Service Manual

Models
G6-42A, G9-43A
& G10-43A
G6-42A
Before S/N 0160048658
G9-43A & G10-43A
Before S/N 0160048671
including 0160048773

31200151

Revised
July 11, 2014

An Oshkosh Corporation Company

 EFFECTIVITY PAGE

May 12, 2006 - A - Original Issue Of Manual

April 19, 2007 -B- Revised pages 2.9, 2.12, 3.14, 5.11, 6.3 & 8.4.
May 1, 2009 - C - Added G10-43A information. Revised covers and pages 1.3, 1.4, 2.3 thru 2.19, 3.2, 3.3, 3.7, 3.12, 4.2,
4.3, 4.7, 4.9, 5.3, 5.4, 5.5, 5.10, 6.3, 6.4, 6.6, 6.7, 7.5, 7.6, 7.7, 7.11, 8.2, 8.3, 8.6 thru 8.12, 8.16, 8.17, 8.21, 8.22, 8.26,
9.3 & 9.18 thru 9.27.
September 20, 2011 - D - Revised page numbering and pages 1-3, 2-1, 2-3 thru 2-9, 2-13 thru 2-26, 3-1, 3-13 thru 3-15,
4-1, 4-2, 4-6, 4-7, 4-10 thru 4-12, 6-3, 6-7, 7-1, 7-6 thru 7-8, 7-13, 7-14, 8-6 thru 8-17, 8-23, 9-3, 9-4, 9-7, 9-8, 9-31 thru
9-36, 9-38, 9-41, 9-43, 9-47, 9-51, 9-55, 9-57 thru 9-74.
August 9, 2012 - E - Revised pages 3-1 thru 3-34.
October 31, 2012 - F - Revised cover and page 3-23.
July 15, 2013 - G - Friction Modifier Page 2-16, Emergency Boom Lowering Procedure Pages 3-30 and 3-31.
July 11, 2014 - H - Revised pages 3-20 thru 3-23.

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

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

 SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5 Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.7 Push Beam - Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . 3-16
3.8 Boom Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.11 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.12 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.13 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.14 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.16 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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

Section Subject Page

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6 Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Section 7
Engine ........................................................... 7-1
7.1 Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

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

Section Subject Page

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.11 Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After
including 0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58
9.15 Hand Held Analyzer(G9-43A/G10-43A S/N 0160040675 and After including
0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
9.16 Joystick Fault Codes (G9-43A/G10-43A S/N 0160040675 and After including
0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.17 Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
9.18 SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . . . . . . 9-68

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

 Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

 Safety Practices

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any
the procedures in this manual will help assure safety and service or maintenance. Remove key and disconnect
equipment reliability. battery leads.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.5 SAFETY INFORMATION
procedures, rules, codes, regulations and laws.
To avoid possible death or injury, carefully read,
These instructions cannot cover all details or variations in understand and comply with all safety messages.
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency In the event of an accident, know where to obtain medical
during operation, maintenance, or testing. When additional assistance and how to use a first-aid kit and fire
information is desired consult the local JLG distributor. extinguisher/fire suppression system. Keep emergency
telephone numbers (fire department, ambulance, rescue
Many factors contribute to unsafe conditions: carelessness, squad/paramedics, police department, etc.) nearby. If
fatigue, overload, inattentiveness, unfamiliarity, even working alone, check with another person routinely to
drugs and alcohol, among others. For optimal safety, help assure personal safety.
encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair 1.5.1 Safety Alert System and Signal Words
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
DANGER
operator’s seat looking in a forward direction.
Supplementary information is available from JLG in the DANGER indicates an imminently hazardous situation
form of Service Bulletins, Service Campaigns, Service which, if not avoided, will result in death or serious injury.
Training Schools, the JLG website, other literature and
through updates to the manual itself.
WARNING
1.2 DISCLAIMER
All information in this manual is based on the latest WARNING indicates a potentially hazardous situation
product information available at the time of publication. which, if not avoided, could result in death or serious
JLG reserves the right to make changes and injury.
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation. CAUTION
1.3 OPERATION & SAFETY MANUAL
CAUTION indicates a potentially hazardous situation
The mechanic must not operate the machine until the which, if not avoided, may result in minor or moderate
Operation & Safety Manual has been read and injury.
understood, training has been accomplished and
operation of the machine has been completed under the
supervision of an experienced and qualified operator.
An Operation & Safety Manual is supplied with each
machine and must be kept in the manual holder located
in the cab. In the event that the Operation & Safety
Manual is missing, consult the local JLG distributor before
proceeding.

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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 it is of the proper capacity, in good working order, and
is properly attached.
NEVER stand or otherwise become positioned under a
suspended load or under raised equipment. The load or
equipment could fall or tip.
DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.
G6-42A, G9-43A, G10-43A
Safety Practices
1.6.3 General Hazards
SOLVENTS: Only use approved solvents that are known
to be safe for use.
HOUSEKEEPING: Keep the work area and operator’s
cab clean, and remove all hazards (debris, oil, tools, etc.).
FIRST AID: Immediately clean, dress and report all injuries
(cuts, abrasions, burns, etc.), no matter how minor the
injury may seem. Know the location of a First Aid Kit, and
know how to use it.
CLEANLINESS: Wear eye protection and clean all
components with a high-pressure or steam cleaner
before attempting service.
When removing hydraulic components, plug hose ends
and connections to prevent excess leakage and
contamination. Place a suitable catch basin beneath the
machine to capture fluid run-off.
It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing
the machine is needed, ensure the machine is shut down
before pressure-washing. Should pressure-washing be
utilized to wash areas containing electrical/electronic
components, it is recommended a maximum pressure of
750 psi (52 bar) at a minimum distance of 12 in (30,5 cm)
away from these components. If electrical/electronic
components are sprayed, spraying must not be direct and
for brief time periods to avoid heavy saturation,
Check and obey all Federal, State and/or Local
regulations regarding waste storage, disposal and
recycling.
1-3
 Safety Practices

1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
ENGINE: Stop the engine before performing any service
condition. Use the correct equipment in the proper
unless specifically instructed otherwise.
manner, and make changes or repairs as indicated by the
VENTILATION: Avoid prolonged engine operation in test procedure to achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to
SOFT SURFACES AND SLOPES: NEVER work on a the ground before leaving the machine.
machine that is parked on a soft surface or slope. The
TIRES: Always keep tires inflated to the proper pressure
machine must be on a hard level surface, with the wheels
to help prevent tipover. DO NOT over-inflate tires.
blocked before performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID TEMPERATURE: NEVER work on a machine
Always use matched sets according to machine
when the engine, cooling or hydraulic systems are hot.
specifications.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding. MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
FLUID PRESSURE: Before loosening any hydraulic or
batteries or other items that may reduce or affect the
diesel fuel component, hose or tube, turn the engine
overall weight or stability of the machine.
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use BATTERY: DO NOT charge a frozen battery.Charging a
a piece of cardboard or wood instead. If injured, seek frozen battery may cause it to explode. Allow the battery
medical attention immediately. Diesel fluid leaking under to thaw before jump-starting or connecting a battery
pressure can explode. Hydraulic fluid and diesel fuel charger.
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. 1.7 SAFETY DECALS
Relieve all pressure before disconnecting any
Check that all safety decals are present and readable on
component, part, line or hose. Slowly loosen parts and
the machine. Refer to the Operation & Safety Manual
allow release of residual pressure before removing any
supplied with machine for information.
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
appropriate container and dispose of in accordance with
prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic fluid are flammable and can cause a
fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.

1-4 G6-42A, G9-43A, G10-43A

 Section 2
General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.3 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5 Service and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.5.3 1000, 1500 & 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.6.1 G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.6.2 G9-43A / G10-43A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

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

 General Information and Specifications

2.1 REPLACEMENT PARTS AND

WARRANTY INFORMATION

DO NOT GO NEAR LEAKS

* High pressure oil easily punctures skin causing serious injury, gangrene or death.
* If injured, seek emergency medical help. Immediate surgery is required to remove oil.
* Do not use finger or skin to check for leaks.
C * Lower load or relieve hydraulic pressure before loosening fittings.
10814B

MY0070
1 1

Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located as indicated in the figure.
Note: The replacement of any part on this machine with
any other than JLG authorized replacement parts can
adversely affect the performance, durability, or safety of
the machine, and will void the warranty. JLG disclaims
liability for any claims or damages, whether regarding
property damage, personal injury or death arising out of
the use of unauthorized replacement parts.
A warranty registration form must be filled out by the JLG
distributor, signed by the purchaser and returned to JLG
when the machine is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the distributor
has returned the business reply card of the warranty
registration form to JLG.

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

 General Information and Specifications

2.2 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners

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

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N Description

0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red) MY4650J

G6-42A, G9-43A, G10-43A 2-3

 General Information and Specifications

2.2.1 SAE Fastener Torque Chart

(Continued)

Values for Zinc Yellow Chromate Fasteners

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque Loctite® 242™ or 271™ Loctite® 262™
Tensile
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263) OR OR
Stress Area
K= 0.20 Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER MY4660J

2-4 G6-42A, G9-43A, G10-43A

 General Information and Specifications

2.2.1 SAE Fastener Torque Chart

(Continued)

SOCKET HEAD CAP SCREWS

Magni Coating*
Torque Torque
Loctite® 242™ or 271™ Loctite® 262™
Tensile Clamp Load Torque OR
Size TPI Bolt Dia OR
Stress Area See Note 4 (Dry) K = .17 Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
OR 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 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4670J

G6-42A, G9-43A, G10-43A 2-5

 General Information and Specifications

2.2.1 SAE Fastener Torque Chart

(Continued)

SOCKET HEAD CAP SCREWS

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

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4680J

2-6 G6-42A, G9-43A, G10-43A

 General Information and Specifications

2.2.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners

CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS

Torque
Torque Torque Loctite®
Tensile
Clamp Torque Loctite® 262™ 242™ or 271™
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR OR
Area 263TM) Vibra-TITE™ 131 Vibra-TITE™
111 or 140

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4690J

G6-42A, G9-43A, G10-43A 2-7

 General Information and Specifications

2.2.2 Metric Fastener Torque Chart

(Continued)

Values for Zinc Yellow Chromate Fasteners

CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™
Clamp or Loctite® 262™
Size PITCH Stress OR OR
Load Loctite® 263™
Area Vibra-TITE™ Vibra-TITE™ 131
111 or 140
K = 0.20 K= 0.18 K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4700J

2-8 G6-42A, G9-43A, G10-43A

 General Information and Specifications

2.2.2 Metric Fastener Torque Chart

(Continued)

Magni Coating*

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™ Loctite® 262™
Clamp Load or
Size PITCH Stress OR OR
See Note 4 Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131
Area
111 or 140
K = .17 K = .16 K = .15

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

3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4710J

G6-42A, G9-43A, G10-43A 2-9

 General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand
O-Ring Face Seal & JIC Torque Chart tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
Size ORFS JIC Flats Method
is 3 lb-ft (4 Nm).
13 lb-ft 13 lb-ft 2. Mark a dot on one of the swivel nut flats and another
4 1.5 to 1.75
(18 Nm) (18 Nm) dot in line on the hex of the adapter it’s connecting
23 lb-ft 23 lb-ft to.
6 1 to 1.5
(31 Nm) (31 Nm) 3. Use the double wrench method while tightening to
40 lb-ft 40 lb-ft avoid hose twist.
8 1.5 to 1.75
(54 Nm) (54 Nm) 4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
60 lb-ft 60 lb-ft
10 1.5 to 1.75 covering the dots indicating that the connection has
(81 Nm) (81 Nm)
been properly tightened.
136 lb-ft 136 lb-ft
12 1.0 to 1.5
(100 Nm) (100 Nm)
115 lb-ft 115 lb-ft
16 0.75 to 1.0
(156 Nm) (156 Nm)
170 lb-ft 170 lb-ft
20 0.75 to 1.0
(230 Nm) (230 Nm)
200 lb-ft 200 lb-ft
24 0.75 to 1.0
(271 Nm) (271 Nm)
270 lb-ft
32 N/A 0.75 to 1.0
(366 Nm)

Note: By definition the “Flats Method“ will contain some

variance. Use the “Flats Method” only when accessibility
with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
3. Use the double wrench method while tightening to
avoid hose twist.
4. Torque wrench must be held at the center of the grip.
Apply constant force until it clicks.
5. After the connection has been properly tightened,
mark a straight line across the connecting parts
indicating that the connection has been properly
tightened.

2-10 G6-42A, G9-43A, G10-43A

 General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

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

First Gear 3.7 mph (5,6 km/h) 3.2 mph (5,1 km/h)
Second Gear 8.0 mph (12,9 km/h) 7.0 mph (11,2 km/h)
Third Gear 16.1 mph (25,9 km/h) 14.0 mph (22,5 km/h)
Fourth Gear 20.5 mph (32,9 km/h) 19.5 mph (31,4 km/h)

2.3.2 Hydraulic Cylinder Performance

Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine
at operating temperature.

Approximate Times (seconds)

Function
G6-42A G9-43A & G10-43A
Boom Extend (Boom Level) 13.8 13.4
Boom Retract 13.4 10.2
Boom Lift 12.6 10.7
Boom Lower 9.4 8.6
Attachment Tilt Forward 3.8 3.5
Attachment Tilt Rearward 3.4 3.1
Frame Level - Full Right to Left 7.7 9.3
Frame Level - Full Left to Right 3.5 10.7
Outriggers Down (Boom Level- No Load) N/A 5.8 (G10-43A Only)
Outriggers Up (Boom Level- No Load) N/A 4.4 (G10-43A Only)

G6-42A, G9-43A, G10-43A 2-11

 General Information and Specifications

2.3.3 Engine Performance Specifications

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

a. John Deere
G6-42A (Before S/N 0160007869) G9-43A (Before S/N 0160007868)

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

Engine Make/Model John Deere PE 4045D150 John Deere PE 4045TF150
Displacement 276 in³ (4,5 liters) 276 in³ (4,5 liters)
Low Idle (with A/C) 825 to 875 rpm (950 to 1000 rpm) 825 to 875 rpm (950 to 1000 rpm)
High Idle 2,675 to 2,750 rpm 2,675 to 2,750 rpm
Horsepower 80 HP (60 kW) @ 2500 rpm 100 HP (75 kW) @ 2500 rpm
Peak Torque 215 lb-ft (292 Nm) @ 1200 rpm 274 lb-ft (372 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection Fuel Injection
Average Fuel Consumption
2.6 gal/hr (9,8 l/hr) 3.0 gal/hr (11,4 l/hr)
(depending on load/duty)
Dry Type, Replaceable Primary and Dry Type, Replaceable Primary and
Air Cleaner
Safety Elements Safety Elements

b. John Deere or Perkins Engine

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

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

Engine Make/Model John Deere PE 4045TF270
Displacement 275 in³ (4,5 liters)
Low Idle (with A/C) 800 to 900rpm
High Idle 2600 rpm
Horsepower 99 HP (74 kW) @ 2500 rpm
Peak Torque 272 lb-ft (369 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection
Average Fuel Consumption
3.2 gal/hr (12,1 l/hr)
(depending on load/duty)
Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2-12 G6-42A, G9-43A, G10-43A

 General Information and Specifications

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

Engine Make/Model Perkins 1104-C 44T
Displacement 268 in³ (4,4 liters)
Low Idle 800 to 850 rpm
High Idle 2475 to 2525 rpm
Horsepower 99 HP (74 kW) @ 2500 rpm
Peak Torque 372 lb-ft (504 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection
Average Fuel Consumption
Not Available
(depending on load/duty)
Air Cleaner Dry Type, Replaceable Primary and Safety Elements

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

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

Engine Make/Model Cummins QSB3.3
Displacement 201 in³ (3,3 liters)
Low Idle 1000 rpm
High Idle 2600 rpm
Horsepower 99 HP (74 kW) @ 2600 rpm
Peak Torque 306 lb-ft (415 Nm) @ 1600 rpm
Fuel Delivery Fuel Injection
Average Fuel Consumption
Not Available
(depending on load/duty)
Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.4 Electrical System

Battery:
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Reserve Capacity 1000 Cold Cranking Amps @ 0° F (-18° C)
Group/Series Group 31
Alternator (with Optional A/C) 12V, 65 Amps (12V, 105 Amps)

G6-42A, G9-43A, G10-43A 2-13

 General Information and Specifications

2.3.5 Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm)
Note: Pressures for foam filled tires are for initial fill ONLY.

a. G6-42A & G9-43A

Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
Pneumatic 65 psi (4,5 bar)
13.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply
Foam - Approx. 542 lb (246 kg) 60 psi (4,1 bar)
Pneumatic 65 psi (4,5 bar)
13.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply
Foam - Approx. 542 lb (246 kg) 65 psi (4,5 bar)
Pneumatic 70 psi (4,8 bar)
13.00 x 24 G-2/L-2 Radial 1 Star
Foam - Approx. 542 lb (246 kg) 70 psi (4,8 bar)
Pneumatic 58 psi (4,0 bar)
15.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply
Foam - Approx. 600 lb (272 kg) 58 psi (4,0 bar)
Pneumatic 65 psi (4,5 bar)
15.50 x 25 G-3/L-3 Bias Ply Rock 12 Ply
Foam - Approx. 600 lb (272 kg) 65 psi (4,5 bar)
Pneumatic 70 psi (4,8 bar)
15.50 x 25 G-2/L-2 Radial 1 Star
Foam - Approx. 600 lb (272 kg) 70 psi (4,8 bar)
Pneumatic 76 psi (5,2 bar)
370/75x28 DuraForce 14 Ply
Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)

a. G10-43A

Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
Pneumatic 70 psi (4,8 bar)
14.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply
Foam - Approx. 720 lb (327 kg) 62 psi (4,3 bar)
Pneumatic 70 psi (4,8 bar)
14.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply
Foam - Approx. 720 lb (327 kg) 62 psi (4,3 bar)
Pneumatic 76 psi (5,2 bar)
400/75-28 DuraForce 16 Ply
Foam-Approx 570 lb (2259 kg) 73 psi (5,0 bar)

2-14 G6-42A, G9-43A, G10-43A

 General Information and Specifications

2.4 FLUID AND LUBRICANT CAPACITIES

Engine Crankcase Oil

Capacity with Filter Change
G6-42A - Before S/N 0160040678
G9-43A & G10-43A - Before S/N 0160040675
excluding 0160040468 & 0160040672
John Deere
Before S/N 0160007869 14.5 quarts (13,7 liters)
S/N 0160007869 thru 0160040674 15.5 quarts (14,7 liters)
Perkins 7 quarts (6,5 liters)
G6-42A - S/N 0160040678 & After
G9-43A & G10-43A - S/N 0160040675 & After including
0160040468 & 0160040672
Cummins 7.6 quarts (7,2 liters)
Oil Type
0° to 104° F (-20° to 40° C) 15W-40 CH
-40° to 0° F (-40° to -20° C) 0W-40 CH
Fuel Tank
Capacity 38 gallons (144 liters)
Type of Fuel
0° to 104° F (-20° to 40° C) Low Sulfur Diesel #2
-40° to 0° F (-40° to -20° C) Low Sulfur Diesel #1
Anti-gel Fluid
-40° to 0° F (-40° to -20° C) 16 ounce (0,5 liters)
Cooling System
System Capacity
G6-42A - Before S/N 0160040678 15.2 quarts (14,4 liters)
G6-42A - S/N 0160040678 & After 18 quarts (17 liters)
G9-43A & G10-43A - Before S/N 0160040675
22 quarts (20,8 liters)
excluding 0160040468 & 0160040672
G9-43A & G10-43A - S/N 0160040675 & After
18 quarts (17 liters)
including 0160040468 & 0160040672
Overflow Bottle Capacity
G6-42A - S/N 0160040678 & After
G9-43A & G10-43A - S/N 0160040675 & After 2.5 quart (2,4 liters)
including 0160040468 & 0160040672

G6-42A, G9-43A, G10-43A 2-15

 General Information and Specifications

Type of Fluid
0° to 104° F (-20° to 40° C) 50/50 ethylene glycol & water
-40° to 0° F (-40° to -20° C) 60/40 ethylene glycol & water
Coolant Conditioner (refer engine manual) 0.5 quarts (0,47 liters)
Transmission
Capacity with Filter Change
G6-42A 4.2 gallons (15,8 liters)
G9-43A & G10-43A - Before S/N 0160040675
3.4 gallons (12,9 liters)
excluding 0160040468 & 0160040672
G9-43A & G10-43A - S/N 0160040675 & After
4.2 gallons (15,8 liters)
including 0160040468 & 0160040672
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
-40° to 0° F (-40° to -20° C) Mobilfluid® LT (75W-80) Hydraulic Fluid
Transfer Case
Capacity
G6-42A - Before S/N 0160040678 0.8 quarts (0,8 liters)
G6-42A - S/N 0160040678 & After
1.5 quarts (1,4 liters)
G9-43A & G10-43A
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
-40° to 0° F (-40° to -20° C) Mobilfluid® LT (75W-80) Hydraulic Fluid
Axles
G6-42A - Differential Housing Capacity
Front 9.0 quarts (8,5 liters)
Rear 8.5 quarts (8,0 liters)
Friction Modifier (Front differential only) 14.4 ounce (425,8 milliliter)
Wheel End Capacity 1.7 quarts (1,6 liters)
G9-43A/G10-43A - Differential Housing Capacity
Front 8.7 quarts (8,2 liters)
Rear 13.0 quarts (12,3 liters)
Friction Modifier (Front differential only) 13.9 ounce (411,0 milliliter)
Wheel End Capacity 1.75 quarts (1,65 liters)
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
-40° to 0° F (-40° to -20° C) Mobilfluid® LT (75W-80) Hydraulic Fluid

2-16 G6-42A, G9-43A, G10-43A

 General Information and Specifications

Hydraulic System
System Capacity
G6-42A 43 gallons (163 liters)
G9-43A & G10-43A 40 gallons (151 liters)
Reservoir Capacity
G6-42A 20 gallons (75,7 liters)
G9-43A & G10-43A 23.3 gallons (88,2 liters)
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
-40° to 0° F (-40° to -20° C) Exxon Univis HVI All Season Hydraulic Fluid
Air Conditioning System (if equipped)
System Capacity 2.5 lb (1134 g)

G6-42A, G9-43A, G10-43A 2-17

 General Information and Specifications

2.5 SERVICE AND MAINTENANCE

SCHEDULE

2.5.1 10, 1st 50 & 50 Hour

EVERY
10

Check Fuel Air Filter Check Engine Check Hydraulic Check Tire
Level Restriction Oil Level Oil Level Condition &
Indicator Pressure

Check Check Hydraulic Return

Transmission Filter Indicator (Before
Oil Level S/N 0160040675)

1st
50
LB/F
T (N
m)

Check Wheel
Lug Nut
Torque

EVERY
50

Drain Fuel/ Check Engine Check Check Washer Lubrication

Water Coolant Level Battery Fluid Level Schedule
Separator (if equipped)
MY6040

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

 General Information and Specifications

2.5.2 1st 250, 250 & 500 Hour

1st
250

Change Change Wheel Change Change

Axle Oil End Oil Transmission Transfer Case
Oil & Filter Oil

EVERY
250

Change Engine Check Axle Check Wheel Air Filter Check

Oil and Filter* Oil Level End Oil Levels Vacuator Fan Belt
Valve

Check Boom Check Transfer Check Lubrication

Wear Pads Case Oil Level Rear Axle Schedule
Stabilization

EVERY
500
LB/F
T (N
m)

Change Fuel Change Fuel Check Wheel

Filters Strainer (Before Lug Nut
S/N 0160040675) Torque
MY6050

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

G6-42A, G9-43A, G10-43A 2-19

 General Information and Specifications

2.5.3 1000, 1500 & 2000 Hour

EVERY
1000

Change Change Change Change Wheel Check

Transmission Transfer Case Axle Oil End Oil Air Intake
Oil & Filter Oil System

Check Boom Lubrication

Chains Schedule

EVERY
1500

Change Change Change Engine

Hydraulic Hydraulic Tank Coolant (Before
Fluid & Filters Breather S/N 0160040675)

EVERY
2000

Engine Valve Change Engine

Lash Coolant (S/N
Adjustment 0160040675 & After)
MY6060

2-20 G6-42A, G9-43A, G10-43A

 General Information and Specifications

2.6 LUBRICATION SCHEDULE

2.6.1 G6-42A

a. 50 Hour

EVERY
50

2
2 B
B

B
B 2
2
2 B 2
B

B B
2 B 2
2

OY2270

G6-42A, G9-43A, G10-43A 2-21

 General Information and Specifications

b. 250 Hour

EVERY
250

2
2 B
B

B
B 2
2

B
2 B B B
2 2 2

2 2
A A

A A
2 2

OY2280

2-22 G6-42A, G9-43A, G10-43A

 General Information and Specifications

c. 1000 Hour

EVERY
1000

B
B

OY2290

G6-42A, G9-43A, G10-43A 2-23

 General Information and Specifications

2.6.2 G9-43A / G10-43A

a. 50 Hour

EVERY
50

G10-43A

2
2 B
B

B
B 2
2

2
B

B B 2
2 B 2
2

2
2 2 2
2
4
2

2
G10-43A
OY2550

2-24 G6-42A, G9-43A, G10-43A

 General Information and Specifications

b. 250 Hour

EVERY
250

2
2 B
B

B B
2 2

B
2 B B B
2 2
2

2
A 2
A

A A A A A A
A A
2 2

G10-43A

OY2560

G6-42A, G9-43A, G10-43A 2-25

 General Information and Specifications

c. 1000 Hour

EVERY
1000

B
B

G10-43A

OY2570

2-26 G6-42A, G9-43A, G10-43A

 Section 3
Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Complete Boom Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.1 Second and Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.3 Push Beam - Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . 3-8
3.5.4 Push Beam - Extend/Retract Cylinder Installation and Third Boom Section
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.5 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.6.1 Extend/Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.6.2 Extend/Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7 Push Beam - Extend/Retract Cylinder Removal/Installation. . . . . . . . . . . . . . . . 3-16
3.7.1 Push Beam - Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . 3-16
3.7.2 Push Beam - Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . 3-18
3.8 Boom Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8.1 Chain Tension Inspection—G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8.2 Chain Tension Adjustment—G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8.3 Chain Tension Inspection— G9-43A/G10-43A . . . . . . . . . . . . . . . . . . . . . 3-22
3.8.4 Chain Tension Adjustment— G9-43A/G10-43A . . . . . . . . . . . . . . . . . . . . 3-23
3.9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.9.1 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.9.2 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.9.3 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.9.4 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.10.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.10.2 Boom Head-Mounted Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.11 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.11.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.11.2 Wear Pad Installation and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

G6-42A, G9-43A, G10-43A 3-1

 Boom

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

3.12.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.12.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.12.3 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.13 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.14 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.14.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.14.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.16 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-2 G6-42A, G9-43A, G10-43A

 Boom

3.1 BOOM SYSTEM COMPONENT

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

THIRD
BOOM
SECTION

EXTEND CHAIN
SECOND BOOM (INSIDE BOOM)
SECTION

FIRST BOOM
SECTION

TILT EXTEND/RETRACT
CYLINDER CYLINDER
(INSIDE BOOM)
QUICK
SWITCH RETRACT CHAIN
(INSIDE BOOM)

HOSE SHEAVE
(INSIDE BOOM)

MY0110

G6-42A, G9-43A, G10-43A 3-3

 Boom
3.2 BOOM SYSTEM - THREE SECTION
3.2.1 Boom System Operation
The three section boom consists of the first, second and
third assemblies with a single extend chain, and a single
retract chain.
As the extend/retract cylinder, which is anchored at the
rear of the first boom section, and the front of the push
beam begins to extend, it forces the second and third
boom sections out of the first boom section.
The boom sections are connected by extend and retract
chains. These chains are routed around sheaves on the
front of the push beam and the rear of the second boom
section. As the extend/retract cylinder is forced out
hydraulically, the second boom section is pulled out by
the push beam, and third boom section is pulled out by
the extend chain.
As hydraulic pressure is applied to the retract port on the
extend/retract cylinder, the retract chain pulls the third
boom section and the push beam pulls the second boom
section back into the first boom section.
The mechanical linkage formed by the chains and
supporting hardware, extend and retracts the second and
third boom sections at the same rate.
The boom section lifts and lowers via action of the lift/
lower cylinder.
3-4
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 the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.The boom assembly consists of the first,
second and third section booms and supporting
hardware.
Note: Before removing the boom or boom section, the
carriage or any other attachment must be removed from
the quick coupler.
Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.
During service of the boom, perform the following:
1. Check wear pads. (Refer to Section 3.11, “Boom
Wear Pads.”)
2. Check hose sheaves and chain rollers.
3. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.6, “Lubrication Schedules.”)
4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.
Note: Depending on your particular circumstance, the
following procedures explain the removal/installation of
individual boom sections or removal/installation of the
complete boom.
WARNING
NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
G6-42A, G9-43A, G10-43A

3.4 COMPLETE BOOM REMOVAL/
INSTALLATION
3.4.1 Complete Boom Removal
1. Remove any attachment from the quick coupler
assembly. Refer to Section 3.15, “Troubleshooting.”
2. Remove the quick coupler assembly. Refer to
Section 3.9.1, “Quick Switch Removal.”
3. If equipped, remove the boom head mounted winch.
Refer to Section 3.9.4, 3.10. “Boom Head - Mounted
Winch.”
4. Park the machine on a hard, level surface, level the
machine, fully retract the boom, level the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
5. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
6. Open the engine cover. Allow the system fluids to
cool.
7. Properly disconnect the battery.
8. Using a suitable sling or hoist, support the boom.
9. Label, disconnect and cap the hydraulic hoses at the
rear of the boom. Cap all fittings to keep dirt & debris
from entering the hydraulic system.
10. Label and disconnect any electrical cables
(if equipped) at the rear of the boom.
11. Remove the pin from the rod end of the
compensation cylinder being careful not to drop the
cylinder. Lower the cylinder onto the frame rails.
12. Remove the pin from the rod end of the lift/lower
cylinder. Lower the cylinder onto the frame rails.
MY1520 1 required.
13. Confirm that the boom assembly is balanced with
the sling and remove the boom assembly
pivot pin (1).
G6-42A, G9-43A, G10-43A
Boom
14. Lift the boom assembly from the machine and lower
onto suitable supports.
3.4.2 Complete Boom Installation
1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
the park brake, chock the wheels and shut the
engine OFF.
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
frame pivot bore with the boom assembly pivot bore.
Install the boom pivot pin (1).
3. With the sling still in place, install the compensation
cylinder, pins and bolts. Apply Loctite® 242TM and
torque lock bolt to 100-110 lb-ft (135-149 Nm).
4. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt. Apply Loctite®
242TM and torque lock bolt to 200-215 lb-ft
(271-291 Nm).
Note: Raising the boom up or down with the sling my be
necessary so the boom, compensation and lift/lower
cylinder bores can be aligned for easier pin installation.
Note: Grease the boom pivot bore, compensation
cylinder rod end, lift/lower cylinder rod end and pins
before installing.
5. Uncap and reconnect the previously labeled
hydraulic hoses to the extend/retract cylinder.
6. Uncap and connect and remaining hydraulic fittings
to their appropriate locations.
7. Recheck wear pad gaps to ensure they meet the
minimum gap requirement. Shim if necessary.
8. Ensure that the boom chains are properly adjusted.
Refer to Section 3.8, “Boom Adjustments.”
9. If equipped, install the boom head mounted winch.
Refer to Section 3.9.4, 3.10. “Boom Head - Mounted
Winch.”
10. Properly connect the battery.
11. Install the quick coupler assembly. Refer to Section
3.9.2, “Quick Switch Installation.”
12. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic fluid level in the reservoir; add fluid if
13. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
14. Close and secure the engine cover.
3-5
 Boom
15. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
16. Install the previously removed attachment to the
quick coupler assembly. Refer to Section 3.15,
“Troubleshooting.”
3.5 BOOM SECTION REMOVAL/
INSTALLATION
3.5.1 Second and Third Boom Section
Removal
Note: Refer to Section 3.14.2, 3.16. “Push Beam
Temporary Brackets,” for diagrams of the Temporary
Extend Bracket and Temporary Retract Bracket
designed to hold the chains in place on the push beam
during disassembly and reassembly.
These brackets are NOT a purchasable part and must be
manufactured locally.
They are solely designed to aid in the removal and
installation of the push beam assembly.
Note: Refer to Section 8.8, “Hydraulic Cylinders.” for
general tilt cylinder removal.
1. Remove the access cover from the rear of the first
boom section.
7 7 G6-42A
1
5 8
4 MY3860
3 G9-43A
G10-43A
2 2
6 6
MAL2660
2. Remove the locknut, adjustment nut and six
belleville washers (1) from the extend chain clevis
rod at the rear of the boom.
3. Loosen and remove both extend/retract cylinder
tubes (2) from the rear of the boom. Cap and/or plug
3-6
all open hoses, tubes and/or fittings to prevent dirt
and debris from entering the hydraulic system.
4. Slowly loosen and remove the extend/retract
cylinder counterbalance valve (3). Plug (M27x1.5)
the open port on the extend/retract cylinder to
prevent dirt and debris from entering the hydraulic
system.
5. Remove the retaining clips from the extend/retract
cylinder mounting pin (4), remove the extend/retract
cylinder pin.
6. Remove the four mounting bolts securing the strong
back (5) to the first boom section.
7. Remove the strong back (5) from the rear of the
boom.
8. Remove the right or left side wear pads, shims and
backing plates (6) from the rear of the second boom
section. Label and tag each set of wear pads being
removed.
9. Remove the top wear pads, shims and backing
plates (7) from the rear of the second boom section.
Label and tag each set of wear pads being removed.
8 11
9
10
10. Loosen and remove the four bolts (8) securing the
retract chain anchor plate (9).
11. Between the bottom front of the first and second
boom sections, feed a rope or wire to the retract
chain anchor plate and secure to the second or third
boom section.
12. Disconnect both tilt tubes (10) and (if equipped) both
auxiliary tubes from the fittings on the hose retainer
brackets (11) at the bottom front inside the boom.
Plug the tube ends to prevent dirt and debris from
entering the hydraulic system.
13. Disconnect both tilt hoses (not shown) and (if
equipped) both auxiliary hoses from the hose
retainer brackets at the bottom front inside the boom.
Plug the hose ends to prevent dirt and debris from
entering the hydraulic system.
14. Loosen and remove the hose retainer brackets (11)
and (if equipped) both auxiliary take-up brackets.
G6-42A, G9-43A, G10-43A

15. Between the bottom front of the first and second
boom sections, feed a rope or wire to both tilt hoses
(not shown) and (if equipped) both auxiliary hoses
and secure to the second or third boom section.
16. Place a suitable sling around the second boom
section. Slowly pull the second and third boom
sections approximately 25% out of the first boom
section. Lower the second and third boom sections
onto a suitable support.
12
13 12
13
12 12
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 the sling or using two slings for better
stability, balance the two boom sections and slowly
pull them out of the first boom section being careful
not to damage the hydraulic hoses or chains. Lower
the second and third boom sections onto suitable
supports.
3.5.2 Third Boom Section Removal
1 1
2 5. Loosen and remove the tilt hoses and (if equipped)
MY3880
G6-42A, G9-43A, G10-43A
Boom
1. Loosen and remove the tilt cylinder hose guide (1)
and if equipped, the auxiliary hose guide from the
rear of the third second section.
Note: The hose guide mounting bolts also hold the push
pin beams in place.
2. Loosen and remove all retract chain sheave
components (2) and the hydraulic hose rollers and
components.
Note: Offset the extend chain rod to the left or right of
the push beam assembly allowing the push beam to be
raised enough to allow the removal of the chain and
hose sheaves.
4 3
5
6 MY4070
3. Attach the Temporary Extend Chain Retention
Bracket (3) between the extend chain rod (4) and the
push beam tube (5). Snug in place. Do Not tighten.
Note: Refer to Section 3.16, “Push Beam Temporary
Brackets,” for Temporary Extend Chain Bracket diagram.
4. At the rear of the boom, remove the retract chain (6)
from the chain clevis.
8 7
MY4110
auxiliary hoses from the hose retainers (7 & 8) at the
front of the third boom section.
3-7
 Boom

6. Loosen and remove the tilt hose and auxiliary hose 12. Relocate the sling or using two slings for better
retainers (7 & 8) from the front of the third boom stability, balance the third boom section and slowly
section. pull the third boon section out of the second boom
10 10 section. Lower the third boom section onto suitable
supports.

