43A G10 43A Cab and Covers 4 3 4 Boom Joystick Assembly a Joystick Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 3 Open engine cover Allow the system fluids to cool 4 Properly disconnect the battery If Equipped If Equipped X 5 Lift joystick s rubber sleeve 11 remove bolts securing boom joystick to cab 6 Lift joystick from its mounting position 7 Label disconnect and cap hydraulic hoses attached to boom joystick
214. nition key Switch and steering wheel Open engine cover Allow system fluids and exhaust system to cool Properly disconnect the battery 7810 Loosen and remove the clamp 7 securing exhaust tail pipe 8 to frame at bottom rear corner of the engine pod Loosen and remove clamp 9 securing exhaust tail pipe 8 Remove exhaust tail pipe Loosen and remove clamp 10 securing engine pod exhaust pipe 11 to muffler 12 Remove engine pod exhaust pipe Loosen and remove clamps 13 securing exhaust flex pipe 14 to muffler and turbo charger 15 Remove exhaust flex pipe Loosen and open clamp strap 16 securing muffler to bottom of engine pod Remove the muffler 2A G9 43A G10 43A 7 5 2 Exhaust System Installation ULS Note Keep all clamps loosened until entire exhaust system is in place 1 Secure muffler to engine pod with clamp strap Install the flex pipe 14 to turbo charger 15 Install clamps 13 securing flex pipe Install the engine pod exhaust pipe 11 and secure with clamp 10 Install exhaust tail pipe 8 with clamps 9 and clamp 7 to engine pod Adjust the muffler exhaust and tail pipes for proper clearance then tighten all clamps Properly connect the batteries Start engine and check for exhaust leaks at all exhaust connections Adjust as needed Close and secure the engine cover Remove the Do Not Operate Tags from
215. ns And Maintenance Information 6 3 6 4 Transmission 6 3 6 4 1 Transmission 6 3 6 4 2 Transmission Inspection and Internal 6 5 6 4 3 Transmission 1 5 6 5 6 4 4 After Transmission Service or 6 6 6 5 Transmission Cooler Thermal By Pass Valve 6 7 6 5 1 Thermal ByPass Valve Cartridge 6 7 6 5 2 Thermal By Pass Valve Cartridge 6 7 6 6 Torque Convertor Diaphragm 6 8 6 6 1 Torque Convertor Diaphragm 6 8 6 6 2 Torque Convertor Diaphragm 1 5 6 8 6 7 Troubleshooting 5 lt 6 9 G6 42A G9 43A G10 43A 6 1 6 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 SHIFT S
216. nsmission 6 3 6 5 Transmission Cooler Thermal By Pass 6 7 6 6 Torque Convertor 6 8 6 7 Troubleshooting 3 44 235 ER reed hie 6 9 Section 7 Engine 54 ave mad a Dir I Ra dad 7 1 7 1 Introduction Cummins 1 7 2 7 2 Engine Cooling System 7 5 7 8 Engine Electrical 7 8 7 4 on cio ooh xS Eie vb ete Eee 7 8 7 5 Engine Exhaust 7 11 7 6 Air Cleaner Assembly esia uses et dees sedans pAb E 7 13 7 7 Engine 7 15 Section 8 Hydraulle Syst m pcr eh OR E 8 1 8 1 Hydraulic Component Terminology 8 2 8 2 Satety Information 8 4 8 3 Hydraulic Pressure Diagnosis 8 5 8 4 Hydraulic Circuits iee EPIS 8 6 8 5 Hydraulic 8 15 8 6 implement PUD sre set ER SE A
217. nut 4 and extend chain lock nut 1 without adding any additional spring load Torque each lock nut to 100 Ib ft 135 Nm G6 42A G9 43A G10 43A 3 8 3 Chain Tension Inspection G9 43A G10 43A p e 1 Park machine on level ground Place transmission control lever NEUTRAL engage parking brake ji and level boom 2 Place a Do Not Operate Tag on both ignition key switch and steering wheel 3 Extend the boom 4 5 ft 1 2 1 5 m then fully retract the boom Verify boom is level 4 Measure the following three dimensions A B amp C Fr MAL2630 C A gt 2740 5 Atthe boom head verify dimension A is between 17 000 17 312 in 421 8 439 7 mm il LA doe ro 2621 6 Atthe bottom front of the boom verify dimension is 1 500 1 512 in 38 1 38 4 mm of the washer stack on the retract chain clevis G6 42A G9 43A G10 43A 7 Atthe back of the boom verify dimension 3 069 in 77 9 mm on the extend chain clevis Note Belleville washers are shown in the un compressed state 8 Boom adjustment will be required if the above dimensions are not met Chain Tension Adjustment G9 43A G10 43A 3 8 4 MAL2580
218. o rings and seals 3 Replace o rings and seals 5 8 G6 42A G9 43A G10 43A Axles Drive Shafts Wheels and Tires 5 5 DRIVE SHAFTS 5 5 1 Inspect areas where drive shaft flange yokes and slip yokes mount to drive shafts Attempt to turn each drive shaft in both directions Look for excessive looseness missing parts cracks or other damage Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise Drive Shaft Inspection and Service Note To help ensure optimum performance drive shaft assemblies are specially balanced as a unit at factory When servicing any flange yoke slip yoke or drive shaft tube order a complete assembly if components are bent or damaged Refer to the appropriate parts manual for ordering information Note Any bolt removed from the drive shaft assembly MUST be replaced Do Not re torque 5 5 2 Refer to Section 2 5 Fluids and Lubricant Capacities for information regarding lubrication of drive shafts Drive Shaft Maintenance 5 5 3 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL engage park brake and shut engine OFF Drive Shaft Removal 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel Open engine cover Allow the system fluids to cool Properly disconnect the battery Block the w
219. o the condition does not repeat itself o Qr MZ1467 e eae MZ1468 The types of cracks are Fatigue Cracking Fatigue cracks 9 area result of repeated cyclic loading beyond the chain s endurance limit Stress Corrosion Cracking The outside link plates are particularly susceptible to stress corrosion cracking 10 Corrosion Fatigue Cracking Corrosion fatigue cracks are very similar to fatigue cracks in appearance Corrosion fatigue is the combined action of an aggressive environment and cyclic stress 9 MZ1469 Other Modes of Failure Ultimate Strength Failure These types of failures are caused by overloads far in excess of the design load Either 2 Y fractured plates 1 or 2 enlarged holes 2 can occur If either of these METH failures occurs the chain should be replaced immediately Tight Joints All joints in the chain should flex freely Tight joints 3 resist flexing If the problem is caused by dirt or foreign substance packed in the joints clean and lubricate thoroughly before re installing the chain If the problem is caused by corrosion and rust or bent pins replace the chain CORTE 3 21471 3 30 3 11 4 After inspection and before being returned to service chains must be lubricated Refer to Section 2 5 Fluid and Lubricant Capacities Chain Lubrication The lubricant must penetrate the chain joint to prevent wear Applying lubricant
220. of four torque convertor diaphragm bolts through access plug in bell housing Install them one at a time DO NOT fully tighten until all of capscrews and locknuts are in place Torque to 26 39 Ib ft 85 59 Nm Replace access plug 8 Install the exhaust pipe Refer to Section 7 5 Engine Exhaust System 9 Secure air cleaner tube to turbo charger 10 Connect fuel inlet line 11 Connect fuel return line to engine 12 Install Power Distribution bracket 13 Connect all previously labeled electrical wire connections on Power Distribution bracket 14 Connect all previously labeled electrical wire connections on engine 15 Install both heater hoses to engine and tighten clamps if equipped 16 Install complete radiator assembly Refer to Section 7 2 3 Radiator Assembly and Replacement 17 Install the engine cover and adjust 18 Install and properly connect battery 7 16 19 Check that all hydraulic system electrical system cooling system fuel system and exhaust system connections are correct and connected tightly 20 From within cab lightly depress accelerator pedal to full throttle position As needed adjust limit stop screw until it touches 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 engine While engine is cooling check for leaks 22 Allow engine to cool Check radiator coolant leve