3.5.3 Push Beam - Extend/Retract Cylinder

Removal

CAUTION
The complete push beam assembly weighs over
1,200 lb (545 kg).
9 9

MY3890

7. Remove the right or left side wear pads, shims and

backing plates (9) from the rear of the third boom
section. Label and tag each set of wear pads being
removed.
8. Remove the top wear pads, shims and backing
plates (10) from the rear of the third boom section.
13 MY4060
Label and tag each set of wear pads being removed.
9. Place a suitable sling around the third boom section. 14 17 16 15
Slowly pull the third boom section approximately
1. Loosen the Temporary Extend Chain Retention
25% out of the second boom section. Lower the third
Bracket (13) and push the push beam (14) forward
boom section onto a suitable support.
3-4 in (76,2-101,6 mm).

12
2. Attach the Temporary Extend Chain Retention
Bracket (15) between the chain clevis (16) and the
end of the push beam (14).
11 11
Note: Refer to Section 3.16, “Push Beam Temporary
Brackets,” for Temporary Extend Chain Bracket diagram.
3. Lift the push beam (14) to unload the clevis pin (17)
and remove the pin securing the clevis to the third
12
boom section.
11 11 4. Tighten the Temporary Extend Chain Retention
Bracket (13) to remove any slack in the extend chain.
MY3870 5. Secure a rope or wire to the front of the push beam
and pull the push beam (14) towards the front of the
10. Remove all wear pads, shims and backing plates boom.
(11) from the front inside of the second boom
6. Support the push beam assembly with pry bars
section. Label and tag each set of wear pads being
using the access holes on each side of the third
removed.
boom section.
11. Remove wear pad mounting plates (12) from the
front inside of the second boom section.

3-8 G6-42A, G9-43A, G10-43A


14
19
18
20 MY3930
7. Remove the guide bar (18) and chain retainer (19).
Remove the push beam wear pad (20).
8. Lower the push beam assembly and remove the pry
bars.
9. Push/pull the push beam assembly along with the
extend chain, to the front of the third boom section.
NOTICE
Guide the push beam/extend/retract cylinder
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
10. Place a sling around the push beam assembly. Lift
and slowly pull the push beam assembly
approximately half way out of the third boom section.
Lower the push beam onto a suitable support.
11. Relocate the sling or using two slings for better
stability, balance the push beam assembly and
slowly pull the push beam assembly out of the third
boom section. Lower the push beam assembly onto
suitable supports.
12. Remove all remaining brackets, clevises, hoses,
wear pads, shims, backing plates and hardware from
the second and third boom sections. Label all parts
and hardware being removed from each section.
Note: Inspect all chains, hoses and sheaves for wear
and/or damage and replace as needed.Safety
Information
G6-42A, G9-43A, G10-43A
Boom
3.5.4 Push Beam - Extend/Retract Cylinder
Installation and Third Boom Section
Assembly
Note: Inspect the wear pad surfaces of the second and
third boom sections. Verify all areas are clean and free of
any weld spatter, paint, etc., before beginning the re-
assembly procedure.
Note: Inspect and lubricate all extend and retract chains
before re-assembly. Refer to Section 3.12, “Boom
Extend and Retract Chains,” for detailed information.
1. Place the third boom section onto suitable supports.
2. Clean and lubricate the bottom and sides of the third
boom section where the push beam guide bar
travels.
3. Place a sling or using two slings for better stability,
lift and slowly push the push beam assembly
approximately half way into the third boom section.
Lower the push beam onto a suitable support.
4. Relocate the sling and slowly insert the push beam
assembly into the front of the third boom section.
NOTICE
Guide the push beam/extend/retract cylinder
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
6
5
7
8
4
MY3930
5. Install the push beam wear pad (4) to the previously
removed chain retainer (5) using two bolts and two
washers. Torque as required.
6. Lift the push beam assembly (6) with pry bars using
the access holes on each side of the third boom
section and install the guide bar (7) and chain
retainer (5) using the previously removed hardware
(8). Torque to 25-30 lb-ft (34-41 Nm).
3-9
 Boom

13. Install the hose retainer assembly (13) using existing

hardware. Torque as required.
14. Remove caps from the hose retainer fittings and
plugs from the tilt cylinder hoses and (if equipped)
the auxiliary hoses.
15. Connect the tilt cylinder hoses and (if equipped) the
auxiliary hoses to their proper locations. Torque as
required.
9 MY4060

10 11
7. Loosen the Temporary Extend Chain Bracket (9).
8. Apply CAT Thread Lubricant to the clevis mounting
pin (10).
9. Lift the push beam and install the pin and retaining
clips (10) securing the clevis to the third boom
section.
10. Remove the Temporary Retract Chain Bracket (11). 15 15

14 14
MY3890

12 16. Install the previously removed wear pads, shims and

MY3940
11. Install the tilt cylinder hoses and (if equipped) the
auxiliary hoses through the front of the third boom
section.
Note: Verify the tilt cylinder hoses and (if equipped) the
auxiliary hoses are routed UNDER the hose guide (12)
at the rear of the third boom section at the retract chain
clevis bracket.
12. Snug the Temporary Extend Chain Bracket (9).
13
MY3900
spacers (14) at the bottom rear of the third boom
section. Snug mounting bolts. Shim as needed
AFTER boom section is installed. Refer to Section
3.11.2, “Wear Pad Installation and Lubrication,” for
detailed information.
17. Install the previously removed wear pad and spacer
(15) on the left or right side of the third boom section.
Snug mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.11.2, “Wear
Pad Installation and Lubrication,” for detailed
information.
3.5.5 Third Boom Section Installation
Note: Using a straight bar approximately 20 in
(508 mm) long will aid in the installation of the wear pads
located on the inside front of each boom section.
1. Place the second boom section onto suitable
supports.
2. Lubricate the bottom of the third boom section where
the wear pads of the second boom section contact
the third boom section.
3. Place the sling, or two slings for better stability,
around the third boom section and insert the tilt
cylinder hoses and if equipped, auxiliary hoses into
the second boom section, followed slowly by the
third boom section being careful not to damage any
surrounding components.

3-10 G6-42A, G9-43A, G10-43A

 Boom

4. Lower the third boom section onto a suitable
support, relocate one sling and insert the third boom
section assembly approximately 75% into the
second boom section.
3
4 4
5 5
14. Secure the retract chain, tilt cylinder hoses and if
equipped, auxiliary hoses to the bottom of the boom
head with rope or wire.
Note: Keep the retract and extend chain free of any dirt
and/or contaminates.
15. Remove the Temporary Extend Chain Bracket.
7

1
4 2 2 4

MY3870

5. Install the previously removed wear pad mounting

plate (1) with existing hardware at the bottom front of 8
the second boom section. Torque as required
6. Install the previously removed wear pads, shims and 6
spacers (2) with existing hardware at the bottom MY3960

front of the second boom section. Torque as

16. Install the previously removed pin (6), chain roller
required.
(7), tilt hose sheave (8) and if equipped, auxiliary
7. Install the wear pad mounting plate (3) with existing hose sheave assemblies at the rear of the second
hardware at the inside top front of the second boom boom section with existing hardware and shim as
section. Torque as required. required.
8. Install the previously removed wear pads, spacers
and shims on each side at the front of the second
boom section (4). Snug mounting bolts. Shim as
needed AFTER boom section is installed. Refer to
Section 3.11.2, “Wear Pad Installation and
Lubrication,” for detailed information.
10
9. Install wear pads, spacer (5) using bolts and
washers at the top front of the second boom section.
Snug mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.11.2, “Wear
9
Pad Installation and Lubrication,” for detailed 9 MY3970
information.
9 9 9 9
10. Feed the tilt cylinder hoses and if equipped, auxiliary
hoses through the access holes at the rear of the 17. Thrust washers (9) are to be used as required to
second boom section. shim the hose sheave and retract chain sheave
11. Push the third boom section the remainder of the within 0.0625 in (1,6 mm) of a tight fit. At least one
way into the second boom section. thrust washer (9) is required at each noted location.
12. Feed the retract chain through the access holes at 18. Center the retract chain sheave (10) between the
the rear of the second boom section. mounting plates.
13. Connect the retract chain to the chain clevis at the 19. Feed the tilt cylinder hoses and (if equipped) the
rear of the second boom section using the existing auxiliary hoses over and around the hose sheaves.
pin and retaining clips.

G6-42A, G9-43A, G10-43A 3-11

 Boom
11 11
12 12
MY3880
20. Align the push beam bores with the second boom
section bores and install the previously removed
pins (11).
Note: Verify the cross holes in push beam pins align
with holes in each pin bore on the second boom section.
21. Install the previously removed tilt cylinder hose guide
(12) and if equipped, the auxiliary hose guide at the
rear of the third boom section using the existing
hardware. Torque as required.
14 14
13 13
MY3910
22. Install the previously removed wear pad and spacer
(13) on the left or right side of the third boom section.
Snug mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.11.2, “Wear
Pad Installation and Lubrication,” for detailed
information.
23. Install the previously removed wear pad and spacer
(14) on the top of the third boom section. Snug
mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.11.2, “Wear
Pad Installation and Lubrication,” for detailed
information.
3-12
17
16 16
15 15
MY3880
24. Install the previously removed wear pad and spacer
(15) on the bottom rear of the second boom section.
Snug mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.11.2, “Wear
Pad Installation and Lubrication,” for detailed
information.
25. Install the previously removed wear pad and spacer
(16) on the left or right side of the second boom
section. Snug mounting bolts. Shim as needed
AFTER boom section is installed. Refer to Section
3.11.2, “Wear Pad Installation and Lubrication,” for
detailed information.
26. Install the previously removed counterbalance valve
(17). Torque to 44 lb-ft (59,7 Nm).
27. Torque all wear pad mounting bolts as required.
3.5.6 Second and Third Boom Section
Installation
Note: Using a straight bar approximately 20 in
(508 mm) long will aid in the installation of the wear pads
located on the inside front of each boom section.
1. Lubricate the bottom of the second boom section
where the wear pads of the first boom section
contact the second boom section.
2. Place the sling, or two slings for better stability,
around the third boom section and slowly insert the
second and third boom section into the first boom
section being careful not to damage hoses, chains
and/or surrounding components.
3. Lower the second and third boom section onto a
suitable support, relocate one sling and insert the
second and third boom section assembly allowing
access for the installation of the bottom plate, wear
pads, spacers and shims at the front of the first
boom section.
G6-42A, G9-43A, G10-43A

4. Remove any rope or wire securing the retract chain
and tilt hoses and (if equipped) auxiliary hoses as
the second and third boom sections are installed into
the first boom section.
4 4
3 9
5 5
5 5
2 1 2 hoses (10) and (if equipped) both auxiliary hoses.
MY3840
5. Install the previously removed mounting plate (1) at
the bottom front of the first boom section. Torque as
required.
6. Install the previously removed wear pads, spacers
and shims at the bottom front of the first boom
section (2). Snug mounting bolts. Shim as needed
AFTER boom section is installed. Refer to Section
3.11.2, “Wear Pad Installation and Lubrication,” for
detailed information.
7. Install the previously removed mounting plate (3) at
the top front of the first boom section. Torque as
required.
8. Install the previously removed wear pads, Spacers
(4) P/N 298-1729 and shims at the top front of the
first boom section. Snug mounting bolts. Shim as
needed AFTER boom section is installed. Refer to
Section 3.11.2, “Wear Pad Installation and
Lubrication,” for detailed information.
9. Install the previously removed wear pads, spacers
and shims at both sides on the front of the first boom
section (5). Snug mounting bolts.
7 MY3980
7 6
10. Install the anchor plate (6) using existing hardware
(7) into the first boom section. Torque as required.
G6-42A, G9-43A, G10-43A
Boom
10
8
11
9
MY3990
11. Install the previously removed tilt hose retainer
bracket (8) and (if equipped) both auxiliary hose
retainer at the bottom of the first boom section using
mounting bolts (9). Torque as required.
12. Remove plugs from the previously removed tilt
13. Connect both tilt hoses (10) and (if equipped) both
auxiliary hoses to the fittings on the hose retainer
bracket. Torque as required.
14. Connect both tilt tubes (11) and (if equipped) both
auxiliary tubes to the fittings on the hose retainer
bracket. Torque as required.
15. Push the second and third boom sections the
remainder of the way into the first boom section.
13 13
12
12
MY3890
16. Install the previously removed wear pad and spacer
(12) on the left or right side of the second boom
section. Snug mounting bolts. Shim as needed
AFTER boom section is installed. Refer to Section
3.11.2, “Wear Pad Installation and Lubrication,” for
detailed information.
17. Install the previously removed wear pad and spacer
(13) on the top of the second boom section. Snug
mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.11.2, “Wear
Pad Installation and Lubrication,” for detailed
information.
3-13
 Boom
G6-42A
18
17 19
16
G9-43A
G10-43A
20 20
MAL2660
18. Install the previously removed strong back (16) with
the existing hardware. Torque as required.
19. Install the extend/retract cylinder pin (17) through the
strong back (16). Secure the pin with the retaining
rings.
20. Apply CAT Thread Lubricant to the extend chain
clevis rod threads (18).
21. Install the extend chain clevis rod (18) into the strong
back (16).
22. Install the belleville washers (19) as previously
removed (cupped washer facing strong back). Install
the adjustment nut and lock nut. Snug, but Do Not
tighten at this time.
23. Remove the caps and plugs from the extend/retract
cylinder fittings and the extend/retract tubes (20).
24. Install both extend/retract tubes (20) and torque as
required.
25. Uncap and reconnect the previously labeled
hydraulic hoses to the extend/retract cylinder.
26. Uncap and connect and remaining hydraulic fittings
to their appropriate locations.
27. Recheck wear pad gaps to ensure they meet the
minimum gap requirement. Shim if necessary.
28. Ensure that the boom chains are properly adjusted.
Refer to Section 3.8, “Boom Adjustments.”
29. Properly connect the battery.
3-14
30. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic fluid level in the reservoir; add fluid if
required.
31. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
32. Close and secure the engine cover.
33. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
3.6 EXTEND/RETRACT CHAIN
REMOVAL/INSTALLATION
3.6.1 Extend/Retract Chain Removal
The following section explains the removal of the extend/
retract chains without removing or disassembling the
boom assembly.
1. Park the machine on a hard, level surface, level the
machine, fully retract the boom, level the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the cover from the rear of the first boom
section.
6
5
4
MY0580
6. Remove the extend/retract cylinder hydraulic
tubes (4). Plug the tube ends and cap the fittings to
keep dirt & debris from entering the hydraulic
system.
7. Remove the extend/retract cylinder mounting pin (5)
from the strong back.
G6-42A, G9-43A, G10-43A

8. Remove the extend chain adjustment nut and lock
nut (6) from the strong back.
7 5. Place the chain clevis rod to one side of the push
MY1540
9. Remove the retract chain adjustment and lock nuts
(7) from the front of the first boom section.
10. Remove the strong back mounting bolts and remove
the strong back from the boom.
11. Remove the push beam mounting pins from the rear
of the second boom section.
12. Place the chain clevis rod to one side of the push
beam.
13. Lift the push beam to gain access to the chain clevis
at the rear of the third boom section.
14. Reaching inside the rear of the boom at the chain
anchor bracket, remove the cotter pin and pin from
the retract chain clevis. Remove the cotter pin and
pin from the extend chain.
15. Connect wire or rope (approximately 30 ft (9,1 m) to
the end of the extend chain.
16. Lower the push beam. Center the chain clevis rod on
the push beam to aid in removal.
17. Pull the push beam/extend chain from the rear of the
boom. Disconnect the wire or rope from the extend
chain.
18. Pull the retract chain from the rear of the boom.
3.6.2 Extend/Retract Chain Installation
The following section explains the installation of the
retract chains without removing the boom assemblies.
Inspect and lubricate chains thoroughly before
installation.
1. Push the retract chain through the boom from the
rear to the chain adjusting block (7) on the first boom
section. Do not tighten the adjustment and lock nut
at this time. Thread the nut on the clevis enough to
keep the chain in place.
G6-42A, G9-43A, G10-43A
Boom
2. Connect the extend chain to the wire or rope at the
rear of the boom.
3. Slowly pull the wire or rope guiding the extend chain
over the push beam, around the extend chain
sheave, under the push beam and stopping at the
extend chain/retract chain clevis.
4. Remove the wire or rope secured to the extend
chain.
beam.
6. Lift the push beam to gain access to the chain clevis
at the rear of the third boom section.
7. Reaching inside the rear of the boom at the chain
anchor bracket, install the cotter pin and pin from the
extend chain clevis. Install the cotter pin and pin from
the retract chain.
8. Lower the push beam. Center the chain clevis rod on
the push beam.
9. Place the extend chain rod through the strong back
and place the strong back in place at the rear of the
first boom section.
10. Install and torque the strong back mounting bolts to
240-265 lb-ft (325-359 Nm).
11. Install the extend/retract cylinder mounting pin and
secure with retaining clips.
12. Install the adjustment and lock nuts on the chain
clevis rod. Do not tighten at this time.
13. Uncap and connect the extend/retract cylinder
hydraulic tubes to their appropriate locations.
14. Adjust the chain as needed. Refer to Section 3.8,
“Boom Adjustments.”
15. Install the cover on the rear of the boom.
16. Properly connect the battery.
17. Close and secure the engine cover.
18. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
3-15
 Boom

3.7 PUSH BEAM - EXTEND/RETRACT

CYLINDER REMOVAL/ G6-42A
INSTALLATION 5

CAUTION
The complete push beam - extend/retract cylinder
assembly weighs over 1,200 lb (545 kg).

The following section explains the removal of the push G9-43A 4

G10-43A 3
beam - extend/retract cylinder without removing or
MAL2670
disassembling the boom assembly.
7. Loosen and remove the lock nut, adjustment nut (3)
3.7.1 Push Beam - Extend/Retract Cylinder and belleville washers (4) from the retract chain (5)
Removal at the bottom front of the first boom section.
1. Park the machine on a hard, level surface, level the Note: Note the position of the belleville washers for
machine, fully retract the boom, level the boom, reassembly.
place the transmission control lever in 8. Secure a rope or wire to the retract chain (5).
(N) NEUTRAL, engage the park brake and shut the
engine OFF. G6-42A
8
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to 7
cool. 6
4. Remove the cover from the rear of the first boom
section.
G9-43A
G10-43A

MAL2660

9. Loosen and remove the lock nut, adjustment nut (6)

2 and belleville washers (7) from the extend chain
MAL1310
anchor (8) at the rear of the first boom section.
Note: Note the position of the belleville washer for
5. Disconnect both tilt hoses (1) and both auxiliary
reassembly.
hoses (not shown) from the hose retainer brackets
(2) at the bottom front inside the boom. Plug the
hose ends to prevent dirt and debris from entering
the hydraulic system.
6. Remove both hose retainer brackets (2).

3-16 G6-42A, G9-43A, G10-43A

 Boom

16

15
11 11
14

10 10
13

12

9 9 MY3930

15. Loosen and remove the four bolts (12), guide bar
(13) and chain retainer (14) from the front of the
push beam.
16. Disconnect the extend chain (15) from the anchor
MAL1290 rod (16) and lay flat on the bottom of the third boom
section. Remove the anchor rod (16) from the front
Note: Disconnecting one or both extend/retract of the boom.
hydraulic tubes (9) may be required to gain access to the
Note: It may be necessary to lift the extend /retract
hose guide mounting bolts. After removing both hose
cylinder through the access holes in the sides of the third
guides, re-connect one or both extend/retract hydraulic
boom section to remove the chain retainer (14).
tubes BEFORE proceeding.
10. Loosen and remove the tilt cylinder hose guide (10)
and if equipped, the auxiliary hose guide from the 19
rear of the third second section.
20
Note: The hose guide mounting bolts also hold the push
pin beams in place. 20
18
11. Remove the left and right push beam pins (11). 20
12. Start the machine and SLOWLY extend the extend/
retract cylinder 1 - 2 ft (305 - 609 mm) or until the 17 17
push beam assembly can be accessed through the
front of the third boom section.
Note: Only the push beam - extend/retract cylinder MAL1290
assembly should move during this procedure.
17. At the rear of the boom, remove both retaining clips
(17) from the extend/retract cylinder pin (18).
NOTICE Remove the extend/retract cylinder pin from the
strong back (19).
The extend chain rod will move toward the front of
18. Loosen and remove the eight bolts (20) from the
boom. Do Not allow the rod to come into contact with
strong back (19). Remove the strong back.
the chain and/or chain roller.
19. Remove both extend/retract cylinder hydraulic tubes.
13. Shut machine OFF. Plug the tube ends and cap the fittings to prevent dirt
14. Properly disconnect the battery. and debris from entering the hydraulic system.

G6-42A, G9-43A, G10-43A 3-17

 Boom

20. Place a sling around the push beam - extend/retract

cylinder assembly. Lift and slowly pull the push beam
- extend/retract cylinder assembly approximately half
1
way out of the boom assembly. Lower the push
beam onto a suitable support. 2

2
NOTICE 3
2
Guide the push beam - extend/retract cylinder
assembly over the top of the retract chain anchor at 4 4
the rear of the third boom section being careful not to
damage any components.

21. Relocate the sling or using two slings for better MAL1290
stability, balance the push beam - extend/retract
cylinder assembly and slowly pull the push beam - 5. Install the strong back (1) with the previously
extend/retract cylinder assembly out of the boom removed hardware (2) and torque as required.
assembly. Lower the push beam - extend/retract 6. Align the extend/retract cylinder bore with the strong
cylinder assembly onto suitable supports. back bores and install the extend/retract cylinder pin
22. Remove the extend/retract cylinder as required. (3) and secure with the retaining clips (4).
7. Install the anchor rod through the front of the boom
3.7.2 Push Beam - Extend/Retract Cylinder assembly.
Installation
1. Clean and lubricate the bottom and sides of the third 6
boom section where the push beam guide bar
5
travels.
2. Place a sling or using two slings for better stability, 8
lift and slowly push the push beam - extend/retract
cylinder assembly approximately half way into the
7
boom assembly. Lower the push beam onto a
suitable support.
3. Relocate the sling and slowly insert the push beam - 9
extend/retract cylinder assembly into the front of the
boom assembly. MY3930

NOTICE
Guide the push beam - extend/retract cylinder
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
4. Remove the plugs and caps from the extend/retract
cylinder hydraulic tubes. Install both extend/retract
cylinder hydraulic tubes.
8. Connect the extend chain (5) to the anchor rod (6).
9. Install the guide bar (7) and chain retainer (8) to the
front of the push beam with the previously removed
hardware (9).
10. Properly connect the battery.
11. Start the machine and SLOWLY retract the extend/
retract cylinder until the push beam assembly bores
can be aligned with boom sections access bores.
12. Properly disconnect the battery.

3-18 G6-42A, G9-43A, G10-43A

 Boom

15. Install the belleville washers (13) to the extend chain

anchor (14) as previously removed at the rear of the
first boom section.
16. Install the adjustment and lock nut, (15) to the
10 10 extend chain anchor (14) at the rear of the first boom
section.
12 12 G6-42A

16

11 11

G9-43A
G10-43A 18 17
MAL2670

MAL1290
13. 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.
14. Install the tilt cylinder hose guide (12) and the
auxiliary hose guide from the rear of the third second
section.
G6-42A
14
17. Remove the rope or wire from the retract chain (16).
18. Install the belleville washers (17) to the retract chain
clevis (16) as previously removed at the bottom front
of the first boom section.
19. Install the adjustment and lock nut (18) to the retract
chain clevis (16) at the bottom front of the first boom
section.
Note: Note the position of the belleville washer for
reassembly.
20

13
15

G9-43A
G10-43A

19
MAL1310

20. Install both hose retainer brackets (19).

21. Remove the plugs and caps from the tilt hoses and
auxiliary hoses.
22. Connect both tilt hoses (20) and both auxiliary hoses
MAL2660
(not shown) to the hose retainer brackets (19) at the
Note: Note the position of the belleville washers for bottom front inside the boom.
reassembly. 23. Properly connect the battery.

G6-42A, G9-43A, G10-43A 3-19

 Boom

24. Adjust the chain as needed. Refer to Section 3.8,

“Boom Adjustments.”
25. Install the cover on the rear of the boom.
26. Close and secure the engine cover.
27. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

3.8 BOOM ADJUSTMENTS

3.8.1 Chain Tension Inspection—G6-42A

1. Park machine on level ground. Place transmission B MAL2601
control lever in (N) NEUTRAL, engage parking brake
and level boom.
6. At the bottom front of the boom, verify dimension “B”
2. Place a Do Not Operate Tag on both ignition key 0.712-0.725 in (18,1-18,4 mm) of the washer stack
switch and steering wheel. on the retract chain clevis.
3. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract
the boom. Verify boom is level.
4. Measure the following three dimensions; A, B & C.

C MAL2611

7. At the back of the boom, verify dimension “C” is not

MAL2561
5. At the boom head, verify dimension “A” is between
11.500-11.812 in (292,1-300,0 mm).
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 are not met.

3-20 G6-42A, G9-43A, G10-43A

 Boom

3.8.2 Chain Tension Adjustment—G6-42A

A

3 2
1

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.
MAL2561
6. If dimension “A” is greater than 11.625 in
(295,2 mm), push the third section boom IN until
dimension “A” is less than 11.625 in (295,2 mm).

3 2
1
4 6 7

B MAL2551
3. Remove lock nut (4) from retract chain clevis (5).
4. Set the retract chain adjustment nut face (6) flush
with the end of the retract clevis.
5. Verify the belleville washers (7) are in the correct
order as shown. Remove the retract chain
adjustment nut (6) and correct if required.
Note: Belleville washers are shown in the
un-compressed state.
MAL2571 C
7. With dimension “A” less than 11.625 in
(295,2 mm), verify the extend rod Belleville washers
(3) and the retract chain Belleville washers are
loose. Tighten the extend chain rod adjusting nut (2)
until dimension “A” is 12.063-12.188 in
(306,4-309,5 mm).
8. Install and temporarily tighten the extend chain
lock nut (1).

G6-42A, G9-43A, G10-43A 3-21

 Boom

3.8.3 Chain Tension Inspection—

G9-43A/G10-43A

4 6 7
1. Park machine on level ground. Place transmission
control lever in (N) NEUTRAL, engage parking brake
and level boom.
2. Place a Do Not Operate Tag on both ignition key
switch and steering wheel.
5 3. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract
the boom. Verify boom is level.
4. Measure the following three dimensions; A, B & C.
B MAL2551

9. Tighten the retract chain adjustment nut (6) until A

the belleville washers (7) become fully compressed
to dimension “B” 0.712-0.725 in (18,1-18,4 mm). Do
Not Overtighten.
10. Install and temporarily tighten the retract chain
lock nut (4).
11. Start the machine and at low idle, fully extend and
retract the boom three times. Verify boom is fully
retracted and level. Shut machine Off.
12. Recheck the Belleville washers (7) to verify they are
fully compressed to dimension “B” 0.712-0.725 in
(18,1-18,4 mm). If required, re-tighten the retract
chain adjustment nut (6) until dimension “B” is
obtained. MAL2740

Note: If dimension “B” requires adjustment, continue to

step 13. If dimension “B” does NOT require adjustment, 5. At the boom head, verify dimension “A” is between
continue to step 14. 17.000-17.312 in (421,8-439,7 mm).
13. Start the machine and at low idle, fully extend and
retract the boom three times. Verify boom is fully
retracted and level. Shut machine Off.
14. Verify dimension “A” 11.500-11.812 in
(292,1- 300,0 mm). Verify dimension “C” is not less
than 2.850 in (72,4 mm).
Note: Re-adjust boom if dimensions “A” & “C” are not
met. Contact the local JLG Distributor if the procedure
cannot be obtained.
15. Loosen the retract chain lock nut and the extend
chain lock nut and apply Loctite® 242TM.
16. Torque each retract chain lock nut (4) and B MAL2621

extend chain lock nut (1) without adding any

additional spring load. Torque each lock nut to 6. At the bottom front of the boom, verify dimension “B”
100 lb-ft (135 Nm). is 1.500-1.512 in (38,1-38,4 mm) of the washer stack
on the retract chain clevis.