221. 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 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 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 NEUTRAL engage the park brake and start the engine Service Brake Bleeding G6 42A G9 43A G10 43A Hydraulic System
222. ol module issue Active when Machine Setup s AUX HYDRAULIC is set to ENABLED 2358 Auxiliary Hydraulic Joystick Auxiliary Hydraulic A amp B prevented Yes Out Of Range Low The auxiliary joystick s analog voltage was measured to be less than 0 15V Auxiliary hydraulics will be prevented until the next power cycle Active when Machine Setup s AUX HYDRAULIC is set to ENABLED 2397 Fork Tilt Joystick Fork Tilt Up amp Down prevented Yes Voltage Disagreement Analog feedback from the joystick s 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 2398 Fork Tilt Joystick Fork Tilt Up amp Down prevented Yes Out Of Range High Analog feedback from the joystick s 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 2399 Fork Tilt Joystick Fork Tilt Up amp Down prevented Yes Out Of Range Low Analog feedback from the joystick s 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 33191 Fork Tilt Valve desired current i
223. onnections 2 Lift lower hydraulic system not 2 Refer to Section 8 4 Hydraulic operating properly Circuits 3 Faulty lift lower cylinder 3 Repair cylinder Refer to Section 8 8 1 General Cylinder Removal Instructions 4 Seized boom pivot pin bearing 4 Replace bearing 7 Excessive Lift Lower cylinder 1 Insufficient lubrication 1 Lubricate at regular intervals pivot pin noise and or wear Refer to Section 2 6 Service and Maintenance Schedule Replace worn pins as needed Refer to Section 8 8 1 General Cylinder Removal Instructions 2 Worn self aligning bushing s 2 Replace bushing s and lubricate at regular intervals Refer to Section 2 7 Lubrication Schedule G6 42A G9 43A G10 43A 3 35 h Boom Cy Problem Cause Remedy 8 Rapid boom pad wear 1 Incorrect wear pad gap 1 Check wear pad gaps correct as needed Refer to Section 3 10 Boom Wear Pads 2 Rapid cycle times with heavy 2 Reduce cycle times loads 3 Contaminated corroded or 3 Remove contamination and or rusted wear pad sliding corrosion from wear pad sliding surfaces surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s 4 Operating in extremely dusty 4 Clean equipment frequently abrasive conditions 9 Auxiliary hydraulics will not 1 Auxiliary hydraulic system not 1 Refer to Section 8 4 Hydraulic
224. oper 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 400 600 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 G6 42A G9 43A G10 43A Hydraulic System n 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
225. 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 9 17 Electrical System 9 8 2 Windshield Rear Window Washer Reservoir MY1220 Windshield washer motor and reservoir 5 is located in cab behind the seat It is labeled as a unit and cannot be serviced separately a 1 8 b Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Open engine cover Allow system fluids to cool Properly disconnect the battery Remove nuts and lock washers from washer mounting bolts Pull the washer reservoir out and away from the mounting bracket Rotate the washer reservoir label and remove the cab harness connectors from the washer reservoir connectors Remove windshield washer hoses from reservoir Disassembly DO NOT disassemble the pump The pump is not serviceable Replace pump if found to be defective 9 18 Installation and Testing Connect windshield washer hos
226. operly d Inspection 1 Inspect the hydraulic oil reservoir thoroughly for any cracks slices leaks or other damage 2 With hydraulic oil reservoir removed from machine plug all openings except one elbow fitting Install elbow fitting and apply approximately 1 1 5 psi 7 10 kPa of air pressure through elbow Check reservoir for leaks by applying a soap solution to exterior and look for bubbles to appear at the cracked or damaged area e Reservoir Installation 1 Place hydraulic oil reservoir into original orientation 2 Secure hydraulic oil reservoir to frame with 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 5 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 16 8 6 IMPLEMENT PUMP For internal service instructions contact your local JLG Distributor 8 6 1 Implement Pump Replacement a Pump Removal 1 Park machine on a firm level surface level machine fully retract boom lower
227. or brief time periods to avoid heavy saturation Check and obey all Federal State and or Local regulations regarding waste storage disposal and recycling Safety Practices 1 6 4 ENGINE Stop the engine before performing any service unless specifically instructed otherwise Operational Hazards VENTILATION Avoid prolonged engine operation in enclosed areas without adequate ventilation SOFT SURFACES AND SLOPES NEVER work on machine that is parked on a soft surface or slope The machine must be on a hard level surface with the wheels blocked before performing any service FLUID PRESSURE Before loosening any hydraulic or diesel fuel component hose or tube turn the engine OFF Wear heavy protective gloves and eye protection NEVER check for leaks using any part of your body use a piece of cardboard or wood instead If injured seek medical attention immediately Diesel fluid leaking under pressure can explode Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin cause infection gangrene and other serious personal injury Engine fuel lines are pressurized DO NOT attempt repairs unless specific training has been completed Refer to the engine manufacturers manual for specific details concerning the fuel system Relieve all pressure before disconnecting any component part line or hose Slowly loosen parts and allow release of residual pressure before removing any part o
228. ource 516 3514 4 Amber Not Available Sensor Supply 6 Circuit Voltage below normal or shorted to low source 523 611 2 Amber System code 1 OEM Intermediate PTO Speed switch Validation Diagnostic Data Erratic Intermittent or Incorrect Pa Auxiliary Input Output 2 Circuit Voltage Above id fue 3 pube Normal or Shorted to High Source 528 93 2 Amber Switch Data Auxiliary Constrained Operation Curve Validation Switch Data Erratic Intermittent or Incorrect E Auxiliary Input Output 3 Circuit Voltage Above rua 3 Normal or Shorted to High Source Injector Injector Metering Rail 1 Pressure High Data Valid 553 157 16 Amber Metering Rail 1 but Above Normal Operational Range Moderately Pressure Severe Level 555 101 16 Amber Not Available Crankcase Pressure Data Valid But Above Normal Operating Range Moderately Severe Level 556 101 0 Red Not Avallable Crankcase Pressure Data Valid But Above Normal Operating Range Moderately Severe Level Injector Injector Metering Rail 1 Pressure Low Data Valid 559 157 18 Amber Metering Rail 1 but Below Normal Operational Range Moderately Pressure Severe Level Starter Solenoid Starter Relay Driver Circuit Voltage Above Normal m 877 Lockout Relay or Shorted to High Source Driver Circuit T rbocharger Turbocharger 1 Speed High Data Valid but 595 103 16 Amber 9 Above Normal Operational Range Moderately 1 Speed Severe Level 599 640 14 Red Engi
229. ove dash panel 7 Remove any hardware securing joystick to cab 8 Label disconnect and cap hydraulic fittings or cable s attached to joystick 9 Remove joystick from cab b Joystick Installation 1 Uncap and connect previously labeled hydraulic hoses or cable s to their appropriate locations 2 Install bolts securing joystick to cab 3 Install dash panel to its original position with previously used hardware 4 Install joystick knob if necessary 5 Properly connect battery 6 Test the complete range of joystick functions per control decals in cab or appropriate Operator and Safety Manual Note Check the controls of the auxiliary attachments See the appropriate Operation amp 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 8 Window Wiper Washer Windshield Wiper Motor for removal and installation information 4 3 7 Heater Air Conditioning System if equipped Heater Assembly Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in NEUTRAL position engage parking brake and turn the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel Open engine cover All
230. ow the system fluids to cool 4 Properly disconnect the battery Slowly turn surge tank cap to allow any pressure to escape Remove surge tank cap Place a suitable container beneath radiator drain 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 Transfer the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility 9 Tighten the radiator drain petcock 11 Remove the bolts that secure the seat to the cab Remove the seat 0190 Remove the bolts securing the front plate 14 to the seat riser weldment 15 12 Remove the bolts securing the seat riser weldment to the cab Remove the riser weldment G6 42A G9 43A G10 43A Cab and Covers ay 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
231. pentine belt tensioner bracket 2 Apply pressure against tensioner bracket and route serpentine belt onto alternator and engine pulleys Release and check tensioner pulley to verify that it is pivoting freely in order to provide proper tension on belt Check for proper belt alignment Refer to the appropriate Operation amp Safety Manual Connect previously labeled wire leads to alternator Properly connect battery Close and secure engine cover Remove the Do Not Operate Tags from both ignition key switch and steering wheel 9 15 Electrical System 9 7 2 Alternator LS b Alternator Installation 1 Reinstall alternator with hardware removed earlier DO NOT tighten completely at this time 2 Route fan belt onto alternator and engine pulleys 3 Alternator will pivot in bracket away from engine to apply tension to belt Tighten hardware securing alternator to engine and mounting bracket 4 Check for proper belt alignment Refer to the appropriate Operation amp Safety Manual Connect previously labeled wire leads to alternator Properly connect battery Close and secure engine cover Remove the Do Not Operate Tags from both ignition key switch and steering wheel a Alternator Removal 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engin
232. perly disconnect the battery 5 Disconnect the wiring connector at the park brake solenoid lead N IF EQUIPPED FOR ULS MY7320 9 20 IF EQUIPPED FOR LS MY8170 Remove nut on end of park brake coil 7 Remove park brake coil Remove park brake solenoid 8 Remove only if electrical coil is found to not be faulty Disassembly DO NOT disassemble the solenoid The solenoid is not serviceable Replace solenoid if found to be defective 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 aap o If necessary install the park brake solenoid in its original orientation Slide park brake coil over solenoid Tighten nut to secure solenoid DO NOT overtighten Connect wiring connector to park brake coil lead Properly connect battery Close and secure engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G6 42A G9 43A G10 43A Electrical System 9 10 2 Transmission Solenoid Valve Note If the transmission is not shifting properly the transmission shift control switch transmission control lever wiring harness or transmission shift solenoids 9 should be checked in order to determine which component is defective Specific information to determine whi
233. pm 306 Ib ft 415 Nm 1600 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements 2 16 G6 42A G9 43A G10 43A General Information and Specifications 2 4 5 Note Standard wheel lug nut torque is 350 400 Ib ft 475 542 Nm Tires Note Pressures for foam filled tires are for initial fill ONLY a G6 42A 5 Minimum Ply Star Rating Fill Type Pressure Pneumatic 65 psi 4 5 bar 13 00 x 24 G 2 L 2 Bias Ply Traction 12 Ply Foam Approximately 542 Ib 246 kg Pneumatic 58 psi 4 0 bar 15 50 x 25 G 2 L 2 Bias Ply Traction 12 Ply Foam Approximately 600 Ib 272 kg Pneumatic 76 psi 5 2 bar 370 75 28 DuraForce 14 Ply Foam Approximately 464 Ib 210 kg b G9 43A Minimum Ply Star Rating Fill Type Pressure Pneumatic 65 psi 4 5 bar 13 00 x 24 G 2 L 2 Bias Ply Traction 12 Ply Foam Approximately 542 Ib 246 kg Pneumatic 65 psi 4 0 bar 15 50 x 25 G 2 L 2 Bias Ply Traction 12 Ply Foam Approximately 600 Ib 272 kg Pneumatic 76 psi 5 2 bar 370 75 28 DuraForce 14 Ply Foam Approximately 464 Ib 210 kg c G10 43A Minimum Ply Star Rating Fill Type Pressure Pneumatic 65 psi 4 8 bar 14 00 x 24 G 2 L 2 Bias Ply Traction 12
234. pment 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 6 3 SOLVENTS Only use approved solvents that are known to be safe for use HOUSEKEEPING Keep the work area and operator s cab clean and remove all hazards debris oil tools etc FIRST AID Immediately clean dress and report all injuries cuts abrasions burns etc no matter how minor the injury may seem Know the location of a First Aid Kit and know how to use it CLEANLINESS Wear eye protection and clean all components with a high pressure or steam cleaner before attempting service General Hazards When removing hydraulic components plug hose ends and connections to prevent excess leakage and contamination Place a suitable catch basin beneath the machine to capture fluid run off It is good practice to avoid pressure washing electrical electronic components In the event pressure washing the machine is needed ensure machine is shut down before pressure washing Should pressure washing be utilized to wash areas containing electrical electronic components it is recommended a maximum pressure of 750 psi 52 bar at a minimum distance of 12 in 30 5 cm away from these components If electrical electronic components are sprayed spraying must not be direct and f
235. pped 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
236. ption Cummine fee ae Remote Multiplexing Remote Accelerator Pedal or Lever 2858 19 Accelerator Data Error Received Network Data In Error 292 441 14 Red Auxiliary Auxiliary Temperature Sensor Input 1 Temperature 1 Special Instructions OEM Auxiliary Temperature Sensor Input 1 Circuit end Amber Temperature Voltage Above Normal or Shorted to High Source OEM Auxiliary Temperature Sensor Input 1 Circuit Amper Temperature Voltage Below Normal or Shorted to Low Source 295 108 2 Ambr Barometric Barometric Pressure Sensor Circuit Data Erratic Pressure Intermittent or Incorrect 296 1388 14 Red Auxiliary Auxiliary Pressure Sensor Input 1 Pressure Special Instructions Injector Injector Solenoid Cylinder 1 Circuit Bes por Amber Cylinder 01 Current Below Normal or Open Circuit Injector Injector Solenoid Cylinder 3 Circuit Current Below oe 855 Amber Cylinder 03 Normal or Open Circuit Injector Injector Solenoid Cylinder 2 Circuit Current Below a 694 Amber Cylinder 02 Normal or Open Circuit Injector Injector Solenoid Cylinder 4 Circuit Current Below 895 Bot Amaer Cylinder 04 Normal or Open Circuit Engine Control Module Warning internal hardware is Amber failure Bad Intelligent Device or Component Transmission Transmission Output Shaft Speed Data Valid but 349 191 16 Amber Output Shaft Above Normal Operational Range Moderately Speed Severe Level 351 627 12
237. r 3 Start engine Operate machine functions several times to allow hydraulic oil to reach operating temperature The hydraulic oil temperature should be between 100 120 F 38 49 C If a temperature gauge or thermometer is unavailable the hydraulic oil reservoir should be warm to 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 pressure gauge reading It should read as specified in Pressure Readings column of charts found in Section 8 4 Hydraulic Circuits If reading is not as specified turn engine OFF and check other components in system Verify that all related hydraulic components and electrical switches sensors solenoids etc are operating correctly 7 Adjust relief valve by turning adjustment screw clockwise will increase the pressure turning screw counterclockwise will decrease pressure 8 Start engine and check pressure again Turn engine OFF If there is pressure reading in gauge bleed it off then disconnect or remove pressure gauge from the machine Hydraulic System n 8 4 HYDRAULIC CIRCUITS This section covers hydraulic circuits and includes listings for all hydraulic function pressures where and how to c