3-22 G6-42A, G9-43A, G10-43A

 Boom

4 6 7

MAL2630 C
B MAL2591

7. At the back of the boom, verify dimension “C” 3. Remove lock nut (4) from retract chain clevis (5).
3.069 in (77,9 mm) on the extend chain clevis. 4. Set the retract chain adjustment nut face (6) flush
Note: Belleville washers are shown in the with the end of the retract clevis.
un-compressed state. 5. Verify the belleville washers (7) are in the correct
order as shown. Remove the retract chain
8. Boom adjustment will be required if the above
adjustment nut (6) and correct if required.
dimensions are not met.
Note: Belleville washers are shown in the
3.8.4 Chain Tension Adjustment— un-compressed state.
G9-43A/G10-43A

A
3 2
1

MAL2580 C

1. Remove extend chain lock nut (1) and loosen

adjustment nut (2) until belleville washers (3) are
free to turn on extend rod. MAL2740

2. Verify the belleville washers (3) are in the correct

order as shown. Remove the extend chain 6. If dimension “A” is greater than 17.000 in
adjustment nut (2) and correct if required. (421,8 mm), push the third section boom IN until
dimension “A” is less than 17.000 in (421,8 mm).

G6-42A, G9-43A, G10-43A 3-23

 Boom

13. Start the machine and at low idle, fully extend and
3 2 retract the boom three times. Verify boom is fully
1 retracted and level. Shut machine Off.
14. Verify dimension “A” 17.000-17.312 in
(421,8-439,7 mm). Verify dimension “C” is not
less than 3.069 in (77,9 mm).
Note: Re-adjust boom if dimensions “A” & “C” are not
met. Contact the local JLG Distributor if the procedure
cannot be obtained.
15. Loosen the retract chain lock nut and the extend
MAL2580 C
chain lock nut and apply Loctite® 242TM.
16. Torque the retract chain lock nut (5) and extend
7. With dimension “A” less than 17.000 in (421,8 mm),
chain lock nut (1) without adding any additional
verify the extend rod Belleville washers and retract
spring load. Torque each lock nut to 100 lb-ft
chain Belleville washers are loose. Tighten the
(135 Nm).
extend chain rod adjusting nut (2) until dimension “A”
is 17.438-17.562 in (443,0-446,1 mm).
8. Install and temporarily tighten the extend chain
lock nut (1).

4 6 7

B MAL2591

9. Tighten the retract chain adjustment nut (6) until

the belleville washers (7) become fully compress to
distance of “B” 1.500-1.512 in (38,1- 38,4 mm).
Do Not Overtighten.
10. Install and temporarily tighten the retract chain
lock nut (4).
11. Start the machine and at low idle, fully extend and
retract the boom three times. Verify boom is fully
retracted and level. Shut machine Off.
12. Recheck the Belleville washers (7) to verify they are
fully compressed to dimension “B” 1.500-1.512 in
(38,1- 38,4 mm). If required, re-tighten the retract
chain adjustment nut (6) until dimension “B” is
obtained.
Note: If dimension “B” requires adjustment, continue to
step 13. If dimension “B” does NOT require adjustment,
continue to step 14.

3-24 G6-42A, G9-43A, G10-43A


3.9 QUICK SWITCH ASSEMBLY
3.9.1 Quick Switch Removal
G6-42A - Before S/N 0160037722
G9-43A/G10-43A - Before S/N 0160037671
7 G9-43A/G10-43A - S/N 0160037671 & After
2
6 9
1
4
5
MY5080
3 11
1. Remove the lock bolt (1) holding the tilt cylinder rod
end pin (2) to the quick switch assembly (3). Remove
the Tilt Cylinder pin.
2. Support the quick switch assembly (3).Remove the
capscrew (4) and locknut (5) securing the head pin
(6) to the boom head (7).
3. Inspect the above pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
replaced.
3.9.2 Quick Switch Installation
1. Assemble the quick switch assembly (3) to the boom
head (7). Line up the quick switch between the
mounts on the boom head. The quick switch should
be centered in the boom head.
2. Coat the quick switch head pin (6) with an anti-seize
compound. Insert the quick switch head pin through
the quick switch and boom head. Secure with the
previous capscrew (4) and locknut (5).
G6-42A, G9-43A, G10-43A
Boom
3. Align the quick switch with the tilt cylinder rod end
and insert the tilt cylinder pin (2). Align the tilt
cylinder pin and screw in the locking bolt (1). Torque
as required.
3.9.3 Quick Switch Removal
G6-42A - S/N 0160037722 & After
14
13
8
12
10 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.
3.9.4 Quick Switch Installation
1. Assemble the quick switch assembly (10) to the
boom head (14). Line up the quick switch between
the mounts on the boom head. The quick switch
should be centered in the boom head.
2. Coat the quick switch head pin (13) with an 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.
3-25
 Boom

3.10 BOOM HEAD - MOUNTED WINCH 3.11 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear
3.10.1 Boom Head-Mounted Winch Removal pads with metal inserts.
A total of 30 wear pads are installed on the boom sections
of the G6-42A, G9-43A and G10-43A machines.

3.11.1 Wear Pad Inspection

17 1 1

16 Ma2070
15
Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
worn or damaged.

MAL0880 3.11.2 Wear Pad Installation and Lubrication

Note: Inspect all wear pads. Replace as necessary.
1. Using a suitable lifting device, secure the winch
The following wear pad procedure must be followed to
assembly (15) with a nylon strap.
insure the proper wear pad installation:
2. Disconnect the hydraulic hoses (16).
• The wear pad inserts and mounting bolts MUST be
3. Loosen and remove the mounting bolts, washers clean from any grease, oil or other contaminates
and nuts (17). before applying Loctite® 242™ and installing
mounting bolts.
4. Lower the winch assembly (15) onto a suitable skid
or table. • Apply Loctite® 242™ to all wear pad mounting bolts.

4
3.10.2 Boom Head-Mounted Winch
Installation
1. Using a suitable lifting device, secure the winch
assembly (4) with a nylon strap. 3
2
2. Raise the winch assembly (4) into position behind
the boom head.
3. Apply to the previously removed mounting bolts.
4. Install the mounting bolts, washers and nuts (6)(not
shown). Torque to 200 lb-ft (271 Nm).
MAM1390
5. Connect the hydraulic hoses (5).
• A spacer (2) with holes must be used before any
shim (3) is used.
• A shim (3) must be inserted between the spacer (2)
and wear pad support plate, block or boom section
(4).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
each side.

3-26 G6-42A, G9-43A, G10-43A


5 5
MY5510
• Maintain a total boom section clearance (5) of
0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal
and vertical directions.
A dynamic impulse/shock loads can drastically affect
B
MY3620
• The length of the wear pad bolt depends on the
number of shims, spacers and washers being used.
• The thickness of each threaded wear pad insert is
0.312 in (7,92 mm)(A).
• The bolt length should be determined by measuring
the distance from the face of the insert to the face of
the boom (B) including any spacer, shim(s) and
washer(s).
• Bolt thread engagement in the wear pad insert
should be 0.275 ± 0.040 in (6,98 ± 1,0 mm).
• One or two hardened washers are to be used on
each wear pad bolt except where noted otherwise.
DO NOT use more than two hardened washers.
• Use only one hardened washer if mounting bolts are
recessed.
• Wear Pad Bolt Torque:
3/8 - 24 Bolt, 32 - 37 lb-ft (43 - 50 Nm)
3/8 - 24 Hollow Bolt, 15 - 17 lb-ft (20 - 23 Nm)
1/2 - 20 Bolt, 76 - 86 lb-ft (103 - 116 Nm)
1/2 - 20 Hollow Bolt, 45 - 50 lb-ft (61 - 68 Nm)
• Torque wear pad bolts after shimming is completed.
• Lubricate the face and pockets of each wear pad
after being installed.
Boom Section Wear Pad Pathway Lubrication:
• Clean and lightly grease all wear pad pathways with
Mystik Tetrimoly grease.
Clean and lightly grease the hose carrier guide bar
pathways with Mystik Tetrimoly grease.
G6-42A, G9-43A, G10-43A
Boom
3.12 BOOM EXTEND AND RETRACT
CHAINS
3.12.1 Boom Chain Inspection
WARNING
Worn pins, stretched or cracked links or corrosive
environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
load or machine instability.
Under normal operating conditions the boom chains will
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every
1000 hours of operation. Environmental conditions and
normal operating conditions and require more frequent
inspection intervals.
Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive
industrial atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
as follows:
• Moisture - Corrosive rusting reduces chain
strength by pitting and cracking.
• Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of
cold storage results in moisture from
condensation.
• Chemical Solutions or Vapors - Corrosive attack
on the chain components and/or the mechanical
connections between the chain components.
Cracking can be (and often is) microscopic.
Going from microscopic cracking to complete
failure can be either abrupt or may require an
extended period of time.
• Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins and
plates), with a corresponding reduction in chain
strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
the naked eye.
3-27
 Boom
Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
limit of a leaf chain.
• High velocity movement of load, followed by
sudden, abrupt stops.
• Carrying loads in suspension over irregular
surfaces such as railroad tracks, potholes, and
rough terrain.
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle.
The above load cycles and environmental conditions
make it impossible to predict chain life. It is therefore
necessary to conduct frequent inspections until
replacement life can be predicted.
The boom chain’s normal life expectancy can be
expressed as a maximum percent of elongation. This is
generally 3%. As the chain flexes back and forth over the
sheave, the bearing joints (pins and inside link plates)
gradually incur wear due to articulation.
3.12.2 Inspection Guidelines
1. Park the machine on a firm, level surface, level the
boom, place the transmission control lever in (N)
NEUTRAL, engage the park brake switch.
2. Fully extend the boom until the extend chain is taut.
Shut the engine off.
3. The extend chains will be visible for inspection with
the vehicle in this state.
4. While doing the chain inspection, check all chain
clevis ends for distortion or cracking and sheaves for
bearing wear or grooving from the chain.
5. Inspect the retract chains every 1000 hours of
operation.
6. Inspect the chains for the following conditions:
3-28
Edge Wear
1 2
MZ1463
Check the chain for wear on the link plate edges
caused by running back and forth over the sheave.
The maximum reduction of material should not
exceed 5%. Measure and compare to a normal link
plate height by measuring a portion of chain that
does not run over the sheave. If the measured plate
height (1) is 5% less than the normal plate height
(2), discard and replace the chain.
Elongation
It is important to measure the chain in the section
that moves over the sheaves because it receives the
most frequent articulation. Measuring the chain near
its clevis terminals could give an inaccurate reading.
The ends of the chains, near the clevis terminal, will
not have flexed as frequently, if at all, as the middle
of the chains.
It is best to measure in 12 pin increments from pin
center to pin center. For example, if the links are one
inch from pin center to pin center, the distance
should be 12 in (305 mm). If the links are 3/4 in
(9,5 mm) apart, the distance after 12 pins should be
9 in (229 mm).
4
3
MY1360
If the distance measured (3) is 3% greater than the
normal length (4), discard and replace the chain.
G6-42A, G9-43A, G10-43A
 Boom

Distorted or Battered Link Plates Cracked Plates

Distorted or battered link plates (5) on a leaf chain can Inspect the chains very carefully, front and back as
cause tight joints and prevent flexing. 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.
85
It is important, however to determine the cause of
the crack before installing a new chain so the
condition does not repeat itself.
The types of cracks are:
• Fatigue Cracking -
Fatigue cracks (9) are a 9
MZ1466
result of repeated
cyclic loading beyond MZ1467
the chain’s endurance
limit.
Turning or Protruding Pins
• Stress Corrosion
Highly loaded chain, operating with inadequate Cracking - The
lubrication can generate abnormal frictional forces outside link plates 10
between pin and link plates. When chain is allowed are particularly MZ1468
to operate in this condition, a pin or series of pins, susceptible to stress
can begin to twist out of a chain, resulting in failure. corrosion cracking (10).
• Corrosion Fatigue Cracking - Corrosion
fatigue cracks are very similar to fatigue
cracks in appearance. Corrosion fatigue is the
7
6 combined action of an aggressive
8 environment and cyclic stress.
MZ1465 Other Modes of Failure
• Ultimate Strength Failure -
Examine the pin head rivets to determine if the These types of failures are
“VEE” flats are still in correct alignment (6). Chain caused by overloads far in 1
with rotated/displaced heads (7) or abnormal pin excess of the design load. MZ1469
protrusion (8) should be replaced immediately. Either fractured plates (1) or 2
DO NOT attempt to repair the chain by welding or enlarged holes (2) can
driving the pin(s) back into the chain. Once the press occur. If either of these
MZ1470
fit integrity between outside plates and pins has failures occurs, the chain
been altered, it cannot be restored. should be replaced immediately.
Any wear pattern on the pin heads or the sides of the • Tight Joints
link plates indicates misalignment in the system. - All joints in
This condition damages the chain as well as the chain
increases frictional loading and should be corrected. should flex
freely. Tight
3 MZ1471
joints (3)
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.

G6-42A, G9-43A, G10-43A 3-29

 Boom

3.12.3 Chain Lubrication 3.13 FORKS

After inspection and before being returned to service,
chains must be lubricated with Mystik Tetrimoly Grease. Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met,
The lubricant must penetrate the chain joint to prevent forks must be removed from service immediately.
wear. Applying lubricant to the external surfaces will
prevent rust, but the chains should be articulated to Daily Inspection
make sure the lubricant penetrates to the working
surfaces between the pins and links. 3
To prepare the chain for lubrication, the chain plates 6
should be brushed with a stiff brush or wire brush to
clear the space between the plates so that lubricant can 7
5 4
penetrate to the working surfaces.
Lubricant may be applied with a narrow paint brush or
2
directly poured on, but the chain should be well flooded 1
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 9
for this wiping operation. 8
Regular application of lubricant is necessary to make 11
sure that all working surfaces are adequately lubricated.
In extremely dusty conditions, it may be necessary to
lubricate the chains more often. 10 MH6460

Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special
consideration. It is important that a reputable lubrication
specialist, a JLG Distributor or the vehicle distributor be
consulted for guidance.
1. Inspect forks (1) for cracks, paying special attention
to heel (2) and mounting tubes (3).
2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
Yearly Inspection
1. Straightness of the upper face of blade (5) and the
front face of shank (6) should not exceed 0.5 percent
of the length of blade or height of shank.
2. Angle (7) between upper face of blade and front face
of shank should not exceed 93 degrees.
3. Thickness of blade (8) and shank (9) should not be
reduced to 90 percent of original thickness.
Note: Contact the local Caterpillar dealer with the fork
part number to find the manufactured dimensions of the
fork blade.
4. Ensure fork length (10) is adequate for intended
loads.
5. Fork markings should be legible, re-stamp if
required.
6. Compare fork tips (11) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent
of the length of the blade (10).

3-30 G6-42A, G9-43A, G10-43A

 Boom

3.14 EMERGENCY BOOM LOWERING Hoses:

PROCEDURE • Two Hydraulic Hoses - Approximately 10 ft
(3,0 m) each, with a minimum I.D. of
0.375 in (9,5 mm) and a minimum rating of
WARNING 4000 psi (275,8 bar).
G6-42A - Fittings:
To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting the • Two -10 ORFS Caps
lift cylinder. If circumstances prevent retraction of the • Two -10 ORFS Plugs
extend/retract cylinder first, lower the lift cylinder the
Adaptors:
minimum amount necessary and resume retraction of
the extend/retract cylinder as soon as possible in • Two -10 ORFS 90° Adaptors
accordance with the machines load chart. G9-43A/G10-43A - Fittings:
• Two -12 ORFS Caps

WARNING • Two -12 ORFS Plugs

Properly support the boom before attempting to
proceed with the emergency boom lowering
procedure.
Adaptors:
• Two -12 ORFS 90° Adaptors
Note: The adaptor size may vary depending on the
hose ends of the auxiliary hydraulic power supply.

WARNING 3.14.2 Lowering Procedure

If possible, safely remove and/or secure the load on
the machine before starting the boom lowering
procedure. If load cannot be removed, the machine
load chart MUST be followed.
3.14.1 Equipment and Supplies Required
Auxiliary Hydraulic Power Supply:
• Portable hydraulic unit or another machine with
an auxiliary hydraulic power supply with a
capacity to hold up to 22 gal (83 L) of hydraulic
oil from the machine during lowering process.
Note: If another machine is being used, the hydraulic
reservoir must be drained to accept a minimum of 22 gal
(83 L) of hydraulic oil before attempting this procedure.
• Standard Mechanic Tools.
NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.4, “Fluids and Lubricant
Capacities.”
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 oil is limited to the amount trapped
within each tube/hose. Slowly loosen each hydraulic
tube/hose fitting to release any possible hydraulic oil
pressure that may be trapped between the main
control valve and the counterbalance valve of the
extend/retract cylinder or the lift/lower cylinder.

G6-42A, G9-43A, G10-43A 3-31

 Boom

1 3 2 9. Using the hoses and fittings specified, connect the

hoses between the auxiliary hydraulic power supply
and the extend/retract hoses of the affected
machine. Retract hose (3) is the supply and extend
4 hose (4) is the return. Connect the hoses in the
proper order to ensure that the cylinder is retracted,
not extended.
10. Remove the previously installed boom support.
11. Use the auxiliary power supply to slowly retract the
extend/retract cylinder.
12. Properly support the boom as required.
13. Loosen and remove the jumper hoses, caps, plugs
and reconnect the extend/retract cylinder hoses.
Torque as required.

b. Lower the boom as follows:

G6-42A
MY8620
3 hoses between the auxiliary hydraulic power supply
4
1 hose (1) is the return and lower hose (2) is the
2 supply. Connect the hoses in the proper order to
G9-43A
G10-43A
MY8630
7. If access is required, loosen and remove any clamps
securing the lift/lower cylinder (1 & 2) and extend/
retract cylinder tubes (3 & 4) to the frame.
8. Disconnect the extend/retract cylinder tubes from
the extend/retract cylinder hoses (3 & 4). Install caps
or plugs in tubes to prevent fluid loss and to keep dirt
and debris from entering the hydraulic system.
1. Place a suitable receptacle under the tube/hose
connections.
2. Disconnect the lift/lower cylinder hoses from the lift/
lower cylinder tubes (1 & 2). Install caps or plugs in
tubes to prevent fluid loss and to keep dirt and debris
from entering the hydraulic system.
3. Using the hoses and fittings specified, connect the
and the lift/lower hoses of the affected machine. Lift
ensure that the boom is lowered, not raised.
4. Remove the previously installed boom support.
5. Use the auxiliary power supply to slowly lower the
boom.
6. Loosen and remove the jumper hoses, caps, plugs
and reconnect the lift/lower cylinder hoses.
7. Install the previously remove clamps securing the lift/
lower cylinder and the extend/retract tubes. Torque
as required.
8. Install the plastic cover over the main control valve.
9. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil.”
Dispose of used oil at an approved recycling facility.
10. Clean up all debris, hydraulic oil, etc., in, on, near
and around the machine.
11. Remove the Do Not Operate Tag on both the ignition
key switch and steering wheel.

3-32 G6-42A, G9-43A, G10-43A

 Boom

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

Problem Cause Remedy

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 3.11, “Boom
Wear Pads.”

3. Excessive boom pivot pin 1. Insufficient lubrication. 1. Lubricate at regular intervals.

noise and/or wear. Refer to Section 2.6,
“Lubrication Schedule.” Replace
worn pins as needed.

2. Worn bearing(s). 2. Replace bearing(s) and

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

4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/ Refer to Section 2.6,
or wear. “Lubrication Schedule.” Replace
worn pins as needed.

2. Worn bushing(s). 2. Replace bushing(s) and

lubricate at regular intervals.

G6-42A, G9-43A, G10-43A 3-33

 Boom
Problem
5. Drooping chain, or jerky
boom extend or retract
functions.
6. Boom will not raise or lower.
7. Excessive Lift/Lower cylinder
pivot pin noise and/or wear.
3-34
Cause
1. Chain(s) tension not properly
adjusted.
2. Chain(s) stretched or binding.
3. Wear pads loose, contaminated,
excessively worn or damaged.
4. Contaminated, corroded or
rusted wear pad sliding
surfaces.
5. Extend/Retract hydraulic system
not operating properly.
6. Damaged boom section.
1. Broken hydraulic hoses or tubes
and/or connection leaks.
2. Lift/lower hydraulic system not
operating properly.
3. Faulty lift/lower cylinder.
4. Seized boom pivot pin bearing.
1. Insufficient lubrication.
2. Worn self-aligning bushing(s).
Remedy
1. Adjust chain(s).
2. Replace chains as needed.
Refer to Section 3.8, “Boom
Adjustments.”
3. Replace wear pad. Refer to
Section 3.11, “Boom Wear
Pads.”
4. Remove contamination and/or
corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Refer to Section 8.4, “Hydraulic
Circuits.”
6. Replace the damaged boom
section. Refer to Section 3.3,
“Boom Assembly Maintenance.”
1. Locate break, replace hose(s)
or tube(s), tighten connections.
2. Refer to Section 8.4, “Hydraulic
Circuits.”
3. Repair cylinder. Refer to Section
8.8.1, “General Cylinder
Removal Instructions.”
4. Replace bearing.
1. Lubricate at regular intervals.
Refer to Section 2.5, “Service
and Maintenance Schedule.”
Replace worn pins as needed.
Refer to Section 8.8.1, “General
Cylinder Removal Instructions.”
2. Replace bushing(s) and
lubricate at regular intervals.
Refer to Section 2.6,
“Lubrication Schedule.”
G6-42A, G9-43A, G10-43A
 Boom

Problem Cause Remedy

8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.11, “Boom Wear
Pads.”

2. Rapid cycle times with heavy 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
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 2.5, “Service and
Maintenance Schedule.”

3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer

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

4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.5, “Service
and Maintenance Schedule.”
Replace chains as needed.

G6-42A, G9-43A, G10-43A 3-35

 Boom

3.16 PUSH BEAM TEMPORARY BRACKETS

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

5.00
3.125 Tube I.D. 1.3125in - O.D. 2.0in
0.1875
0.250

0.50 0.875

2.0
SEE NOTE A 1.3125
1/4

6.875

7.00

1.50

3/16

X Y

NOTE A: WELD FROM X-Y ONLY

2.1875

4.0

Temporary Retract Chain Bracket

5.00
1.50
3.125
0.1875
3/16 2.0
1.0
3/16
0.50 0.875
2.0
0.50 1.50
Drill 0.3125 Thru

2.50
0.50 3.0
A36 STEEL RECOMMENDED
3.0
ALL WELDS SHALL CONFORM TO AWS D1.1
ALL DIMENSIONS ARE IN INCHES MY4100

3-36 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 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.3 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.4 Boom Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.5 Frame Level, Attachment Tilt, Auxiliary Hydraulics and Outriggers (G10-43A)
Joysticks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.7 Heater/Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . 4-10
4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

G6-42A, G9-43A, G10-43A 4-1

 Cab and Covers

4.1 OPERATOR CAB AND COVERS

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.

4.1.1 General Overview

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

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

FRAME LEVEL
INDICATOR

STEERING WHEEL
BOOM CONTROL
JOYSTICK
INSTRUMENT PANEL

FRAME LEVEL AND

TRANSMISSION ATTACHMENT TILT
CONTROL LEVER CONTROLLER

OUTRIGGER CONTROLS
(IF EQUIPPED)

HEATER AND A/C

CONTROLS
(IF EQUIPPED)

AUXILIARY
HYDRAULICS
CONTROLLER

IGNITION
SWITCH

SERVICE BRAKE
PEDAL MAL0200
ACCELERATOR
PEDAL

4-2 G6-42A,G9-43A, G10-43A

 Cab and Covers

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

FRAME LEVEL HEATER AND A/C

ACCESSORY
INDICATOR CONTROLS
CONTROL
(IF EQUIPPED)
LEVER

BOOM CONTROL
STEERING WHEEL JOYSTICK

INSTRUMENT PANEL FRAME LEVEL

JOYSTICK

TRANSMISSION
CONTROL LEVER

AUXILIARY HYDRAULIC
JOYSTIVCK
(IF EQUIPPED)

IGNITION
SWITCH

SERVICE BRAKE
PEDAL
MY6450
ACCELERATOR
PEDAL

4.1.2 General Overview

G6-42A, G9-43A, G10-43A 4-3
 Cab and Covers

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

FRAME LEVEL HEATER AND A/C

ACCESSORY
INDICATOR CONTROLS
CONTROL
(IF EQUIPPED)
LEVER

BOOM CONTROL
STEERING WHEEL JOYSTICK

INSTRUMENT PANEL
FRAME LEVEL
AND ATTACHMENT TILT
(IF EQUIPPED) JOYSTICK

TRANSMISSION AUXILIARY HYDRAULIC

CONTROL LEVER JOYSTICK

G9-43A

IGNITION
SWITCH

SERVICE BRAKE ACCELERATOR

PEDAL PEDAL MY6460
HEATER AND A/C
ACCESSORY
FRAME LEVEL CONTROLS
CONTROL
INDICATOR (IF EQUIPPED)
LEVER
BOOM CONTROL
STEERING WHEEL JOYSTICK

INSTRUMENT PANEL
FRAME LEVEL
JOYSTICK

TRANSMISSION
CONTROL LEVER
OUTRIGGER
JOYSTICKs

G10-43A

IGNITION
SWITCH

SERVICE BRAKE ACCELERATOR

PEDAL PEDAL MY6470

4-4 G6-42A,G9-43A, G10-43A


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 in
any way. Any modification or damage to cab structural
components requires cab replacement. Refer to the
Operation & Safety Manual.
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
4.2.2 Serial Number Decal
The cab serial number decal is located on the left side of
the cab, behind the seat. Information specified on the
serial number plate includes the cab model number, the
cab serial number and other data. Write this information
down in a convenient location to use in cab
correspondence.
G6-42A, G9-43A, G10-43A
Cab and Covers
4.3 CAB COMPONENTS
4.3.1 Steering Column and Orbitrol Valve
a. Orbitrol Valve Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
Note: It may be necessary to remove the main dash
panel to gain access to the appropriate hydraulic hoses.
Refer to Section 9.12.1, “Analog Gauges.”
3
4
1
MY0120
5. Label, disconnect and cap the four hoses from the
side of the steering valve (1). Cap the fittings on the
steering valve. Label, disconnect and plug the load
sense hose at the front of the steering valve. Cap the
fitting on the steering valve.
4-5
 Cab and Covers

6. Remove the steering wheel (2), disconnect and 4.3.2 Service Brake Pedal
remove the travel select lever (3), disconnect the
instrument panel harness connector (4). a. Brake Valve Removal
7. Remove the steering assembly through the dash Refer to Section 8.7.2, “Service Brake Valve,” for removal
panel opening. information.
8. Support the steering valve, and remove the four hex-
head capscrews and four lockwashers. b. Brake Valve Installation

Note: DO NOT disassemble the orbitrol valve. The Refer to Section 8.7.2, “Service Brake Valve,” for
orbitrol valve is not serviceable and must be replaced in installation information.
its entirety, if defective.
c. Service Brake Pedal Removal
b. Orbitrol Valve Installation 1. Park the machine on a firm, level surface, level the
1. Secure the steering valve to the steering column machine, fully retract the boom, lower the boom,
with four hex-flange capscrews and four place the travel select lever in the (N) NEUTRAL
lockwashers. position, engage the parking brake and turn the
engine OFF.
2. Install the steering column through the dash panel
opening. Position steering valve to its original 2. Place a Do Not Operate Tag on both the ignition key
orientation in the cab. switch and steering wheel.
3. Install the travel select lever, connect the instrument 3. Open the engine cover. Allow the system fluids to
panel harness connector, install the steering wheel cool.
assembly. Torque the steering wheel nut to 29-34 lb-ft 4. Properly disconnect the battery.
(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 1
3
Section 9.12.1, “Analog Gauges.”
7. Properly connect the battery.
8. Carefully examine all connections one last time
before engine start-up. Rectify any faulty conditions. 2
9. Start the engine and check the operation of steering
system. Check for hydraulic fluid leaks. Check the MY0141

hydraulic fluid level in the tank and add fluid as

5. Remove the bolt and lockwasher (1) securing the
required.
service brake pedal pivot pin (2).
10. Close and secure the engine cover.
6. Pull the pivot pin from the service brake pedal
11. Remove the Do Not Operate Tags from both the bracket (3).
ignition key switch and the steering wheel.
7. Remove the service brake pedal from the cab.
c. Steering Test
d. Service Brake Pedal Installation
Conduct a pressure check of the steering hydraulic
1. Position the service brake pedal in its mounting
circuits at the main control valve. Refer to Section 8.3.1,
location within the cab.
“Pressure Checks and Adjustments.”
2. Secure the brake pedal into position with the pivot pin.

4-6 G6-42A,G9-43A, G10-43A


3. Be sure the brake pedal has the correct range of motion.
Secure pivot pin with bolt and lockwasher.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
4.3.3 Throttle Pedal
G6-42A - Before S/N 0160040678
G9-43A/G10-43A - Before S/N 0160040675 excluding
0160040468 & 016040672
a. Throttle Pedal Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Properly disconnect the battery.
4
5 7
6
MAL0990
4. Remove the ball joint (4) connected to the throttle
pedal.
5. Remove the bolt and lockwasher (5) securing the
throttle pedal pivot pin (6).
6. Remove the throttle pedal assembly from the cab.
G6-42A, G9-43A, G10-43A
Cab and Covers
b. Throttle Pedal Installation
1. Position the throttle pedal in its mounting location
within the cab.
2. Secure the throttle pedal into position with the pivot
pin.
3. Install the throttle pedal ball joint to the throttle pedal.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
c. Throttle Adjustment
1. From within the cab, lightly depress the accelerator
pedal to the full-throttle position. As needed, adjust the
limit-stop screw (7) until it touches the pedal. Tighten
the locknut.
Note: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep the transmission in (N) NEUTRAL.
2. Check the engine rpm at full throttle. If the rpm is not
within the specified range, readjust the throttle limit
screw at the throttle pedal within the cab. Refer to
Section 2.3.5, “Engine Performance Specifications.”
G6-42A - S/N 0160040678 & After
G9-43A/G10-43A - S/N 0160040675 & After including
0160040468 & 016040672
a. Throttle Pedal Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Properly disconnect the battery.
4-7
 Cab and Covers

(If Equipped) (If Equipped)

10
11 11
9

MY6480

4. Lift the joystick’s rubber sleeve (11), remove the

bolts securing the boom joystick to the cab.

MAL1000
4. Disconnect the electrical harness connector (8).
5. Remove the bolts (9) securing the throttle pedal to
the throttle pedal bracket (10).
6. Remove the throttle pedal assembly from the cab.
b. Throttle Pedal Installation
1. Position the throttle pedal in its mounting location
within the cab.
2. Secure the throttle pedal into position with the pivot
pin.
3. Install the throttle pedal ball joint to the throttle pedal.
4. Properly connect the battery.
5. Verify proper throttle pedal operation.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
4.3.4 Boom Joystick Assembly
a. Joystick Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
5. Lift the joystick from its mounting position.
6. Label, disconnect and cap the hydraulic hoses
attached to the boom joystick.
7. Disconnect the electrical connectors.
8. Remove the joystick.
b. Joystick Installation
1. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
2. Connect the electrical connectors.
3. Install the bolts securing the joystick to the cab.
4. Properly connect the battery.
5. Test the joystick functions:
a. Move the joystick handle rearward, activating the
boom lift function. The boom should RISE.
b. Move the joystick handle forward, activating the
boom lower function. The boom should LOWER.
c. Move the joystick handle to the right, activating
the boom extend function. The boom should
EXTEND.
d. Move the joystick handle to the left, activating the
boom retract function. The boom should
RETRACT.
(If Equipped) (If Equipped)

place the travel select lever in the (N) NEUTRAL

14
position, engage the parking brake and turn the
engine OFF. 12 13
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Properly disconnect the battery.

MY6480

4-8 G6-42A,G9-43A, G10-43A

 Cab and Covers

e. Push the roller switch (13) down to activate the 5. Properly connect the battery.
tilt up function. The attachment should TILT UP.
6. Test the joystick for proper functions.
f. Push the roller switch (13) up to activate the tilt
Auxiliary Hydraulic Joystick
down function. The attachment should TILT
DOWN. Check the controls of the auxiliary attachments. See
g. Squeeze and release trigger (14) the appropriate Operation & Safety Manual for an
(back side of joystick) once to deactivate the approved list of attachments and control instructions.
Clutch Lock and have the transmission 7. Close and secure the engine cover.
disengage while depressing the service brake.
Quickly squeeze and release the trigger twice to 8. Remove the Do Not Operate Tags from both the
activate the Clutch Lock and keep transmission ignition key switch and the steering wheel.
engaged while depressing the service brake.
Note: Check the controls of the auxiliary attachments.
4.3.6 Windshield Wiper Assembly
See the appropriate Operation & Safety Manual for an Refer to Section 9.9, “Window Wiper/Washer Windshield
approved list of attachments and control instructions. Wiper Motor,” for removal and installation information.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

4.3.5 Frame Level, Attachment Tilt,

Auxiliary Hydraulics and Outriggers
(G10-43A) Joysticks

a. Joystick Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Properly disconnect the battery.
4. Remove the knob on the end of the joystick (9).
5. Remove the screws (10) securing the dash panel to
the cab. Remove the dash panel.
6. Remove any hardware securing the joystick to the
cab.
7. Label, disconnect and cap the hydraulic fittings
attached to the joystick.
8. Remove the joystick from the cab.

b. Joystick Installation
1. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
2. Install the bolts securing the joystick to the cab.
3. Install the dash panel to its original position with the
previously used hardware.
4. Install the joystick knob.