238. r Secure starter with the three fasteners Connect the positive battery cable to upper solenoid stud Install wires to solenoid stud and secure with lock washer and nut Connect wires removed earlier to the solenoid mounting stud Properly connect battery Close and secure engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel G6 42A G9 43A G10 43A Electrical System 9 7 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 amp 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 actuator fuse refer to Section 9 4 1 Engine Compartment 3 Check external alternator wiring and connections and verify that they are in good condition 4 Check the fan belt condition and tension 5 Run engine and check 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 7 1 Alternator ULS a Alternator Removal 1 Park machine o
239. r 3800 psi Stall boom extend Connect gauge to EF1 port Tilt EF1 C Run engine at high idle N A 4000 Stall tilt up Connect gauge to EF1 port Boom Lift EF1 C Run engine at high idle N A 4000 Stall boom retract Connect gauge to EF1 port Run engine at high idle Stall auxiliary on direction 2850 3150 psi Auxiliary EF1 C Check N A 197 217 Bar 3000 psi Stall auxiliary opposite direction Repeat check KOK G6 42A G9 43A G10 43A 5 N DIDY gt eA Tg x MA j 1056 27 72 N A 5 gt 2 WO MY7840 MY7830 4 Hydraulic System 8 4 3 G10 43A Pressure Specifications G9 43A amp Hydraulic Circuit Test Port Function Used to Test Adjustment Location Pressure Range Nominal Pressure Load Sense Relief GLS B Connect gauge to P1 port and adjust standby pressure setting to 250 psi see procedure in sfa step 2 Adjust main compensator to 3950 psi see procedure in sfa step 3 Adjustment may require incrementally increasing load sense relief valve adjustment location 6 and main pump compensator until a setting of 3950 psi can be observed on p1 gauge Adjust load sense relief valve to setting shown at right using gauge in GLS B port Once load sense relief is adjusted to specification main pump p
240. r component Before starting the engine or applying pressure use components parts hoses and pipes that are in good condition connected properly and are tightened to the proper torque Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations COOLANT SYSTEM CAP The cooling system is under pressure and escaping coolant can cause severe burns and eye injury To prevent personal injury NEVER remove the coolant system cap while the cooling system is hot Wear safety glasses Turn the coolant system cap to allow pressure to escape before removing the cap completely Failure to follow the safety practices could result in death or serious injury FLUID FLAMABILTITY DO NOT service the fuel or hydraulic systems near an open flame sparks or smoking materials Properly disconnect battery s prior to servicing the fuel or hydraulic systems NEVER drain or store fluids in an open container Engine fuel and hydraulic fluid are flammable and can cause a fire and or explosion 1 4 DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause an explosion PRESSURE TESTING When conducting any test only use test equipment that is correctly calibrated and in good condition Use the correct equipment in the proper manner and make changes or repairs as indicated by the test procedure to achieve the desired result LEAVING MACHINE Lower the forks or attachment to the ground b
241. r to appropriate parts manual for ordering information If not using an approved replacement tire It is recommended that replacement tires have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability Foam filled tires have a positive effect on the weight stability and handling characteristics of the machine especially under load The use of hydrofill as a tire fill substance is not recommended because of possible environmental impact Large bore valve stems are used to help expedite tire inflation and deflation An inner tube may be used if a tire does not provide an airtight seal Check tire inflation pressures when the tires are cold When mounting a tire on the wheel the tire must be mounted on the wheel respective of the directional tread pattern of the tire this produces a left or right tire and wheel assembly 5 6 1 1 Park the machine on a firm
242. raulic power supply and the extend retract hoses of the affected machine Retract hose 3 is the supply and extend hose 4 is the return Connect the hoses in the proper order to ensure that the cylinder is retracted not extended Remove the previously installed boom support Use the auxiliary power supply to slowly retract the extend retract cylinder Properly support the boom as required Loosen and remove the jumper hoses caps plugs and reconnect the extend retract cylinder hoses Torque as required Lower the boom as follows Place a suitable receptacle under the tube hose connections Disconnect the lift lower cylinder hoses from the lift lower cylinder tubes 1 amp 2 Install caps or plugs in tubes to prevent fluid loss and to keep dirt and debris from entering the hydraulic system Using the hoses and fittings specified connect the hoses between the auxiliary hydraulic power supply and the lift lower hoses of the affected machine Lift hose 1 is the return and lower hose 2 is the supply Connect the hoses in the proper order to ensure that the boom is lowered not raised Remove the previously installed boom support Use the auxiliary power supply to slowly lower the boom Loosen and remove the jumper hoses caps plugs and reconnect the lift lower cylinder hoses Install the previously remove clamps securing the lift lower cylinder and the extend retract tubes Torque as
243. re Sender Inspection and Replacement Inspect sender and wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part 9 22 9 10 5 Engine Coolant Temperature Sender Installation and Testing Thread engine coolant temperature sender into engine block snugly then connect sender connector to wiring harness connector 2 Properly connect the battery 3 Check for proper coolant level Start engine allow it to reach operating temperature and observe the operator s instrument cluster for warning indication If 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 Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Fuel Level Sender a Fuel Level Indicator Testing The fuel level sender wiring harness leads can be accessed from the top of the fuel tank Loosen and remove he four screws securing the fuel sender cover 6 Disconnect the fuel level sender wiring harness leads 7 from the fuel sender 8 With the help of an assistant touch both harness leads together From the operator s cab have the assistant turn the ignition key switch to the RUN position DO NOT start the engine Observe the fuel leve
244. re that machine will remain in place during axle installation Block front and rear of both tires on the axle that is already installed on the machine 2 If applicable raise machine using a suitable jack or hoist Place suitable supports beneath frame and lower machine onto supports allowing enough room for axle installation Ensure that machine will remain in place during axle installation 3 Using a suitable jack hoist or overhead crane and sling remove axle from its support or holding stand Balance axle and prevent it from tipping turning or falling while positioning it beneath machine DO NOT raise or otherwise disturb machine while installing axle Keep axle supported and balanced on jack hoist or overhead crane and sling throughout the installation procedure 4 Position axle under frame and align axle housings with holes in frame 5 Install four axle bolts and nuts Tighten and torque to 530 565 Ib ft 718 766 Nm 6 Move oylinder into position on axle cylinder anchor Insert a cylinder mount pin through cylinder and cylinder anchor Secure the cylinder mount pin with one capscrew and a new locknut 7 Apply multi purpose grease through the self tapping lube fitting to lubricate the self align bearing and the cylinder mount pin 8 Install the drive shaft assemblies Refer to Section 5 5 5 Drive Shaft Installation 9 If reinstalling an axle previously removed from the machine position driveshaft yoke on a
245. 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 references to the right side left side front and rear are given from the operator s seat looking in a forward direction Supplementary information is available from JLG in the form of Service Bulletins Service Campaigns Service Training Schools the JLG website other literature and through updates to the manual itself 1 2 DISCLAIMER All information in this manual is based on the latest product information available at the time of publication JLG reserves the right to make changes and improvements to its products and to discontinue the manufacture of any product at its discretion at any time without public notice or obligation 1 3 OPERATION amp SAFETY MANUAL The mechanic must not operate th
246. 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 affected circuit requiring recalibration or a new relief valve Disassemble each Valve Section 1 Carefully separate the load sense outlet section from lift lower section 2 Remove o rings from between 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 dama
247. required Install the plastic cover over the main control valve Transfer any hydraulic oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility Clean up all debris hydraulic oil etc in on near and around the machine Remove the Do Not Operate Tag on both the ignition key switch and steering wheel G6 42A G9 43A G10 43A 3 33 Cy 3 14 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom Problem Cause Remedy 1 Boom will not extend or 1 Broken hydraulic hose s or 1 Locate break replace hose s retract tube s and or connections or tube s tighten connections leaking 2 Extend retract hydraulic system 2 Refer to Section 8 Hydraulic not operating properly System 3 Faulty extend retract cylinder 3 Repair cylinder Refer to Section 8 8 Hydraulic Cylinders 2 Boom shifts to right or left 1 Boom side wear pads 1 Shim wear pads to correct gap when extending improperly shimmed or worn Replace wear pads as needed Refer to Section 3 10 Boom Wear Pads 3 Excessive boom pivot pin 1 Insufficient lubrication 1 Lubricate at regular intervals noise and or wear Refer to Section 2 7 Lubrication Schedule Replace worn pins as needed 2 Worn bearing s 2 Replace beari
248. ressure may read lower than 3950 psi 3550 3650 psi 245 252 Bar 3600 psi Stand By P1 A Connect gauge to P1 port Run engine at high idle No Function 250 265 psi 17 2 18 2 Bar 250 psi Main P1 A Connect gauge to P1 port Run engine at high idle Stall lift up or frame level 3825 3875 psi 264 267 Bar 3850 psi Pilot 281 C Connect gauge to JS1 port Run engine at high idle Stall steering 500 550 psi 34 5 37 9 500 Service Brake BV1 D Connect gauge to BV1 port Run engine at high idle Stall steering 1050 1150 psi 72 3 79 2 Bar 1100 psi Priority Load Sense Steering GLS B Connect gauge to GLS port Run engine at high idle Stall steering 2350 2450 psi 162 169 Bar 2400 psi Boom Extend GLS B Connect gauge to GLS port Run engine at high idle Stall boom extend N A 3600 3700 psi 248 255 Bar 3650 psi Boom Retract GLS B Connect gauge to GLS port Run engine at high idle Stall boom retract N A 3600 3700 psi 248 255 Bar 3650 psi G6 42A G9 43A G10 43A Hydraulic System Connect gauge to GLS port 3600 3700 psi Stall auxiliary opposite direction Repeat Check Boom Lift GLS B Run engine at high idle N A 248 255 Bar 3650 psi Stall boom lift up Connect gauge to GLS port Run engine at high idle A
249. reviously removed wear pads spacers and shims at both sides on front of first boom section 5 Snug mounting bolts 7 980 FN 3 13 ott Boom 10 11 12 13 14 15 16 Install the anchor plate 6 using existing hardware 7 into the first boom section Torque as required Y MY3990 Install the previously removed tilt hose retainer bracket 8 and if equipped both auxiliary hose retainer at the bottom of the first boom section using mounting bolts 9 Torque as required Remove plugs from the previously removed tilt hoses 10 and if equipped both auxiliary hoses Connect both tilt hoses 10 and if equipped both auxiliary hoses to the fittings on the hose retainer bracket Torque as required Connect both tilt tubes 11 and if equipped both auxiliary tubes to the fittings on the hose retainer bracket Torque as required Push the second and third boom sections the remainder of the way into the first boom section 13 7 13 2 B 12 MY3890 Install the previously removed wear pad and spacer 12 on the left or right side of the second boom
250. ront or rear axle assembly Axle Removal Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on electrical components If using a steam cleaner seal all openings before steam cleaning Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 5 4 1 Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever in the NEUTRAL position engage parking brake straighten all wheels and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel 3 Open engine cover Allow the system fluids to cool 4 Properly disconnect the battery 5 Remove the optional fender assembly MY4180 6 If axle will be disassembled after removal place suitable receptacle under axle 1 and wheel hubs drain plugs 2 Remove drain plugs and allow axle oil to drain into receptacle Transfer used axle oil into a suitable covered container and label container as Used Oil Dispose of used oil at an approved recycling facility 7 Label disconnect and cap the steering and brake lines at the axle Wipe up any spilled oil 8 Block front and rear of both tires on axle that is not being removed Ensure that machine will remain in place during axle removal before pro
251. roperly support the boom before attempting to proceed with the emergency boom lowering procedure A WARNING If possible safely remove and or secure the load on the machine before starting the boom lowering procedure If load cannot be removed the machine load chart MUST be followed 3 13 1 Auxiliary Hydraulic Power Supply Equipment and Supplies Required Portable hydraulic unit or another machine with an auxiliary hydraulic power supply with a capacity to hold up to 22 gal 83 L of hydraulic oil from the machine during lowering process Note another machine is being used the hydraulic reservoir must be drained to accept a minimum of 22 gal 83 L of hydraulic oil before attempting this procedure Standard Mechanic Tools EQUIPMENT DAMAGE Auxiliary Hydraulic Power Supply hydraulic oil must be compatible with hydraulic oil shown in Section 2 4 Fluids and Lubricant Capacities 3 31 A Hoses e Two Hydraulic Hoses Approximately 10 ft 3 0 m each with a minimum 1 0 of 0 375 in 9 5 mm and a minimum rating of 4000 psi 275 8 bar G6 42A Fittings Two 10 ORFS Caps Two 10 ORFS Plugs Adaptors Two 10 ORFS 90 Adaptors G9 43A or G10 43A Fittings Two 12 ORFS Caps Two 12 ORFS Plugs Adaptors Two 12 ORFS 90 Adaptors Note The adaptor size may vary depending on the hose ends of the auxiliary hydraulic power supply 3
252. rrect level with filled with incorrect oil or oil hydraulic oil Refer to Section 2 5 Fluid contaminated or oil level low and Lubricant Capacities 3 Dragging park brake 3 Adjust park brake cable as needed 8 High steering 1 Steering hydraulic system not 1 Refer to Section 8 4 Hydraulic effort required operating properly Circuits 2 Excessive joint housing swivel 2 Correct bearing preload by adding or bearing preload removing shims as needed 3 Worn or damaged swivel bearings 3 Replace swivel bearings as needed 9 Slow steering 1 Steering hydraulic system not 1 Refer to Section 8 4 Hydraulic response operating properly Circuits 2 Steering cylinder leaking internally 2 Repair or replace steering cylinder as needed 10 Excessive noise 1 Brake discs worn 1 Check brake discs for wear Refer to when brakes Section 5 7 Brakes are engaged 2 Brake discs damaged 2 Replace brake discs 11 Brakes will 1 Brake hydraulic system not 1 Refer to Section 8 4 Hydraulic not engage operating properly Circuits 2 Brake piston o rings and seals 2 Replace o rings and seals damaged leaking 12 Brakes will not 1 Brake discs worn 1 Check brake discs for wear Refer to hold the machine Section 2 5 Fluid and Lubricant or braking Capacities power reduced a 2 Brake hydraulic system not 2 Refer to Section 8 4 Hydraulic operating properly Circuits 3 Brake piston