G6-42A, G9-43A, G10-43A 4-9

 Cab and Covers
4.3.7 Heater/Air Conditioning System
(if equipped)
a. Heater Assembly Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the park brake and shut the engine
OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Place a suitable container beneath the radiator.
Slowly turn the radiator cap to the first stop, and
allow any pressure to escape. Remove the radiator
cap.
6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain petcock and allow the coolant to drain.
7. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
8. Tighten the radiator drain petcock.
9. Remove the bolts that secure the seat to the cab.
Remove the seat.
12
11
MY0190
10. Remove the bolts securing the front plate (11) to the
seat riser weldment (12).
11. Remove the bolts securing the seat riser weldment
to the cab. Remove the riser weldment.
4-10
12. Loosen the hose clamps, label and disconnect the
heater hoses (13). Cap or plug the hoses to prevent
debris from entering the heater system.
13
MY0200
13. Label and disconnect any electrical connections.
14. Remove the bolts securing the heater assembly to
the cab. Remove the heater assembly.
b. Heater Assembly Installation
1. Position the heater assembly to its original orientation
in the cab. Secure with the previous hardware.
2. Connect the previously labeled electrical
connections.
3. Connect the previously labeled heater hoses to their
appropriate locations.
4. Install the seat riser weldment.
5. Install the front plate to the seat riser weldment.
6. Install the cab seat.
7. Fill the cooling system completely, allowing time for
the coolant to fill the engine block. The cooling
system fluid and capacity is listed in Section 2.4,
“Fluid and Lubricant Capacities.”
8. Properly connect the battery.
Note: When the engine is initially started, run it briefly at
low idle and check the machine for any visual sign of
fluid leakage. STOP the engine immediately if any
leakage is noted, and make any necessary repairs
before continuing.
9. Wait for the engine to cool and check the coolant
level. Add coolant as required to bring the coolant to
the proper level.
10. Close and secure the engine cover.
11. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
G6-42A,G9-43A, G10-43A

4.4 CAB REMOVAL
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners of correct size and grade, and torqued to
their specified value.
Note: To help ensure safety and optimum performance,
replace the cab if it is damaged. Refer to the appropriate
parts manual for ordering information.
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
discovered, replace the cab. Contact the local distributor
with any questions about the suitability or condition of a
cab.
Note: Remove and label cab components as needed
before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts
to the replacement cab after the replacement cab is
securely mounted on the machine.
1. Park the machine on a firm, level surface. Allow
sufficient overhead and side clearance for cab
removal. Level the machine, fully retract the boom,
lower the boom, place the travel select lever in the
(N) NEUTRAL position, engage the park brake and
shut the engine OFF.
2. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead
and side clearance for cab removal.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain petcock and allow the coolant to drain.
6. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
7. Tighten the radiator drain petcock.
8. Disconnect the cab heater hoses. Refer to Section
4.3.7, “Heater/Air Conditioning System (if
equipped).”
G6-42A, G9-43A, G10-43A
Cab and Covers
9. Remove the necessary dash panels to gain access
to the electrical wiring connections. Label and
disconnect the harnesses. Push the harness
connectors through the opening in the cab.
10. Remove the boom joystick from is mounting
position. Refer to Section 4.3.4, “Boom Joystick
Assembly.” Label, disconnect and cap all hydraulic
hoses attached to the boom joystick. Cap all fittings
and openings to keep dirt and debris from entering
the hydraulic system.
11. Remove the frame level and attachment tilt and
auxiliary control joystick. Refer to Section 4.3.5,
“Frame Level, Attachment Tilt, Auxiliary Hydraulics
and Outriggers (G10-43A) Joysticks.” Label,
disconnect and cap all hydraulic hoses attached to
the joystick. Cap all fittings and openings to keep dirt
and debris from entering the hydraulic system.
12. Label, disconnect and cap all hydraulic hoses
attached to the steering orbital valve. Cap all fittings
and openings to keep dirt and debris from entering
the hydraulic system.
13. Label, disconnect and cap all hydraulic hoses
attached to the steering orbital valve. Cap all fittings
and openings to keep dirt and debris from entering
the hydraulic system.
14. Label, disconnect and cap all hydraulic hoses
attached to the service brake valve. Cap all fittings
and openings to keep dirt and debris from entering
the hydraulic system.
15. Push all the hydraulic hoses through the opening in
the cab.
16. Disconnect the throttle cable from the throttle
assembly. Refer to Section 4.3.3, “Throttle Pedal.”
17. Disconnect the engine air filter and hydraulic oil
reservoir breather from their brackets at the top of
the cab. Move the air filter and breather clear from
the cab so they do not become damaged during cab
removal.
18. Remove the fuel tank from the cab. Refer to Section
7.6.2, “Fuel Tank.”
4-11
 Cab and Covers
14 15
16
MY0610
19. Open Cab: Route a sling with a minimum lifting
capacity of 1000 lbs (453 kg) under the inner four
braces (14) and behind the center cross support
above the wind shield or install two lifting eye bolts
(15) in the threaded holes on the roof of the cab
above the B pillars (16).
20. Enclosed Cab: Install two lifting eye bolts (14) in the
threaded holes on the roof of the cab above the B
pillars (16). Route a sling with a minimum lifting
capacity of 1000 lbs (453 kg) through the lifting eye
bolts.
17
MY4170
18 18
21. Remove the two cab side-mount bolts in the cab
(17).
22. Remove the four cab-to-frame bolts, flat washers and
nuts (18).
23. Remove the mirrors and all other cab components
as needed, if not previously removed.
4-12
24. Carefully begin to lift the cab. Stop and check that all
wiring, hydraulic hoses and fasteners are
disconnected or removed.
25. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift
the cab and remove it from the frame. Readjust the
position of the sling as needed to help balance the
cab during removal.
26. When the cab is completely clear of the machine,
carefully lower it to the ground. Block up or support
the cab so that it does not move or fall. Assure that
no personnel enter the cab while it is being removed
from the machine.
27. Inspect the condition of the fittings, clamps,
hydraulic hoses, etc. Replace parts as indicated by
their condition.
28. Inspect and replace other machine parts that are
exposed with the cab removed. Repair or replace as
required.
4.5 CAB INSTALLATION
1. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead
and side clearance for cab installation.
14 15
17
16
MY0610
2. Open Cab: Route a sling with a minimum lifting
capacity of 1000 lbs (453 kg) under the inner four
braces (14) and behind the center cross support
above the wind shield or install two lifting eye bolts
(15) in the threaded holes on the roof of the cab
above the B pillars (16).
3. Enclosed Cab: Install two lifting eye bolts (14) in the
threaded holes on the roof of the cab above the B
pillars (16). Route a sling with a minimum lifting
capacity of 1000 lbs (453 kg) through the lifting eye
bolts.
G6-42A,G9-43A, G10-43A
 Cab and Covers

4. Use a hoist or overhead crane and sling attached to
the cab. Carefully begin to align the cab with the
mounting holes in the frame. Stop and check that
wiring, hydraulic hoses, cables, etc., will not be
pinched or damaged as the cab is positioned.
Readjust the position of the sling as needed to help
balance the cab during installation.
17
MY4170
14. Fill the cooling system completely with coolant,
allowing time for the coolant to fill the engine block.
The cooling system capacity is listed in Section 2.4,
“Fluid and Lubricant Capacities.”
15. Properly connect the battery.
16. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
Note: When the engine is initially started, run it briefly at
low idle and check the machine for any visual sign of
fluid leakage. STOP the engine immediately if any
leakage is noted, and make any necessary repairs
before continuing.
17
17. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
18. Install the mirrors and all other cab components as
needed, if removed.
19. Close and secure the engine cover.
20. Unblock the wheels.
21. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

18 18
5. Install the four cab-to-frame mount bolts, washers and
nuts (18). Torque to 280-305 lb-ft (379-414 Nm).
6. Install the two cab side mount bolts washers and
nuts (17). Torque to 680-720 lb-ft (922-976 Nm).
7. Install the engine air filter and hydraulic oil reservoir
breather to their brackets at the top of the cab.
8. Install the throttle cable to the throttle pedal
assembly. Refer to Section 4.3.3, “Throttle Pedal.”
9. Pull all the hydraulic hoses and electrical wires
through the cab.
10. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
11. Reconnect the previously labeled electrical
connections to their appropriate locations.
12. For machines equipped with the heater option,
reconnect the heater hoses to the cab heater. Refer
to Section 4.3.7, “Heater/Air Conditioning System (if
equipped).”
13. Install the fuel tank to the cab. Refer to Section 7.6.2,
“Fuel Tank.”

G6-42A, G9-43A, G10-43A 4-13

 Cab and Covers

This Page Intentionally Left Blank

4-14 G6-42A,G9-43A, G10-43A

 Section 5
Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-7
5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-11
5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-12
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7 Towing a Disabled machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

G6-42A, G9-43A, G10-43A 5-1

 Axles, Drive Shafts, Wheels and Tires

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.

REAR STEERING
CYLINDER

TRANSMISSION
DROP BOX
REAR AXLE
ASSEMBLY

FRONT STEERING REAR AXLE

REAR DRIVE SHAFT WHEEL HUBS (2)
CYLINDER

FRONT DRIVE SHAFT

FRONT AXLE FRONT AXLE

MY0570
ASSEMBLY WHEEL HUBS (2)

5-2 G6-42A, G9-43A, G10-43A


5.2 GENERAL INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
Note: To help ensure optimum performance, the drive
shaft assemblies are specially balanced as a unit at the
factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the
appropriate parts manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The axles
and drive shafts should be checked and repaired only by
experienced service technicians who are aware of all
safety instructions and particular component features.
Use suitable products to thoroughly clean all
disassembled mechanical parts to help prevent personal
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. Always replace elastic locknuts and any
damaged, worn, cracked, seized or otherwise improper
parts that could affect the safe and proper functioning of
the machine, axles and drive shafts.
G6-42A, G9-43A, G10-43A
Axles, Drive Shafts, Wheels and Tires
5.3 AXLE ASSEMBLIES
5.3.1 Axle Serial Number Plate
The front and rear axle serial number plate is located on
a mounting pad on the front side of the center section of
each axle. Information on the serial number plate is
required in correspondence regarding the axle.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle
components.
5.3.2 Axle Specifications
General axle specifications are found in Section 2.4,
“Fluid and Lubricant Capacities.”
5.3.3 Axle Internal Service
Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and
troubleshooting information) are provided in the following
manuals:
G6-42A - Before S/N 0160000847
• Carraro (front) - CA357152 (JLG P/N 31200236)
• Carraro (rear) - CA357153 (JLG P/N 31200237)
G6-42A - S/N 0160000847 & After
• Dana - MO212S20 (JLG P/N 31200162)
G9-43A & G10-43A
• Dana - MO223S10 (JLG P/N 31200239)
5.3.4 Axle Maintenance
CLEANING: Clean parts with machined or ground
surfaces (such as gears, bearings and shafts) with
emulsion cleaners or petroleum-based cleaners. DO
NOT steam clean internal components and the interior of
the planetary hub and axle housing. Water can cause
corrosion of critical parts. Rust contamination in the
lubricant can cause gear and bearing failure. Remove old
gasket material from all surfaces.
DRYING: Use clean, lintless towels to dry components
after cleaning. DO NOT dry bearings by spinning them
with compressed air; this can damage mating surfaces
due to lack of lubrication. After drying, lightly coat
components with oil or a rust-preventive chemical to help
protect them from corrosion. If storing components for a
prolonged period, wrap them in wax paper.
5-3
 Axles, Drive Shafts, Wheels and Tires
PERIODIC OPERATION REQUIREMENT: Every two
weeks, drive the machine far enough to cause the drive-
train components to make several complete revolutions.
This will help ensure that internal components receive
lubrication to minimize deterioration caused by
environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to
water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
tube (breather), drain the axle and inspect internal parts
for water damage and contamination. Before assembling
and refilling the unit with the specified lubricant(s), clean,
examine and replace damaged parts as necessary.
Note: Use a suitable puller for bearing removal. Clean,
inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or
cone is necessary, replace the cup and cone as a set.
5.3.5 Axle Removal
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a
steam cleaner, seal all openings before steam cleaning.
Note: Clear the work area of all debris, unnecessary
personnel, etc. Allow sufficient space to raise the
machine and to remove the axle.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, straighten all
wheels and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5-4
MY4180
2 1 2
5. If the axle will be disassembled after removal, place
a suitable receptacle under the axle (1) and wheel
hubs drain plugs (2). Remove the drain plugs and
allow the axle oil to drain into the receptacle.
Transfer the used axle oil into a suitable covered
container, and label the container as “Used Oil.”
Dispose of used oil at an approved recycling facility.
Note: Rotate the wheel hubs until the drain plugs are
facing down.
6. Label, disconnect and cap the steering and brake
lines at the axle. Wipe up any spilled oil.
7. Block the front and rear of both tires on the axle that
is not being removed. Ensure that the machine will
remain in place during axle removal before
proceeding.
8. Raise the machine using a suitable jack or hoist.
Place suitable supports under both sides of the
frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
axle removal.
9. Support the axle that is being removed with a suitable
jack, hoist or overhead crane and sling. DO NOT
raise the axle or the machine.
10. Remove both wheel and tire assemblies from the
axle that is being removed. (Refer to Section 5.5.1,
“Removing Wheel and Tire Assembly from
Machine.”)
Note: The wheel and tire assemblies must be re-installed
later with the directional tread pattern “arrows” facing in
the direction of forward travel.
11. Remove the drive shaft assembly. Refer to Section
5.4.3, “Drive Shaft Removal.”
12. On the front axle remove the capscrew and locknuts
securing the lower position cylinder-mount pin to the
front cylinder. Tap the cylinder mount pin out, and
move the cylinder to prevent it from interfering with
axle removal.
13. Remove the bolts and locknuts securing the axle to
the frame.
G6-42A, G9-43A, G10-43A

14. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
5.3.6 Axle Installation
1. Before proceeding, ensure that the machine will
remain in place during axle installation. Block the
front and rear of both tires on the axle that is already
installed on the machine.
2. If applicable, raise the machine using a suitable jack
or hoist. Place suitable supports beneath the frame
and lower the machine onto the supports, allowing
enough room for axle installation. Ensure that the
machine will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and
sling, remove the axle from its support or holding
stand. Balance the axle and prevent it from tipping,
turning or falling while positioning it beneath the
machine. DO NOT raise or otherwise disturb the
machine while installing the axle. Keep the axle
supported and balanced on the jack, hoist or
overhead crane and sling throughout the installation
procedure.
4. Position the axle under the frame, and align the axle
housings with the holes in the frame.
5. Install the four axle bolts and nuts. Tighten and
torque to 340-365 lb-ft (460-495 Nm) on the G6-42A.
Torque bolts to 530-560 lb-ft (718-759 Nm) on the
G9-43A and G10-43A.
6. Move the cylinder into position on the axle cylinder
anchor. Insert a cylinder-mount pin through the
cylinder and cylinder anchor. Secure the 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
5.4.5, “Drive Shaft Installation.”)
9. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transmission.
G6-42A, G9-43A, G10-43A
Axles, Drive Shafts, Wheels and Tires
3
MY0230
4 4
1
10. Tighten the axle oil drain plugs (1), loosen and
remove the axle oil fill plug (3) and sight plugs (4).
(Refer to Section 2.4, “Fluid and Lubricant
Capacities,” for proper oil and capacities.
2
MT0220
11. Rotate wheel hubs 90 degrees so the drain plug
becomes the fill plug (2). Refer to Section 2.4, “Fluid
and Lubricant Capacities,” for proper oil and
capacities.
12. Install the wheel and tire assemblies. Refer to
Section 5.5.2, “Installing Wheel and Tire Assembly
onto Machine.”
13. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
14. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
and lower the machine to the ground.
15. Remove the blocks from the front and rear of both
tires on the other axle.
Note: ALWAYS use new o-rings when servicing the
machine.
16. Install new o-rings into the fittings. Lubricate the
o-rings with clean hydraulic oil.
17. Uncap and connect the steering and brake lines at
their axle fittings.
18. Check the hydraulic reservoir oil level.
19. Properly connect the battery.
5-5
 Axles, Drive Shafts, Wheels and Tires

20. Start the engine. Turn the steering wheel several

times lock to lock, operate the frame tilt function
several times in both directions and check the
function of the brakes. Check for hydraulic leaks,
and tighten or repair as necessary.
Note: The service brake circuit will need bled after axle
installation. Refer to Section 8.7.3, “Brake Test.”
21. Close and secure the engine cover.
22. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

5-6 G6-42A, G9-43A, G10-43A

 Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.4, “Fluid and
Lubricant Capacities.”

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

bearing preload. adding or 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 oil to correct
level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”

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

2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal

traveling. damaged. joints as needed.

2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.

3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.

2. Drive shaft universal joint(s) 2. Repair or replace universal

worn or damaged. joints as needed.

3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as

unbalanced. needed.

G6-42A, G9-43A, G10-43A 5-7

 Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged tighten plugs to 96 lb-ft
axle housings). or missing. (130 Nm).

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or 3. Replace seal and/or joint

missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.

4. Input shaft multi-seal ring 4. Replace o-rings as needed and

damaged or missing and/or tighten plugs to 96 lb-ft
worn or damaged pinion (input) (130 Nm).
shaft sealing surfaces.

5. Axle casing to brake housing 5. Replace o-rings and seals.

and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.

6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews to 288 lb-ft
(390 Nm).

7. Differential and/or axle 7. Replace housing(s) as needed.

housing(s) damaged.

5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 96 lb-ft
(130 Nm).

2. O-ring between hub and 2. Replace o-ring.

housing (planet carrier)
damaged or missing.

3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

41 lb-ft (55 Nm).

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.

3. Piston rod seal worn or 3. Replace piston rod seal.

damaged.

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

5-8 G6-42A, G9-43A, G10-43A


Problem
7. Axle overheating.
8. High steering effort required.
9. Slow steering response.
10. Excessive noise when brakes
are engaged.
11. Brakes will not engage.
12. Brakes will not hold the
machine or braking power
reduced.
G6-42A, G9-43A, G10-43A
Axles, Drive Shafts, Wheels and Tires
Cause
1. Oil level too high.
2. Axle and/or wheel end housings
filled with incorrect oil or oil
contaminated or oil level low.
3. Dragging park brake.
1. Steering (hydraulic) system not
operating properly.
2. Excessive joint housing swivel
bearing preload.
3. Worn or damaged swivel
bearings.
1. Steering (hydraulic) system not
operating properly.
2. Steering cylinder leaking
internally.
1. Brake discs worn.
2. Brake discs damaged.
1. Brake (hydraulic) system not
operating properly.
2. Brake piston o-rings and seals
damaged (leaking).
1. Brake discs worn.
2. Brake (hydraulic) system not
operating properly.
3. Brake piston o-rings and seals
damaged (leaking).
Remedy
1. Fill oil to correct level. Refer to
Section 2.4, “Fluid and
Lubricant Capacities.”
2. Drain axle and fill oil to correct
level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”
3. Adjust park brake cable as
needed.
1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Correct bearing preload by
adding or removing shims as
needed.
3. Replace swivel bearings as
needed.
1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Repair or replace steering
cylinder as needed.
1. Check brake discs for wear.
Refer to Section 5.6, “Brakes.”
2. Replace brake discs.
1. Refer to Section 8.7.3, “Brake
Test.”
2. Replace o-rings and seals.
1. Check brake discs for wear.
Refer to Section 5.6, “Brakes.”
2. Refer to Section 8.7.3, “Brake
Test.”
3. Replace o-rings and seals.
5-9
 Axles, Drive Shafts, Wheels and Tires
5.4 DRIVE SHAFTS
5.4.1 Drive Shaft Inspection and Service
Whenever servicing the machine, conduct a visual
inspection of the drive shafts and cross and bearing
assemblies (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and
down time later.
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
drive shaft in both directions. Look for excessive
looseness, missing parts, cracks or other damage. Worn
or damaged drive shafts and cross and bearing
assemblies may cause an excessive amount of vibration
or noise.
Note: Any bolt removed from the drive shaft assembly
MUST be replaced. Do Not re-torque.
5.4.2 Drive Shaft Maintenance
Refer to Section 2.4, “Fluid and Lubricant Capacities,” for
information regarding the lubrication of the drive shafts.
5.4.3 Drive Shaft Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Block the wheels.
6. The drive shaft assembly is a balanced assembly.
Mark the yoke and axle, transmission and the shaft
and slip yoke so that these components can be
returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
5-10
TO
TRANSMISSION
1 2
TO AXLE
3
MT0351
4
7. Remove the four bolts (1) and two straps (2)
securing the bearing cross to the transmission
output shaft flange.
8. Remove the four bolts (3) and two straps (4)
securing the bearing crosses to the axle.
9. Remove the front drive shaft assembly.
10. Repeat the above procedure on the rear drive shaft.
5.4.4 Drive Shaft Cleaning and Drying
1. Disassemble and clean all parts using an approved
cleaning fluid. Allow to dry.
2. Remove any burrs or rough spots from all machined
surfaces. Re-clean and dry as required.
5.4.5 Drive Shaft Installation
1. Raise the drive shaft assembly into position. The
slip-yoke end of the drive shaft mounts toward the
axle. If reinstalling a drive shaft previously removed,
align the flange yokes according to the alignment
marks made during removal.
2. Apply Loctite® 243™ to all mounting bolts.
3. Install the two straps (1) and four new bolts (2)
securing the bearing crosses to the transmission.
Torque bolts to 55-60 lb-ft (75-81 Nm).
4. Install the two straps (3) and four new bolts (4)
securing the bearing crosses to the axle. Torque
bolts to 55-60 lb-ft (75-81 Nm).
5. Repeat the above procedure on the rear drive shaft.
6. Properly connect the battery.
7. Close and secure the engine cover.
8. Unblock the wheels.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
G6-42A, G9-43A, G10-43A

5.5 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.
JLG recommends a replacement tire to be the same size,
ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using a JLG approved replacement tire, JLG
recommends that replacement tires have the following
characteristics:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than
original.
• Wheel diameter, width and offset dimensions equal
to the original.
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc.,
without written factory recommendations, may result in
unsafe condition regarding stability.
Foam filled tires have a positive effect on the weight,
stability and handling characteristics of the machine,
especially under load. JLG does not recommend the use
of hydrofill as a tire-fill substance because of possible
environmental impact.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this
produces a left or right tire and wheel assembly.
G6-42A, G9-43A, G10-43A
Axles, Drive Shafts, Wheels and Tires
5
MY4190
The wheel and tire assemblies must be installed with the
directional tread pattern “arrows” (5) facing in the
direction of forward travel.
5.5.1 Removing Wheel and Tire Assembly
from Machine
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
2. Place an Do Not Operate Tag on both the ignition
key switch and steering wheel, stating that the
machine should not be operated.
3. Loosen but DO NOT remove the lug nuts on the
wheel and tire assembly to be removed.
4. Place a suitable jack under the axle pad closest to
the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
sufficient room to lower the machine onto the
support and to remove the wheel and tire assembly.
5. Lower the machine onto the support.
6. Remove lug nuts and lug washers in an alternating
pattern.
7. Remove the wheel and tire assembly from the
machine.
5-11
 Axles, Drive Shafts, Wheels and Tires
5.5.2 Installing Wheel and Tire Assembly
onto Machine
Note: The wheel and tire assemblies must be installed
with the directional tread pattern “arrows” facing in the
direction of forward travel.
TREAD “ARROWS” MUST
POINT FORWARD
INSTALL TIRES ONTO
WHEELS TO ROTATE IN
PROPER DIRECTION
MAH0460
1. Position wheel onto studs on wheel end of axle.
2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
1 8
6 3
9 10
4 5
7 2 MY4200
4. Tighten lug nuts in an alternating pattern as
indicated in figure. Torque to 350-400 lb-ft
(475-542 Nm).
5. Remove machine from supports.
5-12
5.6 BRAKES
Check the brake disks for wear every 1,000 hours of
operation or yearly.
For more information on brake disk inspection, refer to
the appropriate axle repair manual.
5.7 TOWING A DISABLED MACHINE
Towing a disabled machine should only be attempted as
a last resort, after exhausting all other options. Make
every effort to repair the machine, and move it under its
own power, before using the emergency towing
procedures outlined below.
Note: Block the wheels of the machine BEFORE
attempting to release the park brake. Once the park
brake is released the machine’s park brake AND
service brakes are inoperable.
5.7.1 Manually Releasing the Park Brake
a. Before S/N 0160000847
MY0260
1. On one side of the axle, remove the three plugs from
the differential housing.
2. Tighten each release screw (6) revealed by the
plugs, lightly until it just makes contact with the guide
pin.
3. Carefully tighten each release screw a 1/4 turn at a
time in sequence until all three have been turned
one full turn 360°.
Note: Larger turns could cause components to bind and
cause brake failure. DO NOT over tighten.
4. Repeat steps 1 thru 3 for the other side of the
differential.
G6-42A, G9-43A, G10-43A

Note: After the machine has been towed to a secure
location, reactivate the parking brake. Carefully follow
the procedures from start to finish. Consult your local
JLG distributor or the JLG Service Department if you are
unsure about any part of the procedure, or for specific
instructions concerning your particular situation.
b. S/N 0160000847 & After
7 7
7
7 5. After repairs to the machine have been made, start
MZ1020
1. Loosen the nuts of the screws (7) for the manual
release of the braking units. Draw the nuts back
approximately 0.25 in (6 mm).
2. Tighten the screws until they are gently seated on
the driving plate
3. Carefully tighten each release screw a 1/4 turn at a
time in sequence until all have been turned on full
turn 360°.
4. Repeat steps 1 thru 3 for the other side of the
differential.
Note: After the machine has been towed to a secure
location, reactivate the parking brake. Carefully follow
the procedures from start to finish. Consult your local
JLG distributor or the JLG Service Department if you are
unsure about any part of the procedure, or for specific
instructions concerning your particular situation.
G6-42A, G9-43A, G10-43A
Axles, Drive Shafts, Wheels and Tires
5.7.2 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.
a. Before S/N 0160000847
1. Loosen each release screw, only 1/4 turn at a time,
in sequence, until each screw has lost contact with
the guide pin.
2. Back out each screw until it bottoms out against the
stop.
3. Install the previously used plugs over each release
screw.
4. Repeat steps 1 thru 3 for the other side of the
differential.
the machine and check the park brake and service
brakes for proper function.
b. S/N 0160000847 & After
1. Loosen each release screw, only 1/4 turn at a time,
in sequence, until each screw has lost contact with
the guide pin.
2. Remove the screws along with the nuts and seals.
Replace the seals, lubricate the screws with a
silicone-based grease and re-install the screws
along with the nuts.
3. Adjust the nut of the screw heads in relation to the
arm by 1.26 in (32 mm).
4. Repeat steps 1 thru 3 for the other side of the
differential.
5. After repairs to the machine have been made, start
the machine and check the park brake and service
brakes for proper function.
5-13
 Axles, Drive Shafts, Wheels and Tires

This Page Intentionally Left Blank

5-14 G6-42A, G9-43A, G10-43A

 Section 6
Transmission

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . 6-4
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.1 G6-42A - Before S/N 0160040678 G9-43A/G10-43A - Before S/N 0160040675
excluding 0160040468 & 0160040672 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.2 G6-42A - S/N 0160040678 & After G9-43A/G10-43A - S/N 0160040675 & After
including 0160040468 & 0160040672. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6 Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.6.1 Thermal Bypass Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.6.2 Thermal Bypass Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.7.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

G6-42A, G9-43A, G10-43A 6-1

 Transmission

6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.