253. rtical directions oL 620 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 Ib ft 20 23 Nm 1 2 20 Bolt 76 86 Ib ft 103 116 Nm 1 2 20 Hollow Bolt 45 50 Ib ft 61 68 Nm Torque wear pad bolts after shimming is completed Lubricate the face and pockets of each wear pad after being installed G6 42A G9 43A G10 43A 3 10 3 Boom Section Wear Pad Pathway Lubrication Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease 3 27 b Boom CY E 3 11 BOOM EXTEND AND Following are some exa
254. s and 8 5 8 4 Hydraulic Circuits 2 e REEL Re Pa uot ku exis 8 6 8 4 1 Hydraulic Pressures 8 6 8 4 2 Pressure 5 06 42 8 7 8 4 3 Pressure Specifications G9 43A 8 010 4 8 8 8 4 4 Hydraulic 6 42 8 10 8 4 5 Hydraulic Schematic G6 42A Options 8 11 8 4 6 Hydraulic Schematic G9 43A amp 0910 43 8 12 8 4 7 Hydraulic Schematic Manual Controls G9 43A amp G10 43A 8 13 8 4 8 Anti Stall 8 14 8 5 Hydraulic Reservoir 8 15 8 5 1 Hydraulic Oil Reservoir 0 8 15 8 5 2 Hydraulic Oil Reservoir 0 8 15 8 5 3 Hydraulic Oil Reservoir Removal Installation 8 15 8 6 Implement Pump o I etr ER RE unu Ree Gees 8 16 8 6 1 Implement Pump 8 16 8 7 Control 8 17 8 7 1 Main Control 8 17 8 7 2 Service Brake 8 20 8 7 3 Service Brake
255. s for Inspection 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 G6 42A G9 43A G10 43A Boom N 3 11 3 Inspection Guidelines Distorted or Battered Link Plates 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 MZ1466 Distorted or battered link plates 5 on a leaf chain can lx a 3 2 cause tight joints and prevent flexing Turning or Protruding Pins Highly loaded chain operating with inadequate Y lubrication can generate abnormal frictional forces 21463 between and link plates When chain is allowed to operate in this condition a pin or series of pins Elongation can begin to twist out of a chain resulting in failure It is important to measure chain in section that moves over sheaves because it receives most frequent articulation Measuring chain near its clevis terminals could give an inaccurate reading Ends of chains near clevis
256. s greater than 250 but the Yes Open Circuit actual current is less then 75 The fork tilt up digital output was open circuit This fault may be caused by improper wiring or a control module issue 9 32 G6 42A G9 43A G10 43A Electrical System DTC Event Comment Latched 33192 Fork Tilt Valve Short To Battery Fork Tilt Up amp 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 desired current is greater than 250 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 driver s 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 33194 Fork Tilt Down Valve Open Circuit desired current is greater than 250 but the actual current is less then 75 The fork tilt down digital output was open circuit This fault may be caused by improper wiring or a control module issue Yes 33195 Fork Tilt Down Valve Short To Ground The actual current is greater than 200mA PWM is 95 and the digita
257. sa cnp ENG GND E xonca remem H sp rer 1 T NX neuro Siena Sem oem B OUTPUT gt 7 eue usse outeur outeur BLK WE RTN EUCWIFRIN ngs jo e WATER FUEL B ANALOG GROUNDP gt ANALOG 5v OUT 44 paos E M cca m 45 BUX VEC GND 8XL ovid ce see ANALYZER RECEIVE B VEC POWER AND GROUND ga T 8 X gt gt 18 3 dit 48 Jh els dj s E a age dB dg 8g gl le 3b 56 i i z e EEH ala i B 3 dde HE 1 5 8 d E VEUNT YYUMVHYYWU YU YU IVYYYYUTYVYYYVTYYYY Ei El RE AW E B 8 i E 8 E E 8 ENGINE ECM l i RESISTOR 1208 STARTER CUMMINS SRED CO
258. sembly 1 Place the steer select assembly on suitable work surface 2 Separate steer select valve from manifold by removing four socket head capscrews Discard four o rings 3 Remove solenoid valves and cartridges from 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 ultra smooth 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 hyaraulic oil 7 Install the solenoid valves and cartridges in the steer select housing 8 Attach steer select valve to manifold using four new oiled o rings and the four socket head capscrews c Steer Select Valve and Manifold Installation 1 Install steer select valve to the mounting plate under the left front side of the frame using the two bolts 2 Connect all the
259. ssive 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 If equipped for ULS use ultra low sulfur content fuel with a cloud point temperature at which wax crystals form in diesel fuel at least 10 below lowest expected fuel temperature Viscosity of fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication If equipped for LS use low sulfur content fuel with cloud point temperature at which wax crystals form in diesel fuel at least 10 below lowest expected fuel temperature Viscosity of fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication G6 42A G9 43A G10 43A Engine 7 4 2 Fuel Tank 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 NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on bo
260. stallation of the retract chains without removing the boom assemblies Inspect and lubricate chains thoroughly before installation 1 Push the retract chain through the boom from the rear to the chain adjusting block 7 on the first boom section Do not tighten the adjustment and lock nut at this time Thread the nut on the clevis enough to keep the chain in place Connect the extend chain to the wire or rope at the rear of the boom 3 15 b Boom Cy 3 Slowly pull the wire or guiding the extend chain over the push beam around the extend chain sheave under the push beam and stopping at the extend chain retract chain clevis Remove wire or rope secured to extend chain Place chain clevis rod to one side of push beam Lift the push beam to gain access to the chain clevis at the rear of the third boom section 7 Reaching inside rear of the boom at chain anchor bracket install cotter pin and pin from extend chain clevis Install cotter pin and pin from retract chain 8 Lower the push beam Center the chain clevis rod on the push beam 9 Place extend chain rod through strong back and place strong back in place at the rear of the first boom section 10 Install and torque strong back mounting bolts to 240 265 Ib ft 325 359 Nm 11 Install extend retract cylinder mounting pin and secure with retaining clips 12 Install adjustment and lock nuts on chain
261. suitable container Note Proper precautions must be used to ensure any hyaraulic oil being drained is contained and disposed 6 Transfer used hydraulic oil into a suitable covered container and label as Used Oil Dispose of used oil at an approved recycling facility Close drain valve and remove drain hose 7 Wipe up any hydraulic fluid spillage in on near and around machine and work area G6 42A G9 43A G10 43A n 1 Be sure reservoir is clean and free of all debris Hydraulic Oil Reservoir Filling 2 Install a new hydraulic oil filter 3 Fill the reservoir with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities 4 Properly connect the battery 5 Close and secure the engine cover 6 Remove Do Not Operate Tags from both ignition key switch and steering wheel 8 5 3 Hydraulic Oil Reservoir Removal Installation Note determined that hydraulic oil reservoir must be removed hydraulic oil must be drained before reservoir is removed Always dispose of hyaraulic oil properly a Reservoir Removal 1 Park machine on a firm level surface level machine fully retract the boom 2 Raise and properly support boom to adequate height to allow for removal of reservoir tank 3 Place transmission control lever in NEUTRAL engage park brake and shut engine OFF 4 Place a Do Not Operate Tag on both ignition key switch and steering wheel 5 Open engine cover Allow system fluids