6.1.1 General Overview

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

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

FLEX PLATE
ASSEMBLY

SHIFT
SOLENOIDS

TRANSMISSION
FILTER

TRANSMISSION
BREATHER

TRANSFER CASE
TRANSMISSION
BREATHER
FILL TUBE AND
DIPSTICK
OIL FILL
PLUG

OIL LEVEL
SIGHT GAUGE
MAGNETIC
DRAIN PLUG
OIL DRAIN
MY0270 PLUG

6-2 G6-42A, G9-43A, G10-43A

 Transmission

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

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

TRANSFER CASE TRANSMISSION

BREATHER FILL TUBE AND
DIPSTICK

OIL DRAIN OIL FILL

PLUG PLUG

TRANSMISSION
FILTER

SHIFT
SOLENOIDS

SHIFT
SOLENOIDS

OAL0010
OIL DRAIN
PLUG

G6-42A, G9-43A, G10-43A 6-3

 Transmission
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
6.2 TRANSMISSION SERIAL NUMBER
The transmission serial number plate is located on the
front of the transmission case below the converter
housing. Information specified on the serial number plate
includes the transmission model number, the
transmission serial number and other data.
6.3 TRANSMISSION SPECIFICATIONS
AND MAINTENANCE INFORMATION
For transmission, oil specifications and maintenance
information, refer to Section 2, “General Information and
Specifications.”
Detailed transmission service instructions are provided in
the following publications:
Parts Manual - G6-42A (P/N 91474001)
- G9-43A/G10-43A (91514001)
G6-42A - Before S/N 0160040678
G9-43A/G10-43A - Before S/N 0160040675 excluding
0160040468 & 0160040672
Dana Spicer Repair Manual - (P/N 31200163)
G6-42A - S/N 0160040678 & After
G9-43A/G10-43A - S/N 0160040675 & After including
0160040468 & 0160040672
ZF Repair Manual - (P/N 31200241)
6.4 TRANSMISSION REPLACEMENT
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
Note: Cleanliness is of extreme importance. Before
attempting to remove the transmission, thoroughly clean
the exterior of the transmission to help prevent dirt from
entering during the replacement process. Avoid spraying
water or cleaning solution onto or near the transmission
shift solenoids and other electrical components.
6-4
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling with a minimum lifting capacity of
1000 lb (454 kg).
6.4.1 Transmission Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to cool.
4. Remove engine cover to allow easier access to the
transmission.
5. Drain the hydraulic oil reservoir. Refer to Section
8.5.1, “Hydraulic Oil Reservoir Draining.”
6. Disconnect the (+) positive and (-) negative battery
cables and remove the battery.
7. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings, before
proceeding.
DANA TRANSMISSION ZF TRANSMISSION
MY6070
1 2 1 2
8. Place a suitable receptacle under the transmission
drain plug (1). Remove the transmission drain plug,
and allow the transmission oil to drain into the
receptacle. Repeat drain procedure with the drop
box (2).
9. Transfer the used transmission oil into a suitable,
covered container, and label the container as “Used
Oil.” Dispose of used oil at an approved recycling
facility. Clean and reinstall the transmission drain
plug.
10. Remove the transmission-to-axle drive shafts. Refer
to Section 5.4.3, “Drive Shaft Removal.”
11. Remove air cleaner unit and intake tubes.
G6-42A, G9-43A, G10-43A

12. Remove the hydraulic pump. Refer to Section 8.6.1,
“Implement Pump Replacement.”
13. Label and disconnect the transmission temperature
switch connector and shift solenoid wiring harness
connectors.
14. Label, disconnect and cap the transmission oil
cooler inlet and outlet hoses at the transmission. The
transmission oil cooler outlet hose, routed to the
lower radiator fitting, is located on the top of the
transmission. The transmission oil cooler inlet hose,
routed to the upper radiator fitting, is located on top
of the transmission.
15. Remove the access plug from the engine bell
housing. This will allow access to remove the bolts
holding the flex plate to the engine flywheel.
16. Turn the engine over slowly by hand and align each
of the flex plate bolts to be accessed. Remove them
one at a time.
17. Wipe up any spilled hydraulic and transmission oil.
18. Connect a lifting strap or chain to the lifting eye at
the top of the transmission, and to a suitable hoist or
overhead crane. Operate the hoist or crane to
remove slack from the chain, but DO NOT raise the
transmission at this time.
19. Place blocks under rear of engine for support
BEFORE transmission mounts are removed.
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the bolts and washers holding the
transmission to the engine.
23. Remove the capscrews and lockwashers securing
each rear transmission mount to the transmission.
24. Remove the transmission mounts from the machine.
25. Inspect the rubber mounts. Replace the mounts if
damaged.
26. Carefully remove the transmission from the
machine. Avoid causing damage to the transmission
or surrounding parts.
27. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
G6-42A, G9-43A, G10-43A
Transmission
28. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
29. Remove the transmission oil filter and dispose of
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
30. If transmission oil is suspect to contamination or
torque converter is damaged, remove the converter
and flex plate from the transmission.
31. Remove the bolt and washers holding the converter
to the flex plate.
6.4.2 Transmission Inspection and Internal
Repair
If replacing the entire transmission, transfer the
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a
new transmission.
6.4.3 Transmission Installation
1. Install both rear transmission mounts on the
transmission. Torque capscrews to 66 lb-ft (89 Nm).
2. Install two guide studs near the top of the bell
housing holes.
3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
4. Align the torque converter, align the transmission
bolt holes with the two studs in the bell housing.
Install the eight bolts and washers and torque to
53 lb-ft (72 Nm). Remove the two alignment studs
and install and torque the last two transmission
mounting bolts.
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite® 242™ to the transmission mount bolts and
torque to 220 lb-ft (298 Nm).
6. Turn the engine over slowly by hand and align each
flex plate bolts to be accessed. Install them one at a
time. Torque to 26-29 lb-ft (35-39 Nm). Replace
access plug.
7. Remove the hoist or overhead crane and sling.
8. Connect the transmission temperature switch
connector and shift solenoid wiring harness
connectors.
9. Secure the wiring harness to the transmission
housing.
6-5
 Transmission
10. Connect the transmission oil cooler inlet and outlet
hoses at the transmission.
11. Install the hydraulic pump. Refer to Section 8.6.1,
“Implement Pump Replacement.”
12. Install the transmission-to-axle drive shafts. Refer to
Section 5.4.5, “Drive Shaft Installation.”
13. Install the air cleaner and tubing.
14. Clean the transmission oil filter mounting surface.
15. Apply a thin film of clean oil to the new transmission
filter gasket. Install the new filter and torque to
20-25 lb-ft (27-34 Nm).
16. Transmission oil may be added through the dipstick
tube. Remove the dipstick and add clean, fresh oil.
Refer to Section 2.4, “Fluid and Lubricant
Capacities.” Check the oil level by taking intermittent
dipstick readings as outlined in the appropriate
Operation & Safety Manual. DO NOT overfill.
Reinstall the dipstick when finished.
17. Transmission transfer case oil may be added
through the fill plug. Refer to Section 2.4, “Fluid and
Lubricant Capacities,” for proper capacities. Reinstall
the fill plug and tighten.
18. Install the engine cover.
19. Install the battery. Connect the (+) positive and (-)
negative battery cables.
20. Close and secure the engine cover.
21. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
6-6
6.4.4 After Transmission Service or
Replacement
In general:
1. Check the transmission oil level and add oil as
required.
2. Drain and flush the entire transmission cooling
system.
3. Thoroughly clean transmission filter screens and
cases, and replace transmission filter elements.
4. Reassemble all components and fill the transmission
with clean, fresh oil through the dipstick tube
opening. Check the level by taking intermittent
dipstick readings as outlined in the appropriate
Operation & Safety Manual. DO NOT overfill.
Reinstall the dipstick when finished.
5. Run the engine for two minutes at idle to help prime the
torque converter and the transmission oil lines.
6. Recheck the level of the fluid in the transmission
with the engine running at idle.
7. Add hydraulic oil as necessary to bring the fluid level
up until it reaches the FULL mark on the dipstick.
Recheck the oil level when it reaches operating
temperature 180-200° F (83-94° C).
8. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
G6-42A, G9-43A, G10-43A

6.5 ENGINE DRIVE PLATE
6.5.1 G6-42A - Before S/N 0160040678
G9-43A/G10-43A - Before
S/N 0160040675 excluding 0160040468
& 0160040672
a. Drive Plate Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and shut the
engine OFF.
Note: In order to remove the engine drive plates, the
engine and transmission must be separated.
2. Refer to Section 6.4.1, “Transmission Removal,” or
Section 7.9.1, “Engine Removal.”
1
MZ0580
3. Remove the eight bolts holding the drive plates (1) to
the flywheel.
4. With the drive plates and torque converter removed,
loosen and remove the six bolts and six lock
washers holding the three drive plates to the torque
converter.
5. Replace all three drive plates if damaged.
b. Drive Plate Installation
1. Install the three new drive plates on the torque
converter and torque the six bolts with lock washers
to 26-29 lb-ft (35-39 Nm).
2. Mount the drive plate/converter assembly to the
transmission.
3. Refer to Section 6.4.3, “Transmission Installation,”or
Section 7.9.2, “Engine Installation.” for the remainder
of the installation.
G6-42A, G9-43A, G10-43A
Transmission
6.5.2 G6-42A - S/N 0160040678 & After
G9-43A/G10-43A - S/N 0160040675 &
After including 0160040468 &
0160040672
a. Drive Plate Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
Note: In order to remove the engine drive plates, the
engine and transmission must be separated.
2. Refer to Section 6.4.1, “Transmission Removal,” or
Section 7.9.1, “Engine Removal.”
3 4
2
3. Remove the four bolts holding the drive plates to the
flywheel.
4. With the drive plates and torque converter removed,
loosen and remove the four bolts (2) and eight lock
washers holding the two drive plates (3) to the
torque converter (4).
5. Replace both drive plates if damaged.
b. Drive Plate Installation
1. Install the two new drive plates on the torque
converter and install the four bolts with lock washers.
2. Mount the drive plates/converter assembly to the
transmission.
Refer to Section 6.4.3, “Transmission Installation,” or
Section 7.9.2, “Engine Installation.” for the remainder of
the installation.
6-7
 Transmission

6.6 TRANSMISSION COOLER THERMAL

BYPASS VALVE
6 5

6.6.1 Thermal Bypass Valve Removal 4

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel. 3
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect and remove the battery.

MAL1410

NOTE: ITEMS REMOVED FROM ILLUSTRATION FOR CLARITY

7. Remove the transmission oil filter (3) and dispose of

properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
1 8. Place a suitable container beneath the transmission
2 cooler fittings on the hydraulic cooler. Transfer any
MY0980
transmission oil into a properly labeled container.
5. Place a suitable container under the transmission Dispose of properly.
drain plug (1). Remove the transmission drain plug, 9. Label, disconnect and cap both transmission cooler
and allow the transmission oil to drain into the hoses at the radiator. Cap all fittings and openings to
receptacle. Repeat drain procedure with the drop prevent dirt and debris from entering.
box (2). 10. Label, disconnect and cap the hoses (4) at the
6. Transfer the used transmission oil into a suitable, thermal bypass valve (5). Cap all fittings and
covered container, and label the container as “Used openings to prevent dirt and debris from entering.
Oil.” Dispose of used oil at an approved recycling 11. Loosen and remove the two bolts (6) securing the
facility. Clean and reinstall the transmission and drop thermal bypass valve.
box drain plugs.
12. Remove the thermal bypass valve.

6-8 G6-42A, G9-43A, G10-43A

 Transmission

6.6.2 Thermal Bypass Valve Installation

1. Place the new thermal bypass valve (5) in the
engine compartment and secure using the
previously used bolts (6).
2. Uncap and connect the previously labeled hydraulic
oil cooler hoses (4) to the thermal bypass valve.
3. Uncap and connect the previously labeled
transmission oil cooler hoses to the transmission oil
cooler.
4. Clean the transmission oil filter mounting surface.
5. Apply a thin film of clean hydraulic oil to the new
transmission filter gasket. Install the new filter and
torque to 20-25 lb-ft (27-34 Nm).
6. Transmission oil may be added through the dipstick
tube. Remove the dipstick and add transmission oil.
Check the oil level by taking intermittent dipstick
readings as outlined in the appropriate Operation &
Maintenance Manual. DO NOT overfill. Reinstall the
dipstick when finished.
7. Remove drop box fill/level plug and fill with
transmission fluid. Reinstall plug.
8. Install and properly connect the battery.
9. Run the engine for two minutes at idle.
10. Recheck the level of the fluid in the transmission
with the engine running at idle.
11. Add transmission oil as necessary to bring the fluid
level up until it reaches the FULL mark on the
dipstick. Recheck the oil level when it reaches
operating temperature 180-200° F (83-94° C).
12. Recheck all drain plugs, lines, connections, etc., for
leaks and tighten where necessary.
13. Close and secure the engine cover.
14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

G6-42A, G9-43A, G10-43A 6-9

 Transmission

6.7 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that may occur during
operation of the transmission.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
The transmission should be checked, serviced and
repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.

6.7.1 Transmission Troubleshooting

Problem Cause Remedy

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission oil to correct
or will not shift properly. level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”

2. Transmission control lever not 2. Refer to Section 9.5, “Electrical

functioning properly and/or a System Schematics.”
fault in the wiring
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.

3. Transmission valve body 3. Refer to Section 9.5, “Electrical

solenoids not functioning System Schematics.”
properly.

4. Pilot-operated shift valves not 4. Clean the valve spool and

operating properly. housing. Replace return spring
as needed.

5. Pump output pressure low. 5. Refer to Section 6.7.1,

“Transmission Troubleshooting,”
Problem 2. “Low or no pump
flow or pressure.”

6. Clutch piston o-rings damaged. 6. Replace o-rings.

7. Clutch discs worn or damaged. 7. Replace clutch discs.

8. Coupling shafts or gear teeth 8. Replace couplings.

damaged.

6-10 G6-42A, G9-43A, G10-43A

 Transmission

Problem Cause Remedy

2. Low or no pump flow or 1. Low oil level. 1. Fill transmission oil to correct
pressure. level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”

2. Transmission filled with incorrect 2. Drain transmission and fill oil to

oil, or oil contaminated. correct level. (Refer to Section
2.4, “Fluid and Lubricant
Capacities.”)

3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.

4. Central shaft damaged. 4. Replace central shaft.

5. Pump worn or damaged. 5. Repair or replace pump

assembly.

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission oil to correct
level. Refer to Section 2.4,
“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 4. Clean the valve spool and

open. 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

converter stall. specifications. Refer to Engine
Service Manual.

3. Pump output pressure is low. 3. Refer to Section 6.7.1,

“Transmission Troubleshooting,”
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 Section 6.7.1,

“Transmission Troubleshooting,”
Problem 5. “Transmission
overheating (oil above 248° F
(120° C)).”

G6-42A, G9-43A, G10-43A 6-11

 Transmission

Problem Cause Remedy

5. Transmission overheating 1. Low oil level. 1. Fill transmission oil to correct
(oil above 248° F (120° C)). level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”

2. Clogged radiator. 2. Remove debris from the

radiator.

3. Transmission filled with incorrect 3. Drain transmission and fill oil to

oil, or oil contaminated. correct level. Refer to Section
2.4, “Fluid and Lubricant
Capacities.”

4. Excessive “roading.” 4. Stop and idle the engine.

5. Restriction in oil cooler hoses. 5. Replace cooler hoses.

6. Pump worn or damaged. 6. Repair or replace pump

assembly.

7. Engine thermostat stuck. 7. Replace engine thermostat.

Refer to Section 7.4.2,
“Thermostat Replacement.”

8. Thermal by-pass valve 8. Replace thermal by-pass valve.

damaged or flow restricted. Refer to Section 6.6,
“Transmission Cooler Thermal
Bypass Valve.”

6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill transmission oil to correct
from transmission. level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”

2. Transmission filled with incorrect 2. Drain transmission and fill oil to

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

3. Incorrect clutch engagement. 3. Refer to Section 9.11.3,

“Transmission Solenoid Valves.”

4. Internal damage. 4. Repair or replace parts as

needed.

5. Broken drive plate. 5. Replace drive plates. Refer to

Section 6.5, “Engine Drive
Plate.”

6. Loose drive plate mounting 6. Tighten capscrews.

capscrews.

6-12 G6-42A, G9-43A, G10-43A


Problem
7. Oil leaking from transmission.
G6-42A, G9-43A, G10-43A
Cause
1. Oil leaking from vent (high oil
level).
2. Drain plug loose and/or o-rings
damaged or missing.
3. Hose fittings loose.
4. Oil leaking at valve bodies
(possible valve body gaskets
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose.
6. Oil leaking at pump (possible
pump-to-housing o-rings
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell
(possible converter leak and/or
input shaft seal damage).
8. Oil leaking at output shaft
(output shaft seal damaged).
9. Housing damaged.
Transmission
Remedy
1. Remove drain plug and drain oil
as needed, until oil is at correct
level. Refer to Section 2.4,
“Fluid and Lubricant Capacities.”
Replace o-rings as needed and
tighten plugs to 96 lb-ft (130 Nm).
2. Replace o-rings as needed and
tighten plug to 26 lb-ft (35 Nm).
3. Tighten fittings.
4. Replace gaskets and/or tighten
capscrews to 7 lb-ft (9,5 Nm).
5. Tighten capscrews to 34 lb-ft
(46 Nm).
6. Replace o-rings and/or tighten
capscrews to 85 lb-ft (115 Nm).
7. Replace converter and/or input
shaft seal.
8. Replace output shaft seal.
9. Replace housing as needed.
6-13
 Transmission

This Page Intentionally Left Blank

6-14 G6-42A, G9-43A, G10-43A

 Section 7
Engine

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.3.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.3.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.3.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7-6
7.3.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.3 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.8.1 Air Cleaner Assembly Removal (John Deere & Perkins) . . . . . . . . . . . . . 7-13
7.8.2 Air Cleaner Assembly Installation (John Deere & Perkins) . . . . . . . . . . . . 7-13
7.8.3 Air Cleaner Assembly Removal (Cummins) . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.8.4 Air Cleaner Assembly Installation (Cummins). . . . . . . . . . . . . . . . . . . . . . 7-14
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

G6-42A, G9-43A, G10-43A 7-1

 Engine

7.1 INTRODUCTION - JOHN DEERE 7.1.2 Engine Serial Number

The John Deere 4045D150 & 4045TF270 serial number
7.1.1 Disclaimer and Scope Is stamped on a plate which is secured to the engine
block, near the fuel injector pump. Information contained
These instructions are written for worldwide use. In
in the serial number is required in correspondence with
territories where legal requirements govern engine smoke
the engine manufacturer.
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that
7.1.3 Specifications and Maintenance
after maintenance, service and repair of the engine,
Information
engine operation does not violate local regulations.
For engine, coolant and oil specifications, and
Note: These instructions cover only the routine
maintenance information, refer to Section 2, “General
maintenance, removal, installation and troubleshooting
Information and Specifications.”
of the engine. Refer to the local Engine Distributor and
the applicable Engine Service Manual for assistance Detailed John Deere engine service instructions
with comprehensive engine diagnosis, repair and (covering disassembly, inspection, internal repair,
component replacement. A gradual running-in (break-in) assembly, adjustment and troubleshooting information)
of a new engine is not necessary. Full load can be are provided in the appropriate John Deere engine
applied to a new engine as soon as the engine is put into service manual.
service and the coolant temperature is at least 140° F For engine electrical related issues, refer to the John
(60° C). Extended light-load operation during the early Deere Engine Troubleshooting Manual (P/N 31200371).
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.

7-2 G6-42A, G9-43A, G10-43A

 Engine

7.1.4 Component Terminology

To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.

THERMOSTAT

TURBOCHARGER

FUEL INJECTOR
PUMP

ENGINE CONTROL
MODULE (ECM)
MY1011

ALTERNATOR

STARTER

IN LINE FUEL
FILTER

OIL FILTER

MY4500

G6-42A, G9-43A, G10-43A 7-3

 Engine

7.2 INTRODUCTION - PERKINS 7.2.2 Engine Serial Number

The Perkins 1104C-44T serial number Is stamped on top
7.2.1 Disclaimer and Scope of the engine. Information contained in the serial number
is required in correspondence with the engine
These instructions are written for worldwide use. In
manufacturer.
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
7.2.3 Specifications and Maintenance
data and dimensions provided herein in such a way that
Information
after maintenance, service and repair of the engine,
engine operation does not violate local regulations. For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General
Note: These instructions cover only the routine
Information and Specifications.”
maintenance, removal, installation and troubleshooting
of the engine. Refer to the local Engine Distributor and Detailed Perkins engine service instructions (covering
the applicable Engine Service Manual for assistance disassembly, inspection, internal repair, assembly,
with comprehensive engine diagnosis, repair and adjustment and troubleshooting information) are
component replacement. A gradual running-in (break-in) provided in the appropriate Perkins engine service
of a new engine is not necessary. Full load can be manual.
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.

7-4 G6-42A, G9-43A, G10-43A

 Engine

7.2.4 Component Terminology

To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.

THERMOSTAT
ENGINE CONTROL
MODULE (ECM)

FUEL FILTER

FUEL INJECTOR
PUMP

STARTER

OIL FILTER

MAL0260

ALTERNATOR

TURBOCHARGER

MAL0270

G6-42A, G9-43A, G10-43A 7-5

 Engine

7.3 INTRODUCTION - CUMMINS 7.3.2 Engine Serial Number

The Cummins serial number Is stamped on top of the
7.3.1 Disclaimer and Scope engine. Information contained in the serial number is
required in correspondence with the engine
These instructions are written for worldwide use. In
manufacturer.
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
7.3.3 Specifications and Maintenance
data and dimensions provided herein in such a way that
Information
after maintenance, service and repair of the engine,
engine operation does not violate local regulations. For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General
Note: These instructions cover only the routine
Information and Specifications.”
maintenance, removal, installation and troubleshooting
of the engine. Refer to the local Engine Distributor and Detailed Cummins engine service instructions (covering
the applicable Engine Service Manual for assistance disassembly, inspection, internal repair, assembly,
with comprehensive engine diagnosis, repair and adjustment and troubleshooting information) are
component replacement. A gradual running-in (break-in) provided in the appropriate Cummins engine service
of a new engine is not necessary. Full load can be manual.
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.

7-6 G6-42A, G9-43A, G10-43A

 Engine

7.3.4 Component Terminology

To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.

FUEL FILTER
(SECONDARY)

FUEL INJECTOR
PUMP

OIL FILTER
ENGINE CONTROL
MODULE (ECM)

FUEL FILTER
(PRIMARY)

TURBOCHARGER
THERMOSTAT

ALTERNATOR

STARTER

MY5530

G6-42A, G9-43A, G10-43A 7-7

 Engine
7.4 ENGINE COOLING SYSTEM
7.4.1 Radiator Pressure Cap
John Deere/Perkins: For a 210° F (99° C) system, use a
13 psi (90 kPa) radiator cap. An incorrect or
malfunctioning cap can result in the loss of coolant and a
hot-running engine.
Cummins: For a 210° F (99° C) system, use a 16 psi
(110 kPa) radiator cap. An incorrect or malfunctioning
cap can result in the loss of coolant and a hot-running
engine.
7.4.2 Thermostat Replacement
Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If the engine seems to take a long time to warm
up, the thermostat may be stuck in the open
position and requires replacement.
• If the engine runs hot, check the temperature of
the upper radiator hose.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a
leaking cylinder head gasket, cracked cylinder
head or block, and/or other internal engine
damage.
7-8
a. Thermostat Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug and slowly remove to allow the coolant to
drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
TYPICAL
THERMOSTAT
1
2
2
3 MY4520
7. Disconnect the engine water temperature sender (1)
if connected to the thermostat housing.
8. Remove the two capscrews (2) securing the
thermostat housing (3) to the engine.
9. Remove the thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let
any debris into the thermostat opening.
Note: ALWAYS use the correct thermostat and install a
new gasket. NEVER operate the engine without a
thermostat, or engine damage will result.
G6-42A, G9-43A, G10-43A

b. Thermostat Installation
1. Install the engine thermostat, thermostat gasket and
thermostat housing. Secure with the two capscrews
and torque as required.
2. Connect the engine water temperature sender if
connected to the thermostat housing.
3. Properly connect the battery.
4. Open the radiator cap, and fill the radiator
completely with coolant. Replace and tighten the
radiator cap. Add coolant to the overflow bottle until
the bottle is 1/4 to 1/2 full. This overfilling will
compensate for any air trapped in the cooling
system.
5. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
7.4.3 Radiator/Oil Cooler 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.
• If the engine runs hot, check the temperature of
the upper radiator hose.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
a. Radiator/Oil Cooler Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
G6-42A, G9-43A, G10-43A
Engine
5. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
6. Place a suitable container beneath the radiator
drain.
7. Place a funnel at the base of the radiator to channel
the drained coolant into a container. Loosen the
drain cock and slowly remove to allow the coolant to
drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
replaced. Tighten the radiator drain cock.
8. If equipped, label, disconnect and cap the hoses
attached to the coolant recovery tank. Remove the
coolant recovery tank.
CUMMINS RADIATOR ASSSEMBLY
4 6
7
5
5
4
6
7
MY4530
9. Loosen the clamps on the hoses/tubes (4) attached
to the intercooler. Work the hoses off the intercooler.
Position the hoses out of the way to allow radiator
removal, or remove the hoses from the engine.
Inspect the hoses, and replace if necessary.
10. Loosen the clamps on the hoses (5) attached to the
radiator. Work the hoses off the radiator. Position the
hoses out of the way to allow radiator removal, or
remove the hoses/tubes from the engine. Inspect the
hoses, and replace if necessary.
11. Loosen and remove the hoses (6) attached to the oil
cooler. Plug and/or cap the hoses to prevent dirt and
debris from entering the hydraulic system. Position
the hoses out of the way to allow radiator removal, or
remove the hoses from the engine. Inspect the
hoses, and replace if necessary.
7-9
 Engine
12. Loosen and remove the hoses (7) attached to the
transmission cooler. Plug and/or cap the hoses to
prevent dirt and debris from entering the
transmission system. Position the hoses out of the
way to allow radiator removal, or remove the hoses
from the engine. Inspect the hoses, and replace if
necessary.
13. Remove the radiator fan guard.
14. Remove the nuts and washers the radiator fan
shroud and pull the shroud back over the fan.
15. Remove the nuts and washers from the radiator and
oil cooler mounts.
16. Carefully lift the radiator and oil cooler out of the
engine compartment.
Note: If more clearance is needed to remove the
radiator, the engine fan may be removed for easier
access.
b. Radiator/Oil Cooler Installation
1. Install the isolator mounts to the bottom of the
radiator and oil cooler. Place the radiator and oil
cooler in the engine compartment at their original
orientations. Secure with the previously used
hardware.
Note: Be sure there is adequate clearance between the
radiator and the engine fan.
2. If necessary, install the engine fan.
3. Install the radiator fan shroud.
4. Uncap and connect the previously labeled hoses to
the radiator, oil cooler and/or transmission cooler.
5. Connect both intercooler hoses.
6. If equipped, install the coolant recovery tank. Uncap
and connect the previously removed hose.
7. Open the radiator cap and fill the radiator completely
with coolant. Replace and tighten the radiator cap.
Refer to Section 2.4, “Fluid and Lubricant
Capacities,” for proper capacities.
8. Properly connect the battery.
9. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary.
10. Close and secure the engine cover.
11. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
7-10
7.5 ENGINE ELECTRICAL SYSTEM
The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9.5,
“Electrical System Schematics.”
7.6 FUEL SYSTEM
7.6.1 Diesel Fuel
Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
Note: Use only diesel fuel designed for diesel engines.
Some heating fuels contain harmful chemicals that can
seriously affect engine efficiency and performance.
Note: Due to the precise tolerances of diesel injection
systems, keep the fuel clean, and free of dirt and water.
Dirt and water in the fuel system can cause severe
damage to both the injection pump and the injection
nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
rating of 40. #2 diesel fuel gives the best economy and
performance under most operating conditions. Fuels
with Cetane numbers higher than 40 may be needed in
high altitudes or extremely low ambient temperatures to
help prevent misfiring and excessive smoking.
Inform the owner/operator of the machine to use #2
diesel fuel, unless ambient temperatures are below 32° F
(0° C). When temperatures are below 32° F (0° C), a
blend of #1 diesel and #2 diesel fuels (known as
“winterized” #2 diesel) may be used.
Note: #1 diesel fuel may be used, however, fuel
economy will be reduced.
Use a low-sulfur content fuel with a cloud point (the
temperature at which wax crystals form in diesel fuel) at
least 10° below the lowest expected fuel temperature.
The viscosity of the fuel must be kept above
1.3 centistrokes to provide adequate fuel system
lubrication.
G6-42A, G9-43A, G10-43A

7.6.2 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 (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for
use on the replacement tank.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area.
6 drain any fuel into a suitable container. Dispose of
5 3. Clean the fuel tank with a high-pressure washer, or
1 contaminated water properly.
2
3 5. Refill the fuel tank with water until it overflows.
4 tank, and allow it to dry completely.
MY4230
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
Engine
9. Remove screws securing fuel sender (5) to the tank.
Remove fuel sender from tank.
10. Remove the bolts on the fuel tank hold down bar
(13).
11. Lift the empty fuel tank from the rear of the cab.
b. Disassembly
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed and
reused on the new replacement tank. Dispose of the old
tank according to local regulations concerning hazardous
materials disposal.
c. Cleaning and Drying
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned.
Note: If a leak is suspected in the fuel tank, contact JLG
Service Department.
To clean the fuel tank:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Remove the fuel or oil tank drain plug, and safely
fuel properly.
flush the tank with hot water for five minutes and
drain the water. Dispose of contaminated water
properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer
to the 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
Completely flush the tank with water. Empty the fuel
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: If a leak is suspected in the fuel tank, contact a
JLG Service Department.
7-11
 Engine

1. Inspect the fuel tank thoroughly for any cracks,
slices, leaks or other damage.
2. With the fuel tank removed from the machine, plug
all openings except one elbow fitting. Install the
elbow fitting, and apply approximately 1-1.5 psi
(7-10 kPa) of air pressure through the elbow. Check
the reservoir for leaks by applying a soap solution to
the exterior and look for bubbles to appear at the
cracked or damaged area.
f. Fuel Tank Installation
1. Set fuel tank in its original orientation at the rear of
the cab.
2. Install the fuel tank hold down bar.
3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. DO NOT overtighten.
4. Connect the previously labeled fuel hoses to their
appropriate locations. Secure with clamps.
5. Connect the fuel gauge harness.
6. Fill the fuel tank according to specifications.Refer to
Section 2.4, “Fluid and Lubricant Capacities.”
7. Check fuel tank for leaks.
8. Properly connect the battery.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
7.6.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operation &
Safety Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7.7 ENGINE EXHAUST SYSTEM
7.7.1 Exhaust System Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open the engine cover. Allow the system fluids and
the exhaust system to cool.
4. Properly disconnect the battery.
9
8
7
5
10
3
4
1
3 6
MY4240
2
5. Remove the muffler heat shield (1)
6. Remove the exhaust heat shield (2).
7. Loosen and remove both clamps (3) securing the
muffler (4) to the frame mounted brackets. Remove
the muffler.
8. Loosen and remove the clamp (5) securing the
exhaust pipe (6) to the frame at the bottom rear
corner of the engine pod. Remove the exhaust pipe.
Note: Removal of the turbo charger heat shields may be
required to access exhaust pipe bolts.
9. Disconnect and remove the three bolts (7) securing
the exhaust pipe/flex pipe (8) to the turbo charger.
Remove the exhaust pipe/flex pipe from under
machine.

7-12 G6-42A, G9-43A, G10-43A

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

17. Install the engine cover and adjust.

18. Install and properly connect the battery. Install and
properly connect the second battery if equipped.
19. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
20. From within the cab, lightly depress the throttle pedal
to full-throttle position. As needed, adjust the limit-
stop screw until it touches the pedal bracket.
Note: Have an assistant stand by with a Class B fire
extinguisher.
21. Start the engine and run to normal operating
temperature then shut off the engine. While the
engine is cooling, check for leaks.
22. Allow the engine to cool. Check the radiator coolant
level and add coolant if required. Replace the
radiator cap.
23. Check for leaks from the engine, main hydraulic
pump and lines, transmission, hydraulic reservoir
and fuel tank. Check the levels of all fluids and
lubricants. Fill as required.
Note: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steering
wheel.
• Keep the transmission in (N) NEUTRAL.
24. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle.
25. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
26. Check for proper operation of all components.
27. Turn the engine OFF.
28. Install the oil pan cover underneath the engine
compartment.
29. Close and secure the engine cover.
30. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

7-16 G6-42A, G9-43A, G10-43A

 Engine

7.10 TROUBLESHOOTING

TROUBLE POSSIBLE CAUSES (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
Key to Possible Causes
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking 62. Turbo lubricating oil seal leak
20. Poor compression closed 63. Induction system leaks
42. Broken relief valve spring

G6-42A, G9-43A, G10-43A 7-17

 Engine

This Page Intentionally Left Blank

7-18 G6-42A, G9-43A, G10-43A

 Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.2 Pressure Specifications - G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.4.3 Pressure Specifications - G9-43A & G10-43A . . . . . . . . . . . . . . . . . . . . . 8-7
8.4.4 Hydraulic Schematic - G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.4.5 Hydraulic Schematic - G9-43A & G10-43A . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.5.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8-17
8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.7.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.7.3 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.7.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.5 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.6 Outrigger Valve (G10-43A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.8 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.8.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.8.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.8.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.8.4 Cylinder Torque Specifications - G6-42A . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.8.5 Cylinder Torque Specifications - G9-43A & G10-43A . . . . . . . . . . . . . . . . 8-29

G6-42A, G9-43A, G10-43A 8-1

 Hydraulic System

8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

OUTRIGGER EXTEND/RETRACT
CONTROL VALVE CYLINDER HYDRAULIC FLUID LIFT/LOWER COMPENSATION
(G10-43A) (INSIDE BOOM) RESERVOIR CYLINDER CYLINDER

TILT
CYLINDER

MY0601

OUTRIGGER FRAME LEVEL MAIN CONTROL PRIORITY

CYLINDER CYLINDER VALVE VALVE
(G10-43A) (BEHIND TIRE)

8-2 G6-42A, G9-43A, G10-43A


8.2 SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
Petroleum-based hydraulic fluids are used in this
machine. The temperature of hydraulic fluid increases
during the operation of various hydraulic functions. A
heated petroleum-based hydraulic fluid presents a fire
hazard, especially when an ignition source is present.
Hydraulic fluid has a flash point that ranges from
300-600° F (150-318° C) and an auto-ignition temperature
of 500-750° F (262-402° C).
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully
examine any deterioration and determine whether any
further use of the component would constitute a hazard.
If in doubt, replace the component.
Operate the hydraulic controls after the engine has
stopped to relieve trapped pressure.
Note: Residual pressure may remain in hydraulic
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (“bleed off”) pressure.
G6-42A, G9-43A, G10-43A
Hydraulic System
Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic
fluid may occur in most cases. After the hissing sound
has ceased, continue removing the part. Any escaping oil
should be directed into an appropriate container. Cap or
otherwise block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that
the engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is
contamination. Keeping the hydraulic fluid as clean as
possible will help avoid downtime and repairs. Sand, grit
and other contaminants can damage the finely machined
surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
inspect the fluid more often. When servicing the system,
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir,
and pump openings until installation occurs. Protect
threads from contamination and damage.
Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
Schematics,” in this manual.
8-3
 Hydraulic System

8.3 HYDRAULIC PRESSURE DIAGNOSIS 8.3.1 Pressure Checks and Adjustments

When diagnosing trouble in the hydraulic system, use the
JLG Parts Department has a kit available to use for
hydraulic testing information in Section 8.4.1, “Hydraulic
hydraulic system maintenance and troubleshooting: the
Pressures.”
JLG Pressure Test Kit. The kit is contained in a durable
polyethylene carrying case for demanding field service In general, follow the steps below whenever conducting
conditions. pressure checks and performing adjustments:
1. Park the machine on a firm, level surface. Engage
Pressure Test Kit the park brake, place the travel select lever in (N)
The hydraulic pressure test kit is used to pressure test the NEUTRAL, level the boom and turn the engine OFF.
various hydraulic components in the hydraulic system. 2. The test port is located at the top right corner of the
The kit includes: main control valve. Install a pressure gauge capable
• Gauges for testing high and low pressure circuits of measuring at least 10% more pressure than that
which the circuit being checked operates under.
• Fittings, couplers and hoses
3. Start the engine. Operate machine functions several
• Durable carrying case 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 the touch.
4. Refer to Section 8.4.1, “Hydraulic Pressures,” for
testing procedures.
5. Fully depress the accelerator pedal if required. Place
and hold the joystick in the position needed to
operate the particular machine function being
checked. Continue holding the joystick in position
until pressure readings are taken.
6. Check the pressure gauge reading. It should read as
specified in the Pressure Readings column of the
charts found in Section 8.4.1, “Hydraulic Pressures.”
MZ1460 If the reading is not as specified, turn the engine
OFF and check other components in the system.
Contact your local authorized distributor for ordering Verify that all related hydraulic components and
information. electrical switches, sensors, solenoids, etc. are
operating correctly.
Part Description Approximate Price and
Number Weight Availability 7. Adjust the relief valve by turning the adjustment
70000652 Hydraulic Pressure Test 10 lbs. Consult Factory
screw clockwise will increase the pressure; turning
Kit the screw counterclockwise will decrease the
70000101 Digital Hydraulic 7 lbs. Consult Factory pressure.
Pressure Test Kit
8. Start the engine and check the pressure again. Turn
the engine OFF. If there is pressure reading in the
gauge, bleed it off then disconnect or remove the
pressure gauge from the machine.

8-4 G6-42A, G9-43A, G10-43A

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

8.4.2 Pressure Specifications - G6-42A

Hydraulic Test Port Procedure Adjustment Pressure Range

Circuit Location
Service/Park TP (A) Connect gauge to TP port, run engine at 1 450 - 550 psi
Brake low idle. (31,0 - 37,9 Bar)
Stand By P1 (B) Connect gauge to P1 port, run engine at 2 550 - 650 psi
low idle. (37,9 - 44,8 Bar)
Steering CF1 (C) Connect gauge to CF1 port, run engine at Consult 2500 - 2700 psi
high idle, bottom out function. Hold over Factory (172,3 - 186,1 Bar)
relief and check pressure.
Boom Lift EF1 (D) Connect gauge to EF1 port, run engine at 3 3800 - 4200 psi
high idle, bottom out function. Hold over (262,0 - 289,5 Bar)
relief and check pressure.
Boom Retract EF1 (D) Connect gauge to EF1 port, run engine at 3 3800 - 4200 psi
high idle, bottom out function. Hold over (262,0 - 289,5 Bar)
relief and check pressure.
Boom Extend EF1 (D) Connect gauge to EF1 port, run engine at 4 3800 ± 50 psi
high idle, bottom out function. Hold over (262,0 ± 3,4 Bar)
relief and check pressure.
Fork Tilt EF1 (D) Connect gauge to EF1 port, run engine at 5 4100 - 4500 psi
high idle, bottom out function. Hold over (282,6 - 310,2 Bar)
relief and check pressure.
Frame Level EF1 (D) Connect gauge to EF1 port, run engine at 3 3800 - 4200 psi
high idle, bottom out function. Hold over (262,0 - 289,5 Bar)
relief and check pressure.

3
A

5 4 D 2

1
MY0320

MY6010

8-6 G6-42A, G9-43A, G10-43A

 Hydraulic System

8.4.3 Pressure Specifications - G9-43A & G10-43A

a. Before S/N 0160040675 excluding 0160040468 & 0160040672

Hydraulic Test Port Function Used to Test Adjustment Pressure Range

Circuit Location
Pilot TP (A) Connect gauge to P1 port, run engine at 1 450 - 550 psi
high idle. No Function (31,0 - 38,0 Bar)
Steering Primary (B) Connect gauge to Primary port, run 2 2350 - 2550 psi
engine at high idle, bottom out steering. (162,0 - 175,8 Bar)
Hold over relief and check pressure.
Service Brake P1 (C) Connect gauge to P1 port, run engine at 3 1090 - 1110 psi
high idle, bottom out steering. Hold over (75,1 - 76,5 Bar)
relief and check pressure.
Boom Lift, Secondary (D) Connect gauge to Secondary port, run 4 3750 - 3850 psi
Extend/Retract, engine at high idle, bottom boom extend. (258,5 - 265,4 Bar)
Frame Level Hold over relief and check pressure.

1
A 2
3
C

MY0320

D
MY6150

G6-42A, G9-43A, G10-43A 8-7

 Hydraulic System

b. S/N 0160040675 & After including 0160040468 & 0160040672

Hydraulic Test Port Function Used to Test Adjustment Pressure Range

Circuit Location
Stand By P1 (A) Connect gauge to P1 port, run engine at 1 250 - 265 psi
high idle. No Function (17,2 - 18,2 Bar)
Priority Load GLS (B) Connect gauge to GLS port, run engine at 2 2400 - 2500 psi
Sense high idle, bottom out steering. Hold over (165,4 - 172,3 Bar)
(Steering) relief and check pressure.
Pilot JS1 (C) Connect gauge to P1 port, run engine at 3 500 - 550 psi
high idle, bottom out steering. Hold over (34,5 - 37,9Bar)
relief and check pressure.
Service Brake BV1 (D) Connect gauge to BV1 port, run engine at 4 1050 - 1150 psi
high idle, bottom out steering. Hold over (72,3 - 79,2 Bar)
relief and check pressure.
Main P1(A) Connect gauge to P1 port, run engine at 5 3800 - 3900 psi
high idle, bottom boom retract. Hold over (262,0 - 269,0 Bar)
relief and check pressure.
Boom Extend GLS(B) Connect gauge to GLS port, run engine at N/A 3800 - 3900 psi
high idle, bottom boom extend. Hold over (262,0 - 269,0 Bar)
relief and check pressure.
Boom Retract GLS(B) Connect gauge to GLS port, run engine at N/A 3800 - 3900 psi
high idle, bottom boom retract. Hold over (262,0 - 269,0 Bar)
relief and check pressure.
Boom Lift GLS(B) Connect gauge to GLS port, run engine at N/A 3800 - 3900 psi
high idle, bottom boom lift. Hold over relief (262,0 - 269,0 Bar)
and check pressure.
Auxiliary GLS(B) Connect gauge to GLS port, run engine at N/A 2633 - 2733 psi
Hydraulics high idle, bottom function. Hold over relief (181,5 - 188,4 Bar)
and check pressure.

4 3 1
5

MY6100

MY6080
B D C

8-8 G6-42A, G9-43A, G10-43A

 8.4.4

PT

B1 B2

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

A1 A2

FRONT STEERING CYLINDER

REAR STEERING CYLINDER
P T
STEER SELECT
VALVE LIFT CYLINDER
a. Before S/N 0160040678

SERVICE BRAKE
VALVE
CROWD CYLINDER
L R
REAR
SERVICE 5000 TILT CYLINDER
PSI
BRAKES JOYSTICK

5000
PSI
P
OUTLET 5000
PSI
T
1 2 3 4
INLET
SWAY CYLINDER
COMPENSATING
CYLINDER

STEERING ORBITROL
OUTLET
.050
Hydraulic Schematic - G6-42A

.040

RED
PURPLE
YELLOW
GREEN
LP T LS

TANK

SERVICE
BRAKE
T 4300
PSI
PARK
BRAKE
4000 3800 4300
PSI PSI PSI

MAIN CONTROL
VALVE
P B B B B

A A A A

LIFT CROWD TILT SWAY

EF1
EF CF CF1 LS JS

2600 PSI HYDRAULIC

COM
OIL
COOLER

RV

T
RETURN
FILTER
PR B8=75
OR CV

25 PSI
.120 PB
500 PSI 10 MICRON
SV BREATHER
PRIORITY/BRAKE
P1 P BV TP VALVE

IMPLEMENT PUMP
1.97 CU.IN./REV

MY0911
Hydraulic System

8-9
8-10
PT

B1 B2

A1 A2

FRONT STEERING CYLINDER

REAR STEERING CYLINDER
P T
STEER SELECT
VALVE LIFT CYLINDER
b. S/N 0160040678 & After

TE TEST
SERVICE BRAKE PORT
VALVE
CROWD CYLINDER
Hydraulic System

L R
REAR
SERVICE JOYSTICK TILT CYLINDER
BRAKES

5000
PSI
P
5000
OUTLET PSI
T
1 2 3 4
INLET SWAY CYLINDER
COMPENSATING

STEERING ORBITROL
CYLINDER

OUTLET
.040 .050

RED
PURPLE
YELLOW
GREEN
LP T LS

TANK

SERVICE
BRAKE
T 4300
PSI
PARK
BRAKE
4000 3800 4300
PSI PSI PSI

MAIN CONTROL
P B B B B VALVE

A A A A

LIFT CROWD TILT SWAY

EF1
EF CF CF1 LS JS

COM 2600 PSI HYDRAULIC

OIL
COOLER

RV1

550 PSI T
RETURN
FILTER
PR B 8=75
OR CV
RV2

25 PSI
.120 PB
450 PSI 10 MICRON
SV BREATHER

P1 P BV TP PRIORITY/BRAKE
VALVE

IMPLEMENT PUMP
1.97 CU.IN./REV

MY6120

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

 AUXILIARY
HYDRAULICS
PORTS

MY0921

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

T 4100 3000
PSI PSI

3800 4100 4100 4100 3000

PSI PSI PSI PSI PSI
SOLENOID VALVE
TILT CYLINDER
MAIN CONTROL
VALVE T
P B B B B B

A A A A A
P
TILT SWAY AUX. 5000
LIFT CROWD PSI

COMPENSATING
AUXILIARY HYDRAULICS CYLINDER

(IF EQUIPPED)

A B

T 4300
PSI

4000 3800 4300

PSI PSI PSI

MAIN CONTROL
VALVE
P B B B B

A A A A

TILT SWAY EF1 EF CF CF1 LS JS

LIFT CROWD

4300
PSI

4300
C2 .03 PSI
600 PSI
HYDRAULIC
OIL
1000 T
COOLER
B
STABILIZER
VALVE A
STABILIZER BLOCK
CYLINDER
500 PSI PB CROWD
RETURN
FILTER
B 8=75

25 PSI
P1 P BV TP PRIORITY/BRAKE
BLOCK MAIN CONTROL
.03 VALVE
C1

REAR AXLE STABILIZER

(IF EQUIPPED)
RESERVOIR
Hydraulic System

8-11
8-12
8.4.5
PT

MY0651
B1 B2

A1 A2
LIFT CYLINDER

CYLINDER
REAR STEERING

CYLINDER
FRONT STEERING
P T STEER SELECT
5000
VALVE PSI

CROWD CYLINDER
Hydraulic System

L R SERVICE
BRAKE VALVE
REAR JOYSTICK TILT CYLINDER
SERVICE 5000
PSI
BRAKES

P
5000
PSI
T
OUTLET 1 2 3 4

SWAY CYLINDER
COMPENSATING
INLET CYLINDER

STEERING ORBITROL
.040 .050

YELLOW
GREEN
RED
BLUE
OUTLET

LP T LS FRONT
LOAD SERVICE
SENSE BRAKES

PARK
BRAKES

TANK

T 4100
PSI
Hydraulic Schematic - G9-43A & G10-43A

3800 4100 4100 4100

PSI PSI PSI PSI

MAIN CONTROL
P B B B B VALVE
HYDRAULIC
OIL A A A A
COOLER
a. Before S/N 0160040675 excluding 0160040468 & 0160040672

LIFT CROWD TILT SWAY

GAUGE PORT
SECONDARY
P1 BV PB

SV

PRIMARY SECONDARY
PRIMARY PORT PORT
GAUGE
PORT

PR CV

.030
JS
LOAD SENSING P P
SIGNAL PORT
500
PSI
TP
1100
2450 PSI RV1
PSI T T

RETURN
T
PUMP FILTER
B 8=75

25 PSI
VALVE BLOCK

REAR SEC
3.19 CU IN/REV
@2750 RPM FRONT SEC
10 MICRON
.75 CU IN/ REV BREATHER
@2750 RPM

100
MESH

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

 AUXILIARY
HYDRAULICS
PORTS

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

MY0661
T 4100 3000
PSI PSI

3800 4100 4100 4100 3000

PSI PSI PSI PSI PSI TILT CYLINDER

MAIN CONTROL
VALVE
P B B B B B

A A A A A 5000
PSI

TILT SWAY AUX.

LIFT CROWD
COMPENSATING
CYLINDER

AUXILIARY HYDRAULICS
(IF EQUIPPED)
TO JOYSTICK

B A .030 .030

P1 BV PB

SV

4100 4100
T PSI
PSI

3800 4100 4100 4100

PR CV
PSI PSI PSI PSI
.030
P JS
4100 P
MAIN CONTROL PSI
P B B B B VALVE
TP
A A A A
T RV
T
LIFT CROWD TILT SWAY
T
PUMP
VALVE BLOCK

C2 .03
HYDRAULIC
OIL
COOLER
1000

STABILIZER
STABILIZER VALVE TILT ON JOYSTICK
CYLINDER BLOCK
(IF EQUIPPED)
RETURN
FILTER
B 8=75

25 PSI
.03
MAIN CONTROL VALVE
C1

RESERVOIR REAR AXLE STABILIZER

(IF EQUIPPED)
Hydraulic System

8-13
8-14
LEFT OUTRIGGER RIGHT OUTRIGGER
CYLINDER CYLINDER

MY3200
5000 5000
PSI PSI

TO HYDRAULIC
OIL COOLER
Hydraulic System

B B

LOD ROD

PUMP TANK

B B B B B
3800
LOU ROU
PSI
TANK
4100
PSI

4100 3000 A A
PSI PSI OUTRIGGER
VALVE
PUMP POWER
4100 3000
PSI PSI BEYOND

4100
LIFT CROWD PSI TILT SWAY AUX

A A A A A

MAIN CONTROL VALVE

(W/ POWER BEYOND)

JOYSTICK

P
LEFT AND RIGHT
T OUTRIGGER JOYSTICK
1 2 3 4
T

YELLOW
GREEN
RED
BLUE
JS 1 2 1 2
LOD LOU ROD ROU

VALVE BLOCK

RETURN
FILTER
25 PSI

B8=75

10 MICRON
BREATHER

100
OUTRIGGERS MESH

(G10-43A)

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

 PT

B1 B2

A1 A2

REAR STEERING
CYLINDER

FRONT STEERING
CYLINDER

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

P T STEER SELECT
VALVE

TILT CYLINDER

L R SERVICE
BRAKE VALVE
REAR JOYSTICK
5000
SERVICE PSI
BRAKES

P CROWD CYLINDER SWAY CYLINDER

LIFT CYLINDER

T COMPENSATING
OUTLET 1 2 3 4
CYLINDER
.040 .050
INLET 5000
5000 PSI
PSI

STEERING ORBITROL
YELLOW
GREEN
RED
BLUE
OUTLET

LP T LS
FRONT
LOAD SERVICE
SENSE BRAKES

PARK
BRAKES

HYDRAULIC
OIL RIGHT,
COOLER
LEFT
DWN UP,
QA EXTD. QA RET.
AUXILIARY
HYDRAULICS
PORTS
SECONDARY P1 BV PB
GAUGE PORT B B B B B
RV2
SV

PRIMARY SECONDARY 3800

PRIMARY PORT PORT PSI
500
GAUGE PSI 4100
PORT PSI

PR CV

.030 TP 4100 3000

P P PSI PSI
LOAD SENSING
SIGNAL PORT 450
PSI
b. S/N 0160040675 & After including 0160040468 & 0160040672

PUMP 4100 3000 TANK

1100 JS PSI PSI
2450 PSI RV1
PSI T T

4100
T PSI
LIFT CROWD TILT SWAY AUX
PUMP
VALVE BLOCK

A A A A A
REAR SEC
3.19 CU IN/REV
@2750 RPM FRONT SEC
.75 CU IN/ REV
@2750 RPM

MAIN CONTROL VALVE

(W/O POWER BEYOND)

RETURN
FILTER

25 PSI
B8=75

10 MICRON
BREATHER

100
MESH

MY6130D
Hydraulic System

8-15
8-16
LEFT OUTRIGGER RIGHT OUTRIGGER
CYLINDER CYLINDER

5000 5000
PSI PSI

OPTIONAL REMOTE
HYDRAULIC QUICK ATTACH
Hydraulic System

TO HYDRAULIC
OIL COOLER
SHT1

B B

LOD ROD

PUMP TANK
QA CYLINDER
B B B B B
C2 C3
3800
LOU ROU
PSI
TANK
4100
PSI AUXILIARY
HYD. PORTS

4100 3000 OUTRIGGER A A

PSI PSI C1 C4
VALVE
PUMP POWER
4100 3000
PSI PSI BEYOND

4100
LIFT CROWDPSI TILT SWAY AUX

P1 P2
A A A A A

MAIN CONTROL VALVE

(W/ POWER BEYOND)

JOYSTICK

P
LEFT AND RIGHT LEFT RIGHT,
T OUTRIGGER JOYSTICK DWN UP,
1 2 3 4
T QA EXTD. QA RET.
AUXILIARY HYD.
P PORTS @ BOOM NOSE

YELLOW
GREEN
RED
BLUE
SEE SHT #1
JS
1 2 1 2
LOD LOU ROD ROU

VALVE BLOCK

RETURN
FILTER

25 PSI
B8=75

10 MICRON
OUTRIGGER OPTION BREATHER

100
MESH

MY6140D

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


8.5 HYDRAULIC RESERVOIR
BEFORE S/N 0160040675 EXCLUDING 0160040468 & 0160040672
1 2. Install a new hydraulic oil filter.
MY1150
S/N 0160040675 & AFTER INCLUDING 0160040468 & 0160040672
1
MY5300
The hydraulic reservoir (1) is located on the frame
between the engine compartment and the cab.
8.5.1 Hydraulic Oil Reservoir Draining
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Open the filler cap on the hydraulic oil reservoir.
Remove the drain plug on the side of the hydraulic
oil reservoir.
6. Transfer the used hydraulic oil into a suitable
covered container, and label as "Used Oil". Dispose
of used oil at an approved recycling facility. Clean
and reinstall the drain plug.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
G6-42A, G9-43A, G10-43A
Hydraulic System
8.5.2 Hydraulic Oil Reservoir Filling
1. Be sure the reservoir is clean and free of all debris.
3. Fill the reservoir according to specifications. Refer to
Section 2.4, “Fluid and Lubricant Capacities.”
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
8.5.3 Hydraulic Oil Reservoir Removal/
Installation
If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before the
reservoir is removed. Always dispose of hydraulic oil
properly.
a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Drain the hydraulic oil reservoir. Refer to Section
8.5.1, “Hydraulic Oil Reservoir Draining.”
6. Label, disconnect and cap all hydraulic hoses
attached to the hydraulic oil reservoir. Cap all fittings
and openings to keep dirt & debris from entering the
hydraulic system.
7. Remove the bolts securing the hydraulic oil reservoir
to the frame.
8. Remove the hydraulic oil reservoir.
b. Disassembly
The hydraulic oil reservoir is a one-piece unit and cannot
be disassembled. The hydraulic oil level sight- glass and
hydraulic oil filler cap can be removed and reused on the
new replacement reservoir. Dispose of the old reservoir
according to local regulations concerning hazardous
materials disposal.
8-17
 Hydraulic System

c. Cleaning and Drying 8.6 IMPLEMENT PUMP

If contaminated hydraulic oil or foreign material is in the
tank, the tank can usually be cleaned.
Note: If a leak is suspected in the hydraulic oil reservoir,
contact JLG Service Department.
To clean the hydraulic oil reservoir:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Remove the hydraulic oil reservoir drain plug, and
safely drain any hydraulic oil into a suitable
container. Dispose of hydraulic oil properly.
3. Clean the hydraulic oil reservoir with a high-pressure
washer, or flush the tank with hot water for five
minutes and drain the water. Dispose of
contaminated water properly.
d. Inspection
Note: If a leak is suspected in the fuel or hydraulic oil tank,
contact JLG Service Department.
1. Inspect the hydraulic oil reservoir thoroughly for any
cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
1-1.5 psi (7-10 kPa) of air pressure through the
elbow. Check the reservoir for leaks by applying a
soap solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
For internal service instructions contact your local JLG
distributor.
8.6.1 Implement Pump Replacement
a. Pump Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Drain the hydraulic reservoir. Refer to Section 8.5.1,
“Hydraulic Oil Reservoir Draining.”
6. Thoroughly clean the pump and surrounding area,
including all hoses and fittings before proceeding.
Note: Cap all hoses as you remove them to prevent
unnecessary fluid spillage.
7. Label, disconnect and cap the hydraulic hoses
attached to the pump.
2

e. Reservoir Installation
1. Place the hydraulic oil reservoir into its original
orientation.
2. Secure the hydraulic oil reservoir to the frame with
the previous mounting hardware.
3. Uncap and connect the previously labeled hydraulic MY1550
hoses to their appropriate locations.
8. Remove the bolts and lockwashers securing the
4. Install the hydraulic fluid level sight-glass using
pump (2) to the transmission. Remove the o-ring
special designed and drilled capscrews and gaskets.
located between the transmission and the pump.
5. Install hydraulic filter bracket and hydraulic filter. Wipe up any hydraulic oil spillage.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluid and
Lubricant Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8. Properly connect the battery.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

8-18 G6-42A, G9-43A, G10-43A


Note: DO NOT disassemble the operating pump. The
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than an authorized
dealer could void the warranty.
b. Pump Installation
1. Place the pump and a new, oiled o-ring into position
on the transmission. Align the pump shaft with the
internal transmission gear, so that the machined
teeth mesh together.
2. Align the bolt holes with the pump mount holes.
3. Apply Loctite® 242™ previously removed bolts
4. Secure the pump to the transmission with the
previously removed bolts and washers. Torque as
required.
5. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
6. Fill the hydraulic reservoir. Refer to Section 8.5.2,
“Hydraulic Oil Reservoir Filling.”
7. Prime the pump by filling the case drain port with fresh,
filtered hydraulic oil from a clean container before
installing the case drain connector and hose.
8. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
9. Properly connect the battery.
10. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
11. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
12. Close and secure the engine cover.
13. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
c. Pump Test
Refer to Section 8.3.1, “Pressure Checks and
Adjustments.”
G6-42A, G9-43A, G10-43A
Hydraulic System
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 (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the main control valve protective cover.
6. Thoroughly clean the main control valve and
surrounding area, including all hoses and fittings,
before proceeding.
7. Drain the hydraulic fluid reservoir. Refer to Section
8.5.1, “Hydraulic Oil Reservoir Draining.”
8. Place a suitable container to catch hydraulic fluid
drainage beneath the frame.
Note: Slowly remove the hydraulic hoses attached to
the main control valve to relieve any possible trapped
pressure in the hydraulic line.
9. Label, disconnect and cap all the hydraulic hoses,
tubes and wires at the main control valve.
10. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
11. Remove the three bolts, washer and nuts (3)
securing the main control valve to the frame.
8-19
 Hydraulic System

b. Main Control Valve Disassembly

G6-42A

G9-43A & G10-43A

MY0340

8-20 G6-42A, G9-43A, G10-43A


1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the
tie rods (4). Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
Note: DO NOT adjust any of the relief valve assemblies!
Tampering with a relief valve will irrevocably alter
pressure in the affected circuit, requiring recalibration or a
new relief valve.
Disassemble each Valve Section
1. Carefully separate the load sense outlet section from the
lift/lower section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining sections, being
careful not to lose the load sense shuttle ball.
4. Remove both end caps from each end of the valve
sections then remove each control spool.
5. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual
valve section if equipped.
6. Keep all parts being removed from individual valve
sections tagged and kept together.
c. Main Control Valve Parts Cleaning
Clean all components with a suitable cleaner, such as
triclorethylene, before continuing. Blow dry.
d. Main Control Valve Parts Inspection
Inspect all parts and internal passageways for wear,
damage, etc. If inner surfaces of any component DO NOT
display an ultra-smooth, polished finish, or are damaged
in any way, replace the damaged part. Often, dirty
hydraulic fluid causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
and/or harm to other parts.
e. Main Control Valve Assembly
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
Assemble each Valve Section
1. Reassemble any check valves, compensator valves,
anti-cavitation valves or shock valves from each
individual valve sections if equipped.
G6-42A, G9-43A, G10-43A
Hydraulic System
2. Install the control spool being careful not to nick or
scratch the valve section bore or the control spool.
3. Install the end caps on each end of the valve
section.
Assemble the Main Control Valve.
1. Place all three tie rods with the washers and nuts
through the end main control valve section.
2. Stand the end main control valve section on end.
3. Install the proper o-rings and load sense shuttle on
the inner face of the end main control valve section.
Align the next valve section over the three tie rods
and slide onto the end main control valve section.
4. Using the proper o-rings and load sense shuttle,
repeat step three for the remaining valve sections
and lastly the inlet end valve section.
5. Install the three washers and nuts on the tie rods.
Torque to 32 lb-ft (43 Nm) for the G6-42A and to
42 lb-ft (57 Nm) for the G9-43A and G10-43A.
f. Main Control Valve Installation
1. Install the main control valve onto the frame, aligning
the bolts with the holes in the end sections of the
main control valve. Slide the main control valve into
position, and tighten the bolts.
2. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a
clean container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and
connect all previously labeled hoses, clamps, etc. to
the main control valve.
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
5. Fill the hydraulic fluid reservoir. Refer to Section
8.5.2, “Hydraulic Oil Reservoir Filling.”
6. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
7. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8-21
 Hydraulic System
9. Install the main control valve protective cover.
10. Close and secure the engine cover.
11. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
g. Main Control Valve Test
Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
8.3.1, “Pressure Checks and Adjustments.”
8.7.2 Service Brake Valve
a. Service Brake Valve Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
1
MY0140
5. Label, disconnect and cap all hose attached to the
service brake valve (1).
6. Remove the service brake pedal. Refer to Section
4.3.2, “Service Brake Pedal.”
7. Remove the four capscrews, four nuts and four
lockwashers mounting the service brake valve to the
service brake bracket.
Note: DO NOT disassemble the service brake valve.
The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
8-22
b. Service Brake Valve Installation
1. Install the service brake valve with the four
capscrews, four lockwashers and four nuts onto the
service brake bracket.
2. Install the service brake pedal. Refer to Section
4.3.2, “Service Brake Pedal.”
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
3. Use new oiled o-rings as required. Uncap and
connect the previously labeled hoses to the service
brake valve.
4. Check the routing of all hoses, and tubing for sharp
bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
5. Properly connect the battery.
6. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic
functions.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
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 Brake Test
Carefully bleed the brake lines as soon as the brake valve
is installed in the machine. Air in the system will not allow
the brakes to apply properly. There are four brake
bleeder locations on the axles. Work with an assistant to
perform this procedure.
1. Place the travel select lever in (N) NEUTRAL,
engage the park brake, and start the engine.
G6-42A, G9-43A, G10-43A

MY0151
2. Remove the plastic cap from the brake bleeder (2).
Attach one end of a length of transparent tubing over
the brake bleeder. Place the other end of this tubing
in a suitable transparent container that is partially
filled with hydraulic oil. The end of the tubing must
be below the oil level in the container.
3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is pressure at the
brakes. Carefully open the bleeder with a 12mm
wrench. Have the assistant depress the brake pedal.
Close the brake bleeder when air bubbles no longer
appear in the oil. Release the brake pedal. Remove
the tubing from the brake bleeder.
4. Repeat Steps 2 and 3 for the remaining brake
bleeders.
5. Install a vacuum pump on the brake reservoir and
remove the remainder of the trapped air from the
brake system.
6. Check brake fluid level and add fluid if necessary.
7. Conduct a pressure and function check of the
service brake. Refer to Section 8.4.1, “Hydraulic
Pressures.”
8.7.4 Steering Orbitrol Valve
3 cool.
MZ0370
The steering orbitrol valve (3) is located at the base of the
steering wheel shaft, concealed by the lower dash cover.
The valve is not serviceable and must be replaced in its
entirety if defective. For detailed information refer to
Section 4.3.1, “Steering Column and Orbitrol Valve.”
G6-42A, G9-43A, G10-43A
Hydraulic System
8.7.5 Steer Select Valve
4
MY0350
The machine can be used in the front-wheel, four-wheel
or crab steering mode. The steer select valve (4) controls
the direction of hydraulic fluid flow to the steering cylinder
mounted on each axle. The steer select valve is attached
to a mounting plate inside the frame near the left front
corner of the cab.
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve.
Refer to Section 9.5, “Electrical System Schematics,” and
Section 9.12, “Display Monitor and Gauges.” The housing
of the steer select valve is not serviceable and must be
replaced if defective.
a. Steer Select Manifold and Valve Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
4. Properly disconnect the battery.
5. Label, disconnect and cap the hydraulic hoses and
the electrical plugs connected to the steering select
valve.
6. Remove the bolts holding the steer select valve to
the mounting plate on the frame.
7. Remove the steer select manifold with the attached
steer select valve from the machine. Wipe up any
hydraulic fluid spillage in, on, near and around the
machine.
8-23
 Hydraulic System
b. Steer Select Manifold and Valve Disassembly,
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard
the four o-rings.
3. Remove the solenoid valves and cartridges from the
steer select housing.
4. Clean all components with a suitable cleaner before
inspection.
5. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an 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
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
capscrews.
c. Steer Select Valve and Manifold Installation
1. Install the steer select valve to the mounting plate
under the left front side of the frame using the two
bolts.
2. Connect all the hydraulic hoses, fittings, solenoid
wire terminal leads, etc., to the steer select valve
3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps.
4. Properly connect the battery.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
machine or operating any hydraulic functions.
8-24
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
d. Steering Test
Refer to Section 8.4.1, “Hydraulic Pressures.”
1. Conduct a pressure check of the steering hydraulic
circuit.
2. Check each steering mode for proper function.
8.7.6 Outrigger Valve (G10-43A)
a. Outrigger Valve Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, raise the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the cover over the outrigger valve.
5
OAL0070
6. Label, disconnect and cap the hydraulic hoses
connected to the outrigger control valve (5). Cap all
G6-42A, G9-43A, G10-43A

fittings to keep dirt & debris from entering the
hydraulic system.
7. Remove the bolts holding the outrigger control valve
to the frame.
b. Outrigger Valve Installation
1. Install the outrigger valve onto the machine frame.
2. Uncap and connect the previously labeled hydraulic
hoses to the outrigger valve.
3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps.
4. Properly connect the battery.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
G6-42A, G9-43A, G10-43A
Hydraulic System
8.8 HYDRAULIC CYLINDERS
8.8.1 General Cylinder Removal
Instructions
1. Remove any attachment from the machine. Park the
machine on a firm level surface and fully retract the
boom. Allow sufficient work space around the
hydraulic cylinder being removed. Support the boom
if the lift/lower cylinder is being removed. Place the
travel select lever in (N) NEUTRAL, engage the park
brake, shut the engine OFF and chock wheels.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Label, disconnect and cap or plug hydraulic hoses in
relation to the cylinder.
5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can
actually support the cylinder.
6. Remove the lock bolt and/or any retaining clips
securing the cylinder pins. Remove the cylinder pins.
7. Remove the cylinder.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
a. General Cylinder Disassembly
MZ0400
1. Clean the cylinder with a suitable cleaner before
disassembly. Remove all dirt, debris and grease
from the cylinder.
2. Clamp the barrel end of the cylinder in a soft-jawed
vise or other acceptable holding equipment if
possible.
8-25
 Hydraulic System
WARNING
Significant pressure may be trapped inside the
cylinder. Exercise caution when removing a
counterbalance valve or a pilot-operated check valve
from a cylinder.
Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube.
3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
Note: DO NOT tamper with or attempt to adjust the
counterbalance valve cartridge. If adjustment or
replacement is necessary, replace the counterbalance
valve with a new part.
4. Extend the rod as required to allow access to the
base of the cylinder.
Note: Protect the finish of the rod at all times. Damage
to the surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head
gland from the tube. A considerable amount of force
will be needed to remove the head gland. Carefully
slide the head gland down along the rod toward the
rod eye, away from the cylinder barrel.
Note: When sliding the rod and piston assembly out of
the barrel, prevent the threaded end of the barrel from
damaging the piston. Keep the rod centered within the
barrel to help prevent binding.
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
8. Remove the set screw from the piston head.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
oil, then heat the part(s) uniformly to break the bond. A
temperature of 300-400° F (149-204° C) will destroy the
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
8-26
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush
prior to reassembly.
9. Remove the piston head from the rod and carefully
slide the head gland off the end of the rod.
10. Remove all seals, back-up rings and o-rings from the
piston head and all seals, back-up rings and o-rings
from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
catalog for ordering information.
b. Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace
with new items from seal kit to ensure proper
cylinder function.
2. Clean all metal parts with an approved cleaning
solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.
Note: If a white powdery residue is present on threads
or parts, it can be removed by using a soft brass wire
brush. Wipe clean with Loctite Cleaner prior to
reassembly.
c. Cylinder Inspection
1. Inspect internal surfaces and all parts for wear,
damage, etc. If the inner surface of the cylinder
barrel does not display a smooth finish, or is scored
or damaged in any way, replace the barrel.
2. Remove light scratches on the piston, head gland,
rod or inner surface of the cylinder barrel with a 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