262. t 13 and push the push beam 14 forward 3 4 in 76 2 101 6 mm 2 Attach the Temporary Extend Chain Retention Bracket 15 between the chain clevis 16 and the end of the push beam 14 Note Refer to Section 3 15 Push Beam Temporary Brackets for Temporary Extend Chain Bracket diagram 3 Lift push beam 14 to unload clevis pin 17 and remove pin securing clevis to third boom section 4 Tighten the Temporary Extend Chain Retention Bracket 13 to remove any slack in the extend chain 5 Secure rope or wire to front of push beam and pull push beam 14 towards front of boom 6 Support push beam assembly with pry bars using access holes on each side of third boom section 18 MY3930 G6 42A G9 43A G10 43A 7 Remove the guide bar 18 and chain retainer 19 Remove the push beam wear pad 20 8 Lower push beam assembly and remove pry bars 9 Push pull push beam assembly along with extend chain to front of third boom section Guide the assembly over the top of the retract chain anchor at the rear of the third boom section being careful not to damage any components push beam extend retract cylinder 10 Place a sling around the push beam assembly Lift and slowly pull the push beam assembly approximately half way out of the third boom section Lower the push beam onto a suitable support 11 Relocate sling or using two slings for better stability balance push beam assembly and
263. tall pin and retaining clips 10 securing clevis to third boom section 10 Remove the Temporary Retract Chain Bracket 11 3 10 G6 42A G9 43A G10 43A i M P K 16 3 5 5 15 1 i 15 14 P 14 ince EN id Install the previously removed wear pads shims and spacers 14 at the bottom rear of the third boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Install previously removed wear pad and spacer 15 on left or right side of the third boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information Third Boom Section Installation Note Using a straight bar approximately 20 in 508 mm long will aid in the installation of the wear pads located on the inside front of each boom section 1 Place second boom section onto suitable supports Lubricate bottom of third boom section where wear pads of the second boom section contact the third boom section Place sling or two slings for better stability around third boom sect
264. th the ignition key switch and steering wheel 3 Open the engine cover Allow the system fluids to cool 4 Properly disconnect the battery Note If 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 29 MZ 4230 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 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
265. the mounting plates 19 Feed the tilt cylinder hoses and if equipped the auxiliary hoses over and around the hose sheaves d E N MY3880 20 Align push beam bores with second boom section bores and install previously removed pins 11 Note Verify the cross holes in push beam pins align with holes in each pin bore on the second boom section 21 Install the previously removed tilt cylinder hose guide 12 and if equipped the auxiliary hose guide at the rear of the third boom section using the existing hardware Torque as required 14 14 13 13 MY3910 22 Install previously removed wear pad and spacer 13 on left or right side of third boom section Snug mounting bolts Shim as needed AFTER boom section is installed Refer to Section 3 10 2 Wear Pad Installation and Lubrication for detailed information 23 Install previously removed wear pad and spacer 14 on top of the third boom section Snug mounting bolts Shim as nee
266. tic Pressure Intermittent or Incorrect Electrical Battery 1 Voltage Low Data Valid but Below 441 168 18 Amber Potential Normal Operational Range Moderately Voltage Severe Level Electrical Battery 1 Voltage High Data Valid but Above 442 168 16 Amber Potential Normal Operational Range Moderately Voltage Severe Level 449 157 0 Red Injector Fuel Pressure High Data Valid but Above Normal Metering Rail 1 Operational Range Moderately Severe Level Injector Injector Metering Rail 1 Pressure Sensor Circuit n Tor a Amber Metering Rail 1 Voltage Above Normal or Shorted to High Source Injector Injector Metering Rail 1 Pressure Sensor Circuit gog Ld Amber Metering Rail 1 Voltage Below Normal or Shorted to Low Source Manifold 1 Temperature Data Valid but Above Nor 105 18 Amber Intake Manifold mal Operational Range Moderately Severe Level Transmission Transmission Output Shaft Speed Data Valid but 489 191 18 Amber Output Shaft Below Normal Operational Range Moderately Speed Severe Level 497 1377 2 Amber Switch Circuit Multiple Unit Synchronization Switch Circuit Data Erratic Intermittent or Incorrect 9 42 G6 42A G9 43A G10 43A Electrical System SPN ramp E Cummins Description Codes Codes Codes Color Description 515 3514 3 Amber Not Available Sensor Supply 6 Circuit Voltage above normal or shorted to high s
267. tion On Data Erratic Intermittent or Incorrect Accelerator Accelerator Pedal or Lever Position Sensor 2 Circuit 1299 2043 3 Amper Pedal Position Voltage Above Normal or Shorted to High Source Accelerator Pedal Lever Position Sensor 2 Circuit ten 2628 4 Amber Not Available Voltage Below Normal or Shorted to Low Source Accelerator Accelerator Pedal or Lever Position Sensor 1 and 152 a a Reg Pedal Position 2 Data Erratic Intermittent or Incorrect 1695 3513 3 Amber Not Available Sensor Supply 5 Voltage Above Normal or Shorted to High Source 1696 3513 4 Awibar Not Available Sensor Supply 5 Voltage Below Normal or Shorted to Low Source Crankcase Pressure Circuit Voltage Above 943 191 Amber Normal Shorted to High Source 1844 101 4 Amber Not Available Crankcase Pressure Circuit Below Normal or Shorted to Low Source 9 44 G6 42A G9 43A G10 43A Electrical System Fault SPN FMI Lamp SPN EE Codes Codes Codes Color Description Cummine Water in Fuel Water in Fuel Indicator Data Valid but Above 1852 97 16 Amber Normal Operational Range Moderately Indicator Severe Level 1896 2791 13 Amber Not Available EGR Valve Controller Out of Calibration Injector Metering Rail 1 Pressure Data Valid 1911 157 0 Amber je but Above Normal Operational Range Most Meteri
268. to cool 6 Properly disconnect the battery 7 Drain the hydraulic oil reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 8 Label disconnect and cap all hydraulic hoses attached to hydraulic oil reservoir 9 Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 10 Remove the bolts securing the hydraulic oil reservoir to the frame 11 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 8 15 Hydraulic System n c Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank the tank can usually be cleaned Note lf a leak is suspected in the hydraulic oil reservoir contact your local JLG Distributor To clean the hyaraulic 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 pr
269. to initiate calibration or the Yes Enter No ESC ESC key to leave menu Fork Tilt Roller The technician will knurl the fork tilt roller to the AR position and FWD to Max press the ENTER key to confirm Fork Tilt Roller The the technician will release the fork tilt roller and press the ENTER Center key to confirm Fork Tilt Roller The technician will knurl the fork tilt roller to the AR position and Calibrations REV to Max press the ENTER key to confirm Fork Tilt Fork Tilt Roller The the technician will release the fork tilt roller and press the ENTER Center key to confirm Calibrations The control system will display this message to advise that the Complete procedure was successful The technician will press the ESC key to leave this menu Calibrations The control system will display this message to advise that the Failed procedure was unsuccessful The technician will press the ESC key to leave this menu Cal Aux Hyd The technician will press the ENTER key to initiate calibration or the Yes Enter No ESC ESC key to leave menu Aux Hyd Roller The technician will knurl the auxiliary hydraulic roller to the AR FWD to Max position and press the ENTER key to confirm Aux Hyd Roller The the technician will release the auxiliary hydraulic roller and press Center the ENTER key to confirm Aux Hyd Roller The technician will knurl the auxiliary hydraulic roller to the AR Calibrations REV to Max position and press the ENTER key to confirm