Note: The extend/retract cylinder has a spacer that
MUST be installed over the rod AFTER the head gland
and BEFORE the piston head.
3. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
Note: Protect the finish on the cylinder rod at all times.
Damage to the surface of the rod can cause seal failure.
4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the
cylinder rod. Loctite® 242™ and install the set screw in
the piston head. Refer to Section 8.8.4, “Cylinder
Torque Specifications - G6-42A” or Section 8.8.5,
“Cylinder Torque Specifications - G9-43A & 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.
5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
6. Inspect for leaks and check level of hydraulic fluid in
reservoir. Add hydraulic fluid if needed. Shut the
engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the engine cover.
8.8.2 Cylinder Pressure Checking
Attach a 5000 psi (345 bar) gauge to the test port on the
P1 port on the priority valve to check the system
pressure.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
individual circuit. Activate the circuit and if pressure is
obtained turn the main relief counter clockwise one half
turn. Re-check the main relief setting and adjust if
necessary.
8.8.3 Steering Cylinders
STEERING CYLINDER

6. Carefully insert the cylinder rod assembly into the

cylinder barrel.
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section
8.8.4, “Cylinder Torque Specifications - G6-42A” or
Section 8.8.5, “Cylinder Torque Specifications - G9-
43A & G10-43A” for torque specifications for the
head gland.
8. If applicable, install new counter balance valve into
block on the cylinder barrel.

e. General Cylinder Installation

AXLE CENTER SECTION
1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into it’s mounting position.
The steer cylinder is attached to each axle center
2. Align cylinder bushing and install pin, lock bolt or housing.The steer cylinder assembly can be found in
retaining clip. Section 5.3, “Axle Assemblies.” The steer cylinder is
3. Connect the hydraulic hoses in relation to the labels covered in the appropriate manufacturer’s axle literature.
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 8-27

 Hydraulic System

8.8.4 Cylinder Torque Specifications - G6-42A

a. Lift/Lower Cylinder

Head Nut Bolt Plate Valve Valve Screw Set Screw

Before S/N 0160010497 100 lb-ft N/A 95 lb-ft 44 lb-ft 10-12 lb-ft 11 lb-ft
(135 Nm) (129 Nm) (60 Nm) (14-16 Nm) (15 Nm)
S/N 0160010497 & After 100 lb-ft 2025-2075 lb-ft N/A 44 lb-ft 10-12 lb-ft N/A
(135 Nm) (2745-2813 Nm) (60 Nm) (14-16 Nm)

Note: The capscrews for the bolt plate need to be torqued in sequence in an alternating pattern starting at 35 lb-ft to
75 lb-ft to 95 lb-ft. Check the final torque in a circular pattern a minimum of two times.

b. Extend/Retract Cylinder

Head Nut Valve Set Screw

100 lb-ft (135 Nm) 600-650 lb-ft 40-45 lb-ft 11 lb-ft
(813-881 Nm) (54-61 Nm) (15 Nm)

c. Tilt Cylinder

Head Nut Valve Set Screw

200 lb-ft (271 Nm) 1250-1300 lb-ft 40-45 lb-ft 11 lb-ft
(1694-1762 Nm) (54-61 Nm) (15 Nm)

d. Compensation Cylinder

Head Nut
Before S/N 0160008059 200 lb-ft (271 Nm) 1250-1300 lb-ft (1694-1762 Nm)
S/N 0160008059 & After N/A 1100 lb-ft (1491 Nm)

e. Frame Level Cylinder

Head Nut
Before S/N 0160000022 N/A 400 lb-ft (542 Nm)
S/N 0160000022 & After 100 lb-ft (165 Nm) 550-600 lb-ft (745-813 Nm)

f. Stabilizer Cylinder (if equipped)

Head Nut
100 lb-ft (165 Nm) 650-700 lb-ft (881-949 Nm)

8-28 G6-42A, G9-43A, G10-43A

 Hydraulic System

8.8.5 Cylinder Torque Specifications - G9-43A & G10-43A

a. Lift/Lower Cylinder

Piston Valve
460 lb-ft (623 Nm) 44 lb-ft (60 Nm)

Note: The capscrews for the piston need to be torqued in sequence in an alternating pattern starting at 150 lb-ft to
300 lb-ft to the final 460 lb-ft. Check the final torque in a circular pattern a minimum of two times.

b. Extend/Retract Cylinder

Head Nut Valve Set Screw

100 lb-ft (135 Nm) 1000 lb-ft (1355 Nm) 44 lb-ft (60 Nm) 11 lb-ft (15 Nm)

c. Tilt Cylinder

Head Nut Valve Valve Plug

Before S/N 0160007142 200 lb-ft (271 Nm) 1250-1300 lb-ft 45-50 lb-ft N/A
(1694-1762 Nm) (61-67 Nm)
S/N 0160007142 & After 550-600 lb-ft 2025-2075 lb-ft N/A 10-15 lb-ft
(745-813 Nm) (2745-2813 Nm) (14-20 Nm)

d. Compensation Cylinder

Head Nut
Before S/N 0160007176 200 lb-ft (271 Nm) 1250-1300 lb-ft (1694-1762 Nm)
S/N 0160007176 & After 550-600 lb-ft (745-813 Nm) 2025-2075 lb-ft (2745-2813 Nm)

e. Frame Level Cylinder

Head Nut
100 lb-ft (165 Nm) 900 lb-ft (1220 Nm)

f. Stabilizer Cylinder (if equipped)

Head Nut
300-325 lb-ft (407-441 Nm) 650-700 lb-ft (881-949 Nm)

g. Outrigger Cylinder (G10-43A)

Head Nut
N/A 1100 lb-ft (1491 Nm)

G6-42A, G9-43A, G10-43A 8-29

 Hydraulic System

This Page Intentionally Left Blank

8-30 G6-42A, G9-43A, G10-43A

 Section 9
Electrical System

Contents

PARAGRAPH TITLE PAGE

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.6.1 Constant Power Circuit from Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.6.2 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.6.3 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.8.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.9.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . 9-48
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.11 Solenoids and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.11.1 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.11.2 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.11.3 Transmission Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.11.4 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.11.5 Engine Coolant Temperature Sender / Switch . . . . . . . . . . . . . . . . . . . . . 9-53
9.11.6 Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54
9.11.7 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54
9.11.8 Front and Rear Axle Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.12.1 Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.13.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.13.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-57

G6-42A, G9-43A, G10-43A 9-1

 Electrical System

9.14 Variable Displacement Pump Control (G9-43A/G10-43A S/N 0160040675 and After
including 0160040468 & 016040672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58
9.14.1 Pump Displacement Analyzer Software Version A . . . . . . . . . . . . . . . . . . 9-58
9.14.2 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59
9.15 Hand Held Analyzer (G9-43A/G10-43A S/N 0160040675 and After including
0160040468 & 016040672). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
9.15.1 Analyzer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
9.15.2 Analyzer Software - Version A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
9.16 Joystick Fault Codes (G9-43A/G10-43A S/N 0160040675 and After including
0160040468 & 016040672). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.17 Engine Indicator Lamps - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
9.18 SAE Diagnostic Trouble Codes and Fault Codes - Cummins . . . . . . . . . . . . . . . 9-68

9-2 G6-42A, G9-43A, G10-43A

 Electrical System

9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

9.1.1 General Overview

a. Before S/N 0160040675 excluding 0160040468 & 0160040672

IGNITION & DASH

SWITCHES

POWER CONTROL BOARD

(UNDER DASH PANEL)

TILT SPEED
CONTROL

HEATER CONTROLS
(IF EQUIPPED)

MY0410

COOLANT
JOHN DEERE PERKINS
TEMPERATURE COOLANT
SENDER ALTERNATOR TEMPERATURE
SENDER

ALTERNATOR
STARTER
(NOT SHOWN)

FUEL SHUT-OFF
SOLENOID

MY0450
STARTER
OIL PRESSURE
SENDER

MY1600 OIL PRESSURE

SENDER

G6-42A, G9-43A, G10-43A 9-3

 Electrical System

b. S/N 0160040675 & After including 0160040468 & 0160040672

3 IN 1 GAUGE DASH SWITCHES

OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)

OPTIONAL
HEATER/AC CONTROLS

MY4350

IGNITION
SWITCH

COOLANT
TEMPERATURE
SENDER

ENGINE CONTROL
MODULE (ECM)
ALTERNATOR

STARTER

MY6160

9-4 G6-42A, G9-43A, G10-43A

 Electrical System

9.2 SPECIFICATIONS 9.4.2 Cab

Electrical system specifications are listed in Section 2, a. Before S/N 0160040675 excluding 0160040468 &
“General Information and Specifications.” 0160040672

9.3 SAFETY INFORMATION

WARNING TILT SPEED

CONTROL

3
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

a. Before S/N 0160040675 excluding 0160040468 &

0160040672
MY0410
JOHN DEERE PERKINS

1 For access to the fuse and relay panel, remove the

1 screws securing the load chart panel (3) to the dash. The
fuses and sealed 12-volt relays are mounted under the
panel.

b. S/N 0160040675 & After including 0160040468 &

0160040672

MY1510

b. S/N 0160040675 & After including 0160040468 &

0160040672 3
CUMMINS

MY6500

1 MY4550

The starter relay (1) is located on the engine (John

Deere), on the frame directly above the engine (Perkins)
and beside the air cleaner assembly (Cummins).
The power distribution unit (2) is mounted beside the air
cleaner assembly.
G6-42A, G9-43A, G10-43A 9-5
 Electrical System

9.4.3 Power Control Board

a. Before S/N 0160040675 excluding 0160040468 & 0160040672

X1 X2 X3 X4
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

X5 X6 X7

X8 X9 X10
X11
R1 R2 R3 R4
X12 X13

F11 F12 F13 X14 X15

R5 R6 R7 R8 R9

X16 X17 X18 X19 X20 X21

MY0392

Connector Legend
No. Function Amp Rating
F1 Optional Power 30
F2 Horn 10
F3 Key 15
F4 Spare Battery 25
F5 Steer 10
F6 Gauges 10
F7 Relays 10
F8 Lights 25
F9 W/W 25
F10 Fan/Heater 25
F11 Option3 15
F12 Option2 15
F13 Option1 10
R1 ACC
R2 Lights
R3 W/W
R4 Fan/Heater
R5 Opt
R6 Aux Elec2

9-6 G6-42A, G9-43A, G10-43A

 Electrical System

Connector Legend
R7 Aux Elec1
R8 Warn Lt Ck
R9 Rev Alarm
X1 Spare Bat
X2 SL SWA
X3 WL SWA
X4 W/W SW
X5 Gnd 3
X6 Gnd 2
X7 Gnd 1
X8 Opt 3
X9 Opt 2
X10 Opt 1
X11 Fan SW
X12 Heater SW
X13 WL 2
X14 SL SWB
X15 WL SWB
X16 Spare Coil
X17 Gnd 85
X18 SW1-87A
X19 SW2-86
X20 SW2-87A
X21 Sw1-86

G6-42A, G9-43A, G10-43A 9-7

 Electrical System

9.4.4 VEC Module - S/N 0160040675 & After including 0160040468 & 0160040672

F8 F3
IGN1
F15 F4
F16 F14 F13 F1
F9 F7
IGN3
F10
ACCY1
F11 F2
F12 F5
ACCY2
F6

MY4610

Connector Legend
No. Function Amp Rating
F1 Trans/Park Brake Power 15
F2 Alternator Excite 5
F3 Engine ECU Ignition Power 10
F4 Gauge Power 10
F5 Spare Accessory Power 15
F6 Auxiliary Electric Power 10
F7 Horn Power 15
F8 Spare Battery Power 25
F9 Engine ECU Battery Power 25
F10 Steer/Sway Power 10
F11 Rear Axle Stabilizer/Tilt Power 10
F12 Key Battery Power 15
F13 Options Power 3 20
F14 Options Power 4 20
F15 Options Power 1 20
F16 Options Power 2 20
IGN1 Ignition 1
IGN 2 Ignition 2
ACCY1 Accessory 1
ACCY2 Accessory 2

9-8 G6-42A, G9-43A, G10-43A

 Electrical System

9.4.5 VEC Module - Options S/N 0160040675 & After including 0160040468 & 0160040672

F1
R1 R5
F2
F3
R2 R6
F4

F5
R3 R7
F6
F7
R4 R8
F8

MY6240

Connector Legend
No. Function Amp Rating
F1 Wiper 20
F2 Option (Roof Wiper) 5
F3 Option 15
F4 Option 25
F5 Heater 20
F6 Lights 30
F7 Beacon 10
F8 Dash Fan 10
R1 Wiper
R2 Heater Blower
R3 Aux Elec 1
R4 Aux Elec 2
R5 Option 15
R6 Option 25
R7 Lights
R8 Beacon/Fan

G6-42A, G9-43A, G10-43A 9-9

 9.5

9-10
9.5.1

MY0670
DASH PANEL
Electrical System

PARK
BRAKE
GAG PWR LIGHT

DEUTSCH P/N HD-36-24-18-PN

DEUTSCH P/N HD-34-24-18-SN
PB LT GND
HOUR METER 18
DATCON REV AL REV AL
TRANS-E 17 TRANS-E
P/N 56458-10 C
TRANS-D 16 TRANS-D
OIL FUEL 15
OIL GAG TRANS-C TRANS-C
12 UDC 14

DIODE
TRANS-A TRANS-A STEER
2 TRANS-B 13 TRANS-B STR CRB STR CRB
1 A 2W SELECT
PARK BRAKE STR CRB 12 STR CRB GND-7
GND-7 VALVE
B+ CARLING SWITCH STR AW 11 STR AW B
FUL GAG P/N VDD1B6ABARC00-000 GND SP-3 10 SP-3
HMTR GND 12V HR MTR
8 7 ALT EXC 9 ALT EXC
SP-2 8 SP-2 4W
1 4 SP-1 7 SP-1
Before S/N 0160011059

GND
INST GND BAT-2 6 BAT-2
BR SW PWR 2 ST RLY 5 ST RLY
5
4
DIODE
G TEMP
FUL GAG FUL GAG
HORN 3 HORN STR AW STR AW
CLT TMP 3 A
6 2
HR MTR HR MTR GND-8
BAT-1 1 BAT-1 GND-8 B
3

4 IN 1 GAGE
BEEDE CAB FIREWALL
30 86 ST RLY

STEER SP-3

ST RLY
SHFT PWR 1
BRK SW
LIGHT SP-2
ST RLY PWR

SP-1
18 GND-6
17
87 85

SEALED ENDS
HORN 16
LIGHT 15
14
STARTER
TR LT SW 13 TR LT SW RELAY
BRK SOL 12 BRK SOL
CLT TMP 11 CLT TMP
IGNITION SWITCH STEER SELECT
OIL GAG 10 OIL GAG
POLLACK P/N 31-610 CARLING SWITCH
PS IGN 9 PS IGN
P/N VJD1S00BAZC00-000
HORN 8 7 STOP LT 8 STOP LT
CARLING SWITCH GND-2 7 GND-2 STRT SOL
BAT ACC STARTER
P/N V2D1S00BAZC00-000 WORK LT 6 WORK LT
1 4 MOTOR
8 7 5 BAT-2
4 BAT-1
2 5

PS IGN
1 STRT 3 SNSR
4
BACK LT 2 BACK LT ALT BAT
3 6 GND-1 1 GND-1
5
2
IGN

6
3 - + GROUND
HORN

KEY PWR
KEY STRT
HORN

KEY ACC
BATTERY

HORN
HRN PWR
12VDC

STR AW
STR PWR
STR CRB
TRANS GROUND
TEMP

DEUTSCH P/N HD-36-24-18-SN

DEUTSCH P/N HD-34-24-18-PN
(AT ENGINE
WARN
LIGHT
POD)
TRANSMISSION
TEMPERATURE SWITCH

TR LT SW
ELECTRICAL SYSTEM SCHEMATICS

250°F

TR LT
(RISING)
DIODE

TRANS-B SNSR SNSR

A
ALT EXC ALT EXC
B GND-B
#1

BATT #2
SNSR ALTERNATOR
ALT BAT
ALT EXC
DIODE

B
A TRANS-A NOT USED
B GND-A

A
DIODE

A TRANS-C
C
B GND-C

TRANSMISSION
D
DIODE

A TRANS-D

B GND-D
E

DIODE
DIODE
GND-E

PARK BRAKE SOLENOID

TRANS-E
GND-D

A
GND-C

B GND-E
GND-A

B A
GND-B
GND-1
GND-2
GND-7

GND-3
GND-8

BRK SOL
GND-6

GROUND
(AT
STARTER GND-3
SWI-86 SW2-87a SW1-87a SW2-86 GND 85 SPARE_COIL MOTOR)
O
A P
B Q
C R
D FUL GAG
E S
T

(10A) (15A) (15A) FUL GAG REV AL

10 OHM D1 A
30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3
GND-4 BACK-UP
B GND-5
ALARM
R1
87 87 87 87 87

87a 87a 87a 87a 87a FUEL

86 85 86 85 86 85 86 85 AUX 86 85
30 30 30 30 30

OPT-1
OPT-2
OPT-3
REV ELEC2 LEVEL
F ALARM WARN AUX OPT
LT CK ELEC1
SENDER
G
GND1 GND2 GND3
A B C
SL WORK
SWB
LIGHT
U OPTION
F-N-R AND WL
WL2 SWB V
GEAR SELECTOR D7 D8 D9
D6 SP-1
STOP LT
BACK LT
WORK LT

SP-2
SEALED
ENDS

SP-3
HTR FAN
SW 87 87 87 87
SW
87a 87a 87a 87a
86 85 86 85 86 85 86 85
30 30 30 30

FAN/HTR W/W LIGHTS ACC

HR MTR
DEUTSCH PS IGN
P/N DT06-8S
LOCKING WEDGE FUL SOL
W8S H
2 AMPS

1
2
3
4
5
6
7
8
W
X
I
DEUTSCH FUEL
P/N DT04-8P J SOLENOID
K
LOCKING WEDGE

SHIFT-A
SHIFT-B
L

SHIFT-C
TRANS-E
TRANS-D
W8P
Y OIL
CLT TMP

SHIFT STRT
OIL GAG

SHFT PWR 1
SHFT PWR 2
M PRESSURE SWITCH
GND
D10 MOTOROLA (25A) (25A) (25A)
(ON ENGINE)
2-FRONT (25A) (10A) (10A) (10A) (15A) (10A) (30A)
MR 752 FAN/HTR W/W LIGHTS RELAYS SPARE OPT_PWR
GAGES STEER BAT KEY HORN AA
N OR EQUIV

BATT

WL_SWA SL_SWA
W/W_SW SPARE_BAT OIL WATER
PRESSURE TEMP.
SENDER SENDER

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

 DASH PANEL

MY0680
PARK
BRAKE
LIGHT

HOUR METER
DATCON
P/N 56458-10

OIL FUEL

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

12 UDC
2
1
PARK BRAKE
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000
GND 12V

8 7

GND
1 4

G TEMP 2 5

3 6
3

4 IN 1 GAGE
BEEDE

HORN STEER
LIGHT LIGHT

IGNITION SWITCH STEER SELECT

POLLACK P/N 31-610 CARLING SWITCH
P/N VJD1S00BAZC00-000
HORN
CARLING SWITCH 8 7
BAT ACC 8 7 GND 85
P/N V2D1S00BAZC00-000
8 MAST 1 4
7 1 4
SW1-86
8 7
SW1-87a 2 5 SW1-87a GND 85
1 STRT
4 2 5 4
SIDESHIFT 3 6 SW1-86 SWING 1 SW2-86
2 5
2 5 3 6
SW2-87a SW2-87a
IGN 6
EXTRA 3 SW2-86
6
3 MAST

SWING
STAB-SW1 STAB-SW2

TRANS STAB-PWR
TEMP
WARN
LIGHT GND-8

SW1-87a
SW1-86 A B C D A B
SW2-87a
GND-7

SW2-86 OIL
PRESSURE SWITCH
(ON ENGINE)

DIODE
BLUE
WHITE
RED
ORANGE
BLACK

GND 85 5 GND 85 + -
EXTRA EXTRA 4 EXTRA
N.C.
N.O.

SWING SWING 3 SWING

SIDESHIFT SIDESHIFT 2 SIDESHIFT

MAST MAST 1 MAST

STABILIZER STABILIZER
PROXIMITY VALVE
SENSOR

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

TO COMMON GROUND
O ON ENGINE
A P BELL HOUSIING
B Q
C R
D
E S

GND 85

MAST
SIDESHIFT
EXTRA
D1

SWING
T
10 OHM D2 D3 D4 (10A) (15A) (15A)
D5
30W OPT-1 OPT-2 OPT-3
R1

1
2
3
4
5
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
30
REV 30
STABILIZER OPTION

OPT-1
OPT-2
30 30

OPT-3
30
ALARM WARN AUX
F AUX OPT
LT CK ELEC1 ELEC2
G

MAST
GND1 GND2 GND3
EXTRA
SWING
GND 85

SL
SWB SIDESHIFT

U
WL D7 D8 D9 V
WL2
SWB D6

87 87 87 87
"TM" EXTRA (ORANGE)
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
W/W LIGHTS ACC "A" OPEN
FAN/HTR
GROUND (YELLOW)

H
W "S" MAST (BLACK)
X "LT" SIDESHIFT (RED)
I "RT" SWING (BLUE)

J
K
L
Y
M MOTOROLA
(25A) GND
MR 752 (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A)
D10 LIGHTS (30A)
OR EQUIV FAN/HTR W/W RELAYS GAGES STEER SPARE KEY HORN AA
N OPT_PWR
BAT
BAT
WL_SWA SL_SWA

W/W_SW SPARE_BAT
Electrical System

AUX ELECTRIC OPTION

9-11
9-12
DASH PANEL

MY0690
FRONT FRONT
GND L1 WORK
WORK PARK WORK
BRAKE LIGHT LIGHT
LIGHT LIGHT INDICATOR IND LT
(ON CAB) (ON CAB)
HOUR METER
DATCON
P/N 56458-10
OIL FUEL WORK LIGHT
CARLING SWITCH
12 UDC
P/N V1D1S00BAZC00-000
2
1
PARK BRAKE 8 7
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000
1 4 GND 12V
8 7
5
2
GND 1 4
6
3
2 5
G TEMP

3 6
3

4 IN 1 GAGE
Electrical System

BEEDE

LIGHT SW
WORK LT
A B A B

STEER
LIGHT

HORN
LIGHT

IGNITION SWITCH STEER SELECT

POLLACK P/N 31-610 CARLING SWITCH
P/N VJD1S00BAZC00-000
HORN
CARLING SWITCH

DEUTSCH P/N HD-36-24-18-PN

DEUTSCH P/N HD-34-24-18-SN

GND L
GND L

LIGHT-1
LIGHT-2
BAT
8 7
P/N V2D1S00BAZC00-000 ACC

8 7 1 4 REV AL 18 REV AL
STRT TRANS-E 17 TRANS-E
1 4 2 5
TRANS-D 16 TRANS-D
5 3 6 TRANS-C 15 TRANS-C
2 IGN
TRANS-A 14 TRANS-A
6
3
TRANS-B 13 TRANS-B
STR CRB 12 STR CRB
STR AW 11 STR AW
SP-3 10 SP-3
TRANS ALT EXC 9 ALT EXC
TEMP
WARN SP-2 8 SP-2
LIGHT SP-1 7 SP-1
FRONT
BAT-2 6 BAT-2
WORK
ST RLY 5 ST RLY LIGHT
FUL GAG 4 FUL GAG
HORN 3 HORN
HR MTR 2 HR MTR
BAT-1 1 BAT-1

MIRROR-LT
GND
CAB FIREWALL

LIGHT SW LIGHT-2 A B
18

GND L
GND L
17
GND L1 16

IND LT 15
14
TR LT SW 13 TR LT SW REV AL
GND

BRK SOL 12 BRK SOL

CLT TMP 11 CLT TMP BACK-UP
MIRROR-LT

GND 1 ALARM
SW1-87a GND 85 SPARE_COIL OIL GAG 10 OIL GAG
SWI-86 SW2-87a SW2-86

LIGHT SW
WORK LT
PS IGN 9 PS IGN
GND 2
STOP LT 8 STOP LT
O
GND-2 7 GND-2
A P GND-5
WORK LT 6 WORK LT WORK LT C
B Q
5
C R GROUND
4 STOP LT B (AT
D STARTER
S 3
E BACK LT MOTOR)
T BACK LT 2 BACK LT A
D1 1
GND-1 GND-1
10 OHM (10A) (15A) (15A)
30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3
R1

87 87 87 87 87
87a 87a 87a 87a 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30 30 30

OPT-1
OPT-2
30

OPT-3
ALARM WARN AUX

GND L1
AUX
BACK LT
STOP LT
TAIL LT

F LT CK

GND L
GND L
ELEC1 ELEC2 OPT
G
GND1 GND2 GND3

DEUTSCH P/N HD-36-24-18-SN

DEUTSCH P/N HD-34-24-18-PN
SL
SWB GND L A B C

STOP LT
V
LIGHT-1 WL2 WL D7 D8 D9
D6
SWB

87 87 87 87

GND DL
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
FAN/HTR W/W LIGHTS ACC

H BACK-UP STOP TAIL

LIGHT LIGHT LIGHT
(GREEN) (RED) (BLACK)
W
X REAR TAIL LIGHT
I ASSEMBLY

J
K
L
Y

M (25A) (25A) (25A) (10A) (25A) (30A) GND

(10A) (10A) (15A) (10A)
D10 FAN/HTR W/W LIGHTS RELAYS SPARE OPT_PWR
GAGES STEER KEY HORN AA
BAT
N
MOTOROLA BAT
MR 752
WL_SWA SL_SWA

IND LT
OR EQUIV 3-FRONT GND DL
W/W_SW SPARE_BAT

DOME LT DOME LT

DOME
WORK LT LIGHT
DOME
STOP SW LIGHT
SWITCH

STOP LT
STOP SW
WORK LIGHT OPTION

STOPLT SW

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

 DASH PANEL

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

JOYSTICK
BEACON PARK
GND L1
BEACON
LIGHT BRAKE LIGHT RED BLUE
LIGHT INDICATOR IND LT
(ON CAB)
HOUR METER
DATCON
P/N 56458-10
OIL FUEL
BEACON LIGHT
CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1
PARK BRAKE 8 7
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000 1 GND 12V
4
8
7
5
2
GND 1
4
6
3
BLACK
GRAY

2
G TEMP 5

3
6
3

4 IN 1 GAGE
BEEDE A B C D E F DEUTSCH 6-PIN
DT 06-65

BEACON SW
BEACON-1
A B STEER
LIGHT SWI-86 SW2-87a SW1-87a GND 85 SPARE_COIL
SW2-86

HORN
O
LIGHT A P
B Q
C R
IGNITION SWITCH STEER SELECT
D
POLLACK P/N 31-610
TILT UP

CARLING SWITCH E S
P/N VJD1S00BAZC00-000
HORN
TILT PWR1
TILT PWR2
TILT DOWN

CARLING SWITCH D1 T

GND L
BAT 8 7
P/N V2D1S00BAZC00-000 ACC 10 OHM

BEACON SW
(10A) (15A) (15A)
8 7 1 4 30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3
STRT
1 4
R1
2 5

5 3 6 87 87 87 87 87
2
IGN

6 87a 87a 87a 87a 87a

3 86 85 REV 86 85 86 85 86 85 86 85
30 30
OPT-1
OPT-2

30 30 30
OPT-3

ALARM WARN AUX AUX

F LT CK ELEC1 ELEC2 OPT

TRANS G
TEMP GND1 GND2 GND3
WARN
LIGHT
SL
SWB

U
D8 D9 V
WL2 WL D7
SWB D6

87 87 87 87
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
FAN/HTR W/W LIGHTS ACC
GND-15
GND-16

W
X
I
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL J
K
O L
A P
B Y
Q
C R MOTOROLA
M (25A) GND
D MR 752 (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
E S D10 FAN/HTR W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR
OR EQUIV AA
D1 T N BAT
10 OHM (10A) (15A) (15A)

BEACON-1
30W D2 D3 D4 D5 BAT
OPT-1 OPT-2 OPT-3
R1
IND LT

WL_SWA SL_SWA
87 87 87 87 87 W/W_SW SPARE_BAT
TILT DOWN

87a 87a 87a 87a 87a

86 85 REV 86 85 86 85 86 85 86 85
30 30 30

OPT-1
OPT-2
30

OPT-3
30 ALARM WARN AUX AUX
F LT CK ELEC1 OPT
ELEC2
TILT UP

G
GND1 GND2 GND3
SL GND L
SWB
U
D7 D8 D9 V
WL2 WL
SWB D6
TILT DWN TILT UP
87 87 87 87
GND-15 GND-16
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
FAN/HTR W/W LIGHTS ACC
3-FRONT A B
A B

H
DIODE DIODE
W
X
I
J
K
L
Y
MOTOROLA (25A) (25A) (25A) (30A) GND
M (25A) (10A) (10A) (15A) (10A)
MR 752 FAN/HTR W/W (10A) SPARE OPT_PWR
D10 LIGHTS RELAYS KEY HORN
OR EQUIV GAGES STEER BAT AA
N
BAT
WL_SWA SL_SWA

IND LT
MAIN CONTROL MAIN CONTROL
W/W_SW SPARE_BAT VALVE VALVE

MY0700
BEACON LIGHT OPTION TILT ON JOYSTICK OPTION
Electrical System

9-13
9-14
BAT HSW
GND HSW

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

HIG WSW

WAS WSW
LOW WSW

PAR WSW
Electrical System

BAT HSW
GND HSW
O
A P
B Q
C R
D
E S
D1 T
10 OHM (10A) (15A) THERMOSTATIC PRESSURE SWITCH CLUTCH ON
(15A) A B C D E F
30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3 SWITCH A/C COMPRESSOR
R1 (IN CAB)
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30 4A

OPT-1
OPT-2
30 30 30

OPT-3
ALARM WARN AUX AUX
F LT CK ELEC1 ELEC2 OPT

BAT HSW
GND HSW
PAR WSW
LOW WSW
WAS WSW
HIG WSW
G
GND1 GND2 GND3
SL ON ENGINE
SWB
GND HSW
U
D8 D9 V
WL2 WL D7
SWB D6

HTR
SW 87 87 87 87
BAT HSW FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW 30 30 30 30 CONDENSER FANS
FAN/HTR W/W LIGHTS ACC (ON ROOF)
A/C SWITCH IN M
RH CONSOLE
H
17A
W
X
I
M
J
K
L
Y
M MOTOROLA GND

BAT HSW
MR 752 (25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 FAN/HTR W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR
OR EQUIV AA
N BAT
BAT
"C" 86 87a 87
WL_SWA SL_SWA HEATER
W/W_SW SPARE_BAT SWITCH

RELAY

85 30

HIG HSW
MED HSW
LOW HSW
GND HSW
A B C D

A/C AND
HEATER
MOTOR

MY0710
AIR CONDITIONING OPTION

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

 DASH PANEL

PARK

MY0720
BRAKE
LIGHT

HOUR METER
DATCON
P/N 56458-10
OIL FUEL
12 UDC
2
1

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

PARK BRAKE
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000 GND 12V

8 7

GND
1 4

G TEMP 2 5

3 6
3

4 IN 1 GAGE
BEEDE

STEER
WIPER
LIGHT SWITCH
HIG WSW
HORN
LIGHT
LOW WSW

IGNITION SWITCH STEER SELECT

BAT WSW WAS WSW
POLLACK P/N 31-610 CARLING SWITCH
P/N VJD1S00BAZC00-000
HORN PAR WSW
CARLING SWITCH 8 7
P/N V2D1S00BAZC00-000 BAT ACC

8 7 1 4

STRT
1 4 2 5

5 3 6
2
IGN

6
3

TRANS
TEMP
WARN

BAT HSW
GND HSW
LIGHT
HIG WSW

WAS WSW
LOW WSW

PAR WSW

BAT HSW
GND HSW

A B C D E F
BAT HSW
GND HSW
PAR WSW
LOW WSW
WAS WSW
HIG WSW

HIG WSW

LOW WSW

PAR WSW

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

O
A P
B Q
C R
D
E S WIPER
D1 T MOTOR
BAT FAN

GND FAN

10 OHM
30W D2 D4 D5 (10A) (15A) (15A)
D3 OPT-2
OPT-1 OPT-3
R1

87 87 87 87 87
87a 87a 87a 87a 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30