270. ts 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 9 Install the main control valve protective cover 8 19 Hydraulic System n 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
271. use Remedy 1 Transmission will not engage or will not shift properly 1 Oil level too high or low 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 6 Clutch piston o rings damaged 7 Clutch discs worn or damaged 8 Coupling shafts or gear teeth damaged 1 Fill transmission to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities Refer to Section 9 5 Electrical System Schematics Refer to Section 9 5 Electrical System Schematics Clean the valve spool and housing Replace return spring as needed Refer to Problem 2 Low or no pump flow or pressure Replace o rings Replace clutch discs Replace couplings 2 Low or no pump flow or pressure 1 Low oil level 2 Transmission filled with incorrect oil or oil contaminated 3 Pump suction pipe screen clogged 4 Central shaft damaged 5 Pump worn or damaged Fill transmission to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities Drain transmission and fill to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities Cle
272. uxiliary Stall auxiliary one direction 2900 3000 psi n Hydraulics 2 8 8 Check 200 214 S000 e G6 42A G9 43A G10 43A MY4361 4 0 7860 Hydraulic System ry 8 4 4 Hydraulic Schematic G6 42A SERVICE BRAKE MY7880 8 T BE i 5 e 5 9 2 LIE 2 8 2 _ STEER SELECT VALVE CYLINDER SS MMC EE E 1 i CROWD CYLINDER p REAR SERVICE JOYSTICK 1 TILT CYLINDER BRAKES 3 I Y L o
273. w in locking bolt 8 Torque as required Uncap and install hydraulic hoses 17 to proper fittings on quick switch assembly 10 torque as required Secure hoses 17 to cylinder cover 15 with clamp hardware 16 Reinstall cylinder cover 15 with the hardware removed earlier 3 25 Quick Switch Removal FS MY5090 1 Remove the lock bolt 8 holding the tilt cylinder rod end pin 9 to the quick switch assembly 10 Remove the Tilt Cylinder pin 2 Support the quick switch assembly 10 Remove the capscrew 11 and locknut 12 securing the head pin 13 to the boom head 14 3 Inspect the above pins for nicks or surface corrosion Use fine emery cloth to fix minor nicks or corrosion If damaged or if it cannot be repaired the pin must be replaced 3 9 3 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 Quick Switch Installation 2 Coat the quick switch head pin 13 with an anti seize 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 26 3 10 BOOM WEAR PADS
274. worn or damaged 6 Axle housing mounting nuts and 6 Tighten housing nuts and capscrews to capscrews loose 288 Ib ft 390 Nm 7 Differential and or axle 7 Replace housing s as needed housing s damaged 5 Oil leaking from 1 Oil level plugs loose and or 1 Replace o rings as needed and tighten wheel end housing o rings damaged or missing plugs to 96 Ib ft 130 Nm planet carrier 2 O ring between hub and housing 2 Replace o ring planet carrier damaged or missing 3 Shaft seal damaged or missing 3 Replace seal and or fork joint shaft and or worn or damaged shaft sealing surfaces 4 Housing capscrews loose 4 Tighten housing capscrews to 41 Ib ft 55 Nm 5 Housing planet carrier damaged 5 Replace housing planet carrier 6 Oil leaking from 1 Hose fittings loose 1 Tighten fittings steering cylinder 2 Steering cylinder o rings and or 2 Replace o rings and seals seals worn or damaged 3 Piston rod seal worn or damaged 3 Replace piston rod seal 4 Oylinder tube damaged 4 Replace cylinder tube G6 42A G9 43A G10 43A hs Axles Drive Shafts Wheels and Tires Problem Cause Remedy 7 Axle overheating 1 Oil level too high 1 Fill oil to correct level with hydraulic oil Refer to Section 2 5 Fluid and Lubricant Capacities damaged leaking 2 Axle and or wheel end housings 2 Drain axle and fill to co
275. xle according to alignment marks made earlier If installing a new axle note position of driveshaft yoke at transmission Align driveshaft yoke on axle in same plane as yoke on transmission 4180 G6 42A G9 43A G10 43A 10 Tighten axle oil drain plug loosen and remove axle oil fill plug 1 Refer to Section 2 5 Fluids and Lubricant Capacities for proper oil and capacities 11 Rotate wheel hubs 90 degrees so drain plug 2 becomes fill plug 3 Refer to Section 2 5 Fluid and Lubricant Capacities for proper oil and capacities 12 Install the wheel and tire assemblies Refer to Section 5 6 2 Wheel and Tire Assembly Installation 13 Carefully remove jack hoist or overhead crane and sling supporting the axle 14 Carefully raise machine using a suitable jack or hoist Remove supports from beneath frame and lower the machine to ground 15 Remove blocks from front and rear of both tires on other axle Note ALWAYS use new o rings when servicing the machine 16 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil 17 Uncap and connect the steering and brake lines at their axle fittings 18 Check the hydraulic reservoir oil level 19 Start engine Turn steering wheel several times lock to lock operate the frame tilt function several times in both directions and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary
276. y aa SRRZ MY8260 Fault codes will appear in the display area 18 of the gauge 19 9 13 2 Fault Codes Fault SPN FMI Lamp SPN Codes Codes Codes Color Description Cummins poscripiten System Engine Speed Position Sensor Circuit lost both of 115 612 2 Red Diagnostic two signals from the magnetic pickup sensor Data Code 2 Erratic Intermittent or incorrect Intake Manifold Pressure Sensor Circuit Voltage 125 me 3 Amber Boost Pressutg Above Normal or Shorted to High Source 123 102 4 Amber Bo stPressure Intake Manifold Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source Accelerator Accelerator Pedal or Lever Position Sensor Circuit Accelerator 191 d 8 ney Pedal Position Voltage Above Normal or Shorted to High Source 132 91 4 Red Accelerator Accelerator Pedal or Lever Position Sensor Circuit Pedal Position Voltage Above Normal or Shorted to High Source Remote Remote Accelerator Pedal or Lever Position Sensor 133 974 3 Red Circuit Voltage Above Normal or Shorted to Accelerator High Source Remote Remote Accelerator Pedal or Lever Position 134 974 4 Red Sensor Circuit Voltage Below Normal or Shorted to Low Source 9 38 G6 42A G9 43A G10 43A Electrical System Fault SPN FMI Lamp SPN EE Codes
277. y sender with a new part Transmission Temperature Sender Installation and Testing Thread transmission temperature sender into transmission housing snugly then connect sender connector to wiring harness connector 2 Properly connect the battery 3 Check for proper fluid level 4 Start engine allow it to reach operating temperature and observe the operator s display cluster for warning indication If sender is not defective problem could be elsewhere possibly in a shorted wire damaged transmission improper or low fluid etc Close and secure the engine cover Remove the Do Not Operate Tags from both ignition key switch and steering wheel 9 21 Electrical System 9 10 4 a 1 Engine Coolant Temperature Sender Engine Coolant Temperature Sender Removal Park machine on a firm level surface level machine fully retract boom lower boom place transmission control lever NEUTRAL engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Open engine cover Allow system fluids to cool Properly disconnect the battery Unplug the engine coolant temperature sender connector 1 from the wiring harness connector Engine coolant temperature sender 2 is located near upper radiator hose thermostat housing and threaded into engine block Remove the sender Engine Coolant Temperatu
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