OPT-1
OPT-2
30 30 30

OPT-3
ALARM WARN AUX
AUX
F LT CK ELEC2 OPT
ELEC1
G
A B
GND1 GND2 GND3
SL
BAT HSW

SWB GND HSW

U
WL D7 D8 D9 V
WL2 D6
SWB

HTR HEATER
87 87 87 87
SW SWITCH
FAN 87a 87a 87a 87a FAN
BAT HSW 86 85 86 85 86 85 86 85
SW 30 30 30 30 MOTOR
FAN/HTR W/W LIGHTS ACC
HIG HSW
MED HSW
LOW HSW
GND HSW

H
W
X
I
J
K
L
Y
A B C D
M MOTOROLA (25A) (15A) (10A) (30A) GND
WAS WSW

MR 752 (25A) (25A) (25A) (10A) (10A) (10A)

D10 FAN/HTR LIGHTS RELAYS SPARE KEY HORN OPT_PWR
OR EQUIV W/W GAGES STEER BAT AA
N
BAT
WL_SWA SL_SWA
W/W_SW SPARE_BAT
WASHER
BOTTLE
HEATER
MOTOR

BAT WSW

ENCLOSED CAB OPTION

Electrical System

9-15
9-16
9.5.2

DASH PANEL

PARK

MY0730
BRAKE
GAG PWR LIGHT

DEUTSCH P/N HD-36-24-18-PN

DEUTSCH P/N HD-34-24-18-SN
PB LT GND
HOUR METER 18
DATCON REV AL REV AL
TRANS-E 17 TRANS-E
P/N 56458-10 C
TRANS-D 16 TRANS-D
OIL FUEL
OIL GAG TRANS-C 15 TRANS-C
12 UDC 14

DIODE
TRANS-A TRANS-A STEER
2 TRANS-B 13 TRANS-B STR CRB STR CRB
1 A 2W SELECT
STR CRB 12 STR CRB
Electrical System

PARK BRAKE GND-7 GND-7 VALVE

B+ STR AW 11 STR AW B
CARLING SWITCH
FUL GAG P/N VDD1B6ABARC00-000 GND SP-3 10 SP-3
12V
8 7 HMTR GND HR MTR ALT EXC 9 ALT EXC
SP-2 8 SP-2 4W
SP-1 7 SP-1
GND 1 4
INST GND BAT-2 6 BAT-2
ST RLY 5 ST RLY
BR SW PWR 2 5 4

DIODE
G TEMP
FUL GAG FUL GAG
CLT TMP HORN 3 HORN STR AW STR AW
A
3 6 HR MTR 2 HR MTR GND-8 GND-8
BAT-1 1 BAT-1 B
3

4 IN 1 GAGE
BEEDE CAB FIREWALL
30 86 ST RLY

SP-3

ST RLY
SHFT PWR 1
BRK SW
STEER SP-2
LIGHT SP-1
18 GND-6
ST RLY PWR

17
87 85

SEALED ENDS
HORN 16
LIGHT 15
14
STARTER
TR LT SW 13 TR LT SW RELAY
BRK SOL 12 BRK SOL
IGNITION SWITCH CLT TMP 11 CLT TMP
STEER SELECT
POLLACK P/N 31-610 OIL GAG 10 OIL GAG
CARLING SWITCH
P/N VJD1S00BAZC00-000 PS IGN 9 PS IGN
HORN STOP LT 8 STOP LT
CARLING SWITCH 8 7
GND-2 7 GND-2 STRT SOL
P/N V2D1S00BAZC00-000 BAT ACC STARTER
WORK LT 6 WORK LT
1 4 5 BAT-2 MOTOR
8 7
4 BAT-1

PS IGN
STRT 2 5 3 SNSR
1 4
BACK LT 2 BACK LT ALT BAT
3 6 GND-1 1 GND-1
5
2
IGN

6 - +
3 GROUND
HORN

KEY PWR
KEY STRT
HORN

KEY ACC
BATTERY

HORN
HRN PWR
STR AW
12VDC

STR PWR
STR CRB
TRANS GROUND
TEMP (AT ENGINE
WARN
LIGHT TRANSMISSION POD)
TEMPERATURE SWITCH

DEUTSCH P/N HD-36-24-18-SN

DEUTSCH P/N HD-34-24-18-PN
TR LT SW

TR LT
250°F
(RISING)

TRANS-B SNSR SNSR

A
ALT EXC ALT EXC
GND-B
B
#1

BATT #2 ALTERNATOR
ZENER DIODE SNSR

ALT EXC
B TRANS-A ALT BAT
A NOT USED
B
GND-A

A ZENER DIODE
G6-42A - S/N 0160011059 Thru 0160021194
G9-43A - S/N 0160011059 Thru 0160020822

A TRANS-C
C B GND-C

PARK BRAKE SOLENOID

TRANSMISSION
ZENER DIODE
D
A TRANS-D

B GND-D
E
ZENER DIODE
GND-D

DIODE
GND-C

A TRANS-E

B GND-E
B A
GND-A
GND-B
GND-1

-E
GND-2

ZENER DIODE D
N
GND-7

G GND-3
GND-8

BRK SOL
GND-6

GROUND
(AT
STARTER
SWI-86 SW2-87a SW2-86 GND 85 SPARE_COIL
GND-3
SW1-87a MOTOR)
O
A P
B Q
C R
D
FUL GAG
E S
T
D1

10 OHM (10A) (15A) (15A) FUL GAG REV AL

30W D2 D3 D4 D5 A
OPT-1 OPT-2 OPT-3 BACK-UP
R1 GND-4 GND-5
B ALARM
87 87 87 87 87
FUEL
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85 LEVEL
30 30 30

OPT-1
OPT-2
REV 30 30

OPT-3
WARN AUX SENDER
F ALARM AUX
LT CK ELEC2 OPT
ELEC1

GND1 GND2 GND3

WORK A B C
SL
SWB LIGHT
OPTION
F-N-R AND U
GEAR SELECTOR V
WL2 WL D7 D8 D9
SWB D6 SP-1
SP-2
STOP LT
BACK LT
WORK LT
SEALED
ENDS

SP-3
87 87 87 87
HTR FAN 87a 87a 87a 87a
SW SW 86 85 86 85 86 85 86 85
30 30 30 30

FAN/HTR W/W LIGHTS ACC

HR MTR

DEUTSCH PS IGN
P/N DT06-8S FUL SOL
LOCKING WEDGE
H
W8S
W 2 AMPS

1
2
3
4
5
6
7
8
X
DEUTSCH I
P/N DT04-8P FUEL
LOCKING WEDGE J
K
SOLENOID
CLT TMP

W8P L

SHIFT-A
SHIFT-B
OIL GAG

SHIFT-C
Y

TRANS-E
TRANS-D
OIL

SHIFT STRT

SHFT PWR 1
SHFT PWR 2
GND PRESSURE SWITCH
M
MOTOROLA (25A) (25A) (25A) (10A) (25A) (30A) (ON ENGINE)
(10A) (10A) SPARE (15A) (10A)
MR 752 FAN/HTR W/W LIGHTS RELAYS GAGES STEER KEY HORN OPT_PWR AA
D10 BAT
OR EQUIV
N
BATT

WL_SWA SL_SWA
SPARE_BAT
W/W_SW WATER
OIL
PRESSURE TEMP.
SENDER SENDER

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

 DASH PANEL

PARK
BRAKE
LIGHT

HOUR METER
DATCON

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

P/N 56458-10
OIL FUEL
12 UDC
2
1 PARK BRAKE
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000
GND 12V
8 7

GND
1 4

G TEMP 2 5

3 6
3

4 IN 1 GAGE
BEEDE

STEER
LIGHT
STAB-SW1 STAB-SW2
HORN
LIGHT STAB-PWR

GND-8
IGNITION SWITCH
POLLACK P/N 31-610 STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
CARLING SWITCH
P/N V2D1S00BAZC00-000 8 7
BAT ACC 8 7 GND 85
1 4
8 7 1 4
MAST SW1-86 A B C D A B
2 5 8 7 GND 85
STRT
SW1-87a SW1-87a
1 4
GND-7

2 5 3 6
SIDESHIFT SW1-86 SWING 1 4 SW2-86 OIL
5 3 6
SW2-87a 2 5 SW2-87a PRESSURE SWITCH
2
IGN
EXTRA 3 6 SW2-86 (ON ENGINE)
6 MAST
3

SWING DIODE
RED

BLUE
WHITE
BLACK

TRANS
ORANGE

TEMP
WARN
LIGHT

+ -

SW1-87a
N.O.

N.C.

SW1-86
SW2-87a
SW2-86

STABILIZER STABILIZER
PROXIMITY VALVE
SENSOR

GND 85 5 GND 85
TO COMMON GROUND
EXTRA EXTRA 4 EXTRA ON ENGINE
BELL HOUSIING
SWING SWING 3 SWING

SIDESHIFT SIDESHIFT 2 SIDESHIFT

MAST MAST 1 MAST

STABILIZER
SWI-86 SW2-87a SW2-86 SPARE_COIL
OPTION
SW1-87a GND 85

O
A P
B Q
C R
D
E

EXTRA

MAST
GND 85

SWING

SIDESHIFT
S
D1 T
10 OHM (10A) (15A)
D2 D3 D4 (15A)
30W D5 OPT-1 OPT-2 OPT-3
R1

1
2
3
4
5
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30 30 30 30

OPT-1
OPT-2
OPT-3
ALARM WARN AUX
LT CK AUX
F ELEC2 OPT
ELEC1
G

MAST
EXTRA
SWING
GND1 GND2 GND3
GND 85

SL
SIDESHIFT

SWB
U
D8 V
WL2 WL D7 D9
D6
SWB

87 87 87 87
"TM" EXTRA (ORANGE)
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
W/W LIGHTS ACC "A" OPEN
FAN/HTR
GROUND (YELLOW)

W "S" MAST (BLACK)

X "LT" SIDESHIFT (RED)
I "RT" SWING (BLUE)

J
K
L
Y
M MOTOROLA (25A) (25A) (25A) (25A) (15A) (10A) (30A) GND
MR 752 FAN/HTR (10A) (10A) (10A) OPT_PWR
D10 W/W LIGHTS SPARE KEY HORN
OR EQUIV RELAYS GAGES STEER AA
BAT
N
BAT

WL_SWA SL_SWA
SPARE_BAT
W/W_SW

MY0740
AUX ELECTRIC OPTION
Electrical System

9-17
9-18
DASH PANEL

FRONT FRONT

MY0750
GND L1 WORK
WORK PARK WORK
BRAKE LIGHT LIGHT
LIGHT LIGHT INDICATOR IND LT
(ON CAB) (ON CAB)
HOUR METER
DATCON
P/N 56458-10
WORK LIGHT
OIL FUEL CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1 PARK BRAKE 8 7
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000
1 4 GND 12V

8 7
5
2
GND
1 4
6
3
G TEMP 2 5

3 6
3

4 IN 1 GAGE
BEEDE

LIGHT SW
WORK LT
A B A B
STEER
LIGHT
Electrical System

HORN
LIGHT

IGNITION SWITCH
STEER SELECT
POLLACK P/N 31-610
CARLING SWITCH
P/N VJD1S00BAZC00-000
HORN
CARLING SWITCH

DEUTSCH P/N HD-36-24-18-PN

DEUTSCH P/N HD-34-24-18-SN

GND L
8 7

LIGHT-1
P/N V2D1S00BAZC00-000 BAT ACC

LIGHT-2
GND L
8 7 1 4 REV AL 18 REV AL
STRT TRANS-E 17 TRANS-E
1 4 2 5
TRANS-D 16 TRANS-D
5 3 6 TRANS-C 15 TRANS-C
2
IGN
TRANS-A 14 TRANS-A
6
3
TRANS-B 13 TRANS-B
STR CRB 12 STR CRB
STR AW 11 STR AW
SP-3 10 SP-3

TRANS ALT EXC 9 ALT EXC

TEMP SP-2 8 SP-2
WARN
LIGHT SP-1 7 SP-1
BAT-2 6 BAT-2
FRONT
WORK
ST RLY 5 ST RLY LIGHT
FUL GAG 4 FUL GAG
HORN 3 HORN
HR MTR 2 HR MTR
BAT-1 1 BAT-1

GND

MIRROR-LT
CAB FIREWALL

LIGHT SW A B
18

GND L
GND L
LIGHT-2 17
GND L1 16

IND LT 15
14
TR LT SW 13 TR LT SW REV AL
GND

BRK SOL 12 BRK SOL

BACK-UP
MIRROR-LT

CLT TMP 11 CLT TMP ALARM

SPARE_COIL GND 1
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 OIL GAG 10 OIL GAG

LIGHT SW
WORK LT
PS IGN 9 PS IGN GND 2
STOP LT 8 STOP LT
O GND-2 7 GND-2
A GND-5
P WORK LT 6 WORK LT WORK LT C
B Q
C 5
R 4 STOP LT B
D
S 3
E BACK LT
T BACK LT 2 BACK LT A
D1 GND-1 1 GND-1 GROUND
10 OHM (10A) (15A)
D2 D3 D4 D5 (15A) (AT
30W OPT-1 OPT-2 STARTER
OPT-3
R1 MOTOR)

87 87 87 87 87
87a 87a 87a 87 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30 30 30

OPT-1
OPT-2
30

OPT-3
WARN AUX

GND L1
BACK LT
STOP LT
TAIL LT

F ALARM AUX

GND L
GND L
LT CK ELEC2 OPT
ELEC1
G
GND1 GND2 GND3

DEUTSCH P/N HD-36-24-18-SN

DEUTSCH P/N HD-34-24-18-PN
SL
SWB GND L A B C

U
WL D7 D8 D9 V

STOP LT
LIGHT-1 WL2 D6
SWB

87 87 87 87

GND DL
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30

FAN/HTR W/W LIGHTS ACC

BACK-UP STOP TAIL

H LIGHT LIGHT LIGHT
(GREEN) (RED) (BLACK)
W
X REAR TAIL LIGHT
I ASSEMBLY

J
K
L
Y
M MOTOROLA (25A) (25A) (30A) GND
(25A) (25A) (10A) (10A) (10A) (15A) (10A)
D10 MR 752 FAN/HTR W/W LIGHTS RELAYS SPARE KEY HORN OPT_PWR
GAGES STEER
OR EQUIV BAT AA
N
BAT
IND LT
WL_SWA SL_SWA GND DL
SPARE_BAT
W/W_SW
DOME LT
DOME LT

WORK LT DOME
DOME LIGHT
STOP SW LIGHT
SWITCH

STOP LT
STOP SW
WORK LIGHT OPTION

STOPLT SW

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

 DASH PANEL

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

JOYSTICK
BEACON GND L1
PARK BEACON
LIGHT BRAKE LIGHT
RED BLUE
LIGHT INDICATOR IND LT
(ON CAB)

MY0760
HOUR METER
DATCON
P/N 56458-10
OIL FUEL
BEACON LIGHT
CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1 PARK BRAKE 8 7
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000
1 4 GND 12V
8 7
5
2
GND
1 4
6
3
BLACK
GRAY

G TEMP 2 5

3 6
3

4 IN 1 GAGE
BEEDE DEUTSCH 6-PIN
A B C D E F
DT 06-65

BEACON SW
BEACON-1
A B STEER SW1-87a GND 85 SPARE_COIL
LIGHT
SWI-86 SW2-87a SW2-86

HORN
O
LIGHT A P
B Q
C
TILT UP

R
IGNITION SWITCH STEER SELECT D
CARLING SWITCH
TILT PWR1
TILT PWR2

POLLACK P/N 31-610

TILT DOWN

P/N VJD1S00BAZC00-000 E S
HORN
CARLING SWITCH D1 T

GND L
P/N V2D1S00BAZC00-000 BAT ACC 8 7
10 OHM

BEACON SW
D2 D4 D5 (10A) (15A) (15A)
8 7 1 4
30W D3
OPT-1 OPT-2 OPT-3
STRT
R1
1 4 2 5

5 3 6 87 87 87 87 87
2 IGN

6 87a 87a 87a 87a 87a

3 86 85 REV 86 85 86 85 86 85 86 85
30 30 30 30
OPT-1
OPT-2

30
OPT-3

ALARM WARN AUX AUX

F LT CK ELEC1 ELEC2 OPT

TRANS
G
TEMP GND1 GND2 GND3
WARN
LIGHT
SL
SWB

U
WL2 WL D8 D9 V
D6 D7
SWB

87 87 87 87
GND-15
GND-16
TILT UP

HTR FAN 87a 87a 87a 87a

86 85 86 85 86 85 86 85
TILT DOWN

SW SW 30 30 30 30
FAN/HTR W/W LIGHTS ACC

W
X
I
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL J
K
O
L
A P Y
B Q
C R MOTOROLA GND
M (25A) (30A)
D MR 752 (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A)
E S D10 FAN/HTR W/W LIGHTS RELAYS SPARE OPT_PWR
OR EQUIV GAGES STEER KEY HORN AA
D1 T N BAT
10 OHM D4 (10A) (15A) (15A)

BEACON-1
30W D5 BAT
D2 D3 OPT-1 OPT-2 OPT-3
R1 WL_SWA SL_SWA
IND LT

SPARE_BAT
87 87 87 87 87
W/W_SW
87a 87a 87a 87a 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30 30 30 30

OPT-1
OPT-2
OPT-3
ALARM WARN AUX AUX
F LT CK ELEC1 ELEC2 OPT
G
GND1 GND2 GND3
SL
SWB GND L

U
WL2 WL D7 D8 D9 V
D6
SWB
TILT DWN TILT UP
87 87 87 87
GND-15 GND-16
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
FAN/HTR W/W LIGHTS ACC
A B A B

H
DIODE DIODE
W
X
I
J
K
L
Y
M MOTOROLA (25A) (25A) (25A) (25A) (15A) (10A) (30A) GND
MR 752 FAN/HTR W/W LIGHTS (10A) (10A) (10A) SPARE OPT_PWR
D10 KEY HORN
OR EQUIV RELAYS GAGES STEER BAT AA
N
BAT

IND LT
WL_SWA SL_SWA MAIN CONTROL MAIN CONTROL
SPARE_BAT VALVE VALVE
W/W_SW

BEACON LIGHT OPTION TILT ON JOYSTICK OPTION

Electrical System

9-19
9-20
BAT HSW
GND HSW

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

HIG WSW

WAS WSW
LOW WSW

PAR WSW

BAT HSW
GND HSW
O
A P
B Q
C R
Electrical System

D
E S
D1 T
10 OHM (10A) (15A) (15A) THERMOSTATIC PRESSURE SWITCH CLUTCH ON
30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3 A B C D E F
R1 SWITCH A/C (IN CAB) COMPRESSOR
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
30 REV 30 30 30 30

OPT-1
OPT-2
OPT-3
WARN AUX AUX
4A
F ALARM OPT
LT CK ELEC1 ELEC2
G

BAT HSW
GND HSW
PAR WSW
LOW WSW
WAS WSW
HIG WSW
GND1 GND2 GND3
SL
ON ENGINE
SWB GND HSW

U
WL2 WL D6 D7 D8 D9 V
SWB

87 87 87 87
BAT HSW FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW 30 30 30 30 CONDENSER FANS
HTR
SW FAN/HTR W/W LIGHTS ACC (ON ROOF)

M
H
W
17A
X
I
M
J
K
L
Y

M MOTOROLA (25A) GND

(25A) (25A) (10A) (25A) (30A)

BAT HSW
MR 752 (10A) (10A) (15A) (10A)
D10 FAN/HTR W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR
OR EQUIV AA
N BAT
BAT
"C" 86 87a 87
WL_SWA SL_SWA HEATER
W/W_SW SPARE_BAT SWITCH
RELAY

85 30

HIG HSW
MED HSW
LOW HSW
GND HSW
A B C D

A/C AND
HEATER
MOTOR

MY0770
AIR CONDITIONING OPTION

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

 DASH PANEL

MY0780
PARK
BRAKE
LIGHT

HOUR METER
DATCON
P/N 56458-10
OIL FUEL
12 UDC
2
1 PARK BRAKE
B+ CARLING SWITCH
P/N VDD1B6ABARC00-000
GND 12V

8 7

GND
1 4

G TEMP 2 5

3 6

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

3

4 IN 1 GAGE
BEEDE

STEER
LIGHT WIPER
SWITCH HIG WSW
HORN
LIGHT
LOW WSW
STEER SELECT BAT WSW WAS WSW
IGNITION SWITCH CARLING SWITCH
POLLACK P/N 31-610 P/N VJD1S00BAZC00-000
HORN PAR WSW
CARLING SWITCH
P/N V2D1S00BAZC00-000 BAT ACC 8 7

8 7 1 4

STRT
1 4 2 5

5 3
2 6
IGN

6
3
HIG WSW

TRANS
WAS WSW
LOW WSW

PAR WSW

BAT HSW
GND HSW

TEMP
WARN
LIGHT

BAT HSW
GND HSW
A B C D E F
BAT HSW
GND HSW
PAR WSW
LOW WSW
WAS WSW
HIG WSW

HIG WSW

LOW WSW

PAR WSW

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

O
A P
B Q
C R
D
E S WIPER
D1 T MOTOR
BAT FAN

GND FAN

10 OHM (10A) (15A) (15A)

30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3
R1

87 87 87 87 87
87a 87a 87a 87a 87a
86 85 REV 86 85 86 85 86 85 86 85
30 30 30 30

OPT-1
OPT-2
30

OPT-3
ALARM WARN AUX AUX
F LT CK ELEC1 ELEC2 OPT

G A B
GND1 GND2 GND3
SL
SWB GND HSW
BAT HSW

U
WL2 WL D7 D8 D9 V
SWB D6

87 87 87 87 HEATER
FAN FAN SWITCH
BAT HSW 87a 87a 87a 87a
SW 86 85 86 85 86 85 86 85
HTR 30 30 30 30 MOTOR
SW FAN/HTR W/W LIGHTS ACC

H
HIG HSW
MED HSW
LOW HSW
GND HSW

W
X
I
J
K
L
Y
A B C D
M MOTOROLA (25A) (25A) (25A) (10A) (10A) (25A) (15A) (10A) (30A) GND
WAS WSW

(10A)
D10 MR 752 FAN/HTR W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR
OR EQUIV BAT AA
N
BAT

WL_SWA SL_SWA
W/W_SW SPARE_BAT
WASHER
BOTTLE
HEATER
MOTOR
BAT WSW
Electrical System

ENCLOSED CAB OPTION

9-21
9-22
9.5.3
DASH PANEL

GAG PWR

PARK
BRAKE
GAG PWR
LIGHT

PB LT GND
HOUR METER
DATCON
P/N 56458-10
OIL FUEL INST GND
OIL GAG
12 UDC
2
1
PARK BRAKE
B+
CARLING SWITCH
FUL GAG P/N VDD1B6AB-ARC00-000 GND 12V
8 7 HMTR GND HR MTR

GND 1 4
INST GND

BR SW PWR 2 5
G TEMP
CLT TMP
3 6
3

4 IN 1 GAGE
BEEDE GAG PWR

BRK SW

SHFT PWR 1

ST RLY
STEER
Electrical System

GAG PWR
LIGHT

HORN INST GND

DEUTSCH P/N HD-36-24-18-PN

LIGHT

REV AL
18
INST GND TRANS-E
17
STEER SELECT PRE-HEAT TRANS-D
16
CARLING SWITCH CARLING SWITCH TRANS-C
P/N V2D1B60B-AEC3V-100 15
HORN P/N VJD1S00B-AZC00-000 TRANS-A
14
CARLING SWITCH TRANS-B
8 7 8 7 INST GND 13
P/N V2D1S00B-AZC00-000 STR CRB
12
STR AW
1 1
11 TO ENGINE
4 4 SP-3
8 7 10
ALT EXC HARNESS
9
2 5 2 5 SP-2
1 4 8
SP-1
7
BAT-2
3 6 3 6 6
5 ST RLY

GP SW
2 5
FUL GAG
4
6 HORN
PRE-HEAT SWITCH INSTALLED FOR 3
3 HR MTR
CAT/PERKINS ENGINES ONLY. 2

GP SIG
BAT-1
1

PS IGN

HORN
HRN PWR
STR AW
STR PWR
STR CRB
CAB FIREWALL
TRANS
TEMP
SP-3
WARN
LIGHT SP-2
SP-1
18
17
SEALED ENDS

16

TR LT
GP SIG
15
GP SW
14
TR LT SW
13
BRK SOL
12
CLT TMP
IGNITION SWITCH 11 TO ENGINE
OIL GAG
10
PS IGN HARNESS
9
STOP LT
BAT ACC 8 SHEET 2
GND-2
7

BR SW PWR
WORK LT
6
5
STRT 4
3

PS IGN

KEY PWR
BACK LT
2
GND-1
1
G6-42A - S/N 0160021195 Thru 0160040678

KEY STRT
IGN

PS IGN
KEY ACC
SWI-86 SW2-87a SW1-87a SW2-86 GND 85 SPARE_COIL
DEUTSCH P/N HD-36-24-18-SN

O ALT EXC
SHIFT-B A P TRANS-B
TR LT B Q TR LT SW
BRK SW C R BRK SOL
KEY STRT D
SHIFT STRT E D1 S REV AL
T BACK LT

10 OHM (10A) (15A) (15A)

30W D2 D3 D4 D5 OPT-1 OPT-2 OPT-3
R1
87 87 87 87 87

87a 87a 87a 87a 87a

86 85 86 85 86 85 86 85 86 85
30 REV 30 30 30 30
ALARM WARN AUX AUX
SHFT PWR 2 F OPT
LT CK ELEC1 ELEC2
OPT-1
OPT-2
OPT-3

KEY ACC G

SL
GND1 GND2 GND3
SWB

U STOP LT
WL2 WL
SWB V WORK LT

D6 D7 D8 D9

HTR FAN 87 87 87 87
SW SW
87a 87a 87a 87a
86 85 86 85 86 85 86 85
30 30 30 30
FAN/HTR W/W LIGHTS ACC

TO TRANSMISSION
SHIFTER INST GND H

1
2
3
5
7
8

4
6
DEUTSCH W
P/N DT04-8P X
LOCKING WEDGE STR PWR I
W8P
GAG PWR J
HRN PWR K

SHIFT-B
TRANS-E
TRANS-C
TRANS-D

TRANS-A
KEY PWR L

SHIFT STRT
SHFT PWR 2

SHFT PWR 1
Y GND-2

M GND GND-1
MOTOROLA (25A) (25A) (25A) (10A) (25A) (30A)
D10 (10A) (10A) SPARE (15A) (10A)
MR 752 FAN/HTR W/W LIGHTS RELAYS GAGES STEER KEY HORN OPT_PWR AA BAT-2
(NOT REQUIRED) BAT
OR EQUIV
N
BATT BAT-1

WL_SWA SL_SWA
W/W_SW SPARE_BAT

MY1371
G9-43A/G10-43A - S/N 0160020823 Thru 0160040465 Excluding 0160040468 & 0160040672

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

 Electrical System

JOHN DEERE ENGINE

REV AL
18
TRANS-E
17 C
TRANS-D

DIODE
16
DEUTSCH P/N HD-34-24-18-SN

TRANS-C
15
TRANS-A
14
TRANS-B STR CRB STR CRB STEER
13 A 2W SELECT
STR CRB
12 GND-7 GND-7
TO CAB 11
STR AW B VALVE
SP-3
INSTRUMENT 10
ALT EXC
PANEL HARNESS 9
SP-2 4W
8
SP-1
7
BAT-2

DIODE
6
ST RLY
5
FUL GAG
4
HORN STR AW STR AW
3 A
HR MTR
2 GND-8 GND-8
BAT-1 B
1

CAB FIREWALL 30 86 ST RLY

ST RLY PWR
18 GND-6
17 87 85
16
DEUTSCH P/N HD-34-24-18-PN

15
14 STARTER
TR LT SW
13
BRK SOL
RELAY
12
TO CAB 11
CLT TMP
OIL GAG
INSTRUMENT 10
PS IGN
PANEL HARNESS 9
STOP LT STRT SOL
8
GND-2
7
WORK LT
STARTER
6
BAT-2 MOTOR
5
BAT-1
4
SNSR
3
BACK LT ALT BAT
2
GND-1
1

- + GROUND
HORN
HORN
BATTERY
12VDC
GROUND
(AT ENGINE
1 TRANS-A POD)
2 TRANS-B
3 TRANS-C
4 TRANS-D
TRANS-E SNSR SNSR
TO TRANSMISSION 5
BRK SOL ALT EXC ALT EXC
6
HARNESS 7 TR LT SW
GND-9 #1
8
9 GND-10
BATT #2
10 GND-11 SNSR
11 GND-12
GND-13
GND-1

GND-2

12
ALT EXC ALTERNATOR
GND-7
GND-8

NOT USED ALT BAT

GND-6

GROUND
(AT
STARTER GND-3
MOTOR) BRK SOL

PARK BRAKE SOLENOID

FUL GAG

FUL GAG
A
GND-4
WORK B DIODE
LIGHT FUEL
OPTION LEVEL
A B C SENDER
SEALED

B A
ENDS

SP-1
SP-2
SP-3
WORK LT
STOP LT
BACK LT

GND-3

BRK SOL
HR MTR

PS IGN REV AL

FUL SOL
BACK-UP
GND-5 ALARM MY1390
CLT TMP
OIL GAG

2 AMPS

FUEL
SOLENOID

OIL
PRESSURE SWITCH
OIL WATER (ON ENGINE)
PRESSURE TEMP.
SENDER SENDER

G6-42A, G9-43A, G10-43A 9-23

 Electrical System

PERKINS ENGINE

REV AL
18
TRANS-E
17 C
TRANS-D

DIODE
16
DEUTSCH P/N HD-34-24-18-SN

TRANS-C
15
TRANS-A
14
TRANS-B STR CRB STR CRB STEER
13 A 2W SELECT
STR CRB
12 GND-7 GND-7
TO CAB 11
STR AW B VALVE
SP-3
INSTRUMENT 10
ALT EXC
PANEL HARNESS 9
SP-2 4W
8
SP-1
7
BAT-2

DIODE
6
ST RLY
5
FUL GAG
4
HORN STR AW STR AW
3 A
HR MTR
2 GND-8 GND-8
BAT-1 B
1

CAB FIREWALL 30 86 ST RLY

ST RLY PWR
18 GND-6
17 87 85
16 GND-6
DEUTSCH P/N HD-34-24-18-PN

GP SIG
15
GP SW
STARTER
14
TR LT SW RELAY
13
BRK SOL
12
TO CAB 11
CLT TMP
OIL GAG
INSTRUMENT 10
PS IGN
PANEL HARNESS 9
STOP LT STRT SOL
8
GND-2
7
WORK LT
STARTER
6
BAT-2
MOTOR
5
BAT-1
4
GP PWR
3
BACK LT ALT BAT 1
2
GND-1 ALT BAT 2
1

- + GROUND
HORN
HORN
BATTERY
12VDC
GROUND
(AT ENGINE
POD)
ALT EXC

1 TRANS-A
TRANS-B ALT BAT 2 D+
2
TRANS-C ALT BAT 1
3 BATT W
4 TRANS-D
TRANS-E
TO TRANSMISSION 5
BRK SOL
HARNESS
6
TR LT SW ALTERNATOR
7
8 GND-9
GND-10
9
GND-11
PARK BRAKE SOLENOID
10
11 GND-12
12 GND-13
GND-13
GND-12

DIODE
GND-11
GND-10
GND-9
GND-1

GND-2

GND-7

B A
GND-8

GROUND
(AT GND-6
STARTER GND-3 GND-3 GND-3
MOTOR) BRK SOL BRK SOL
GND-5

REV AL
BACK-UP
GND-15

FUL GAG
GND-5 ALARM
GND-14

FUL GAG
A
GND-4
WORK B
LIGHT FUEL FUSE, 50 AMP GLOW PLUGS
OPTION LEVEL SLOW BLOW
A B C SENDER GP PWR GP RLY
SEALED

FP PWR
ENDS

SP-1
SP-2 GP SIG 86 30
SP-3
WORK LT
STOP LT
BACK LT

GND-6 GLOW PLG

85 87

GLOW PLUG
RELAY
GND-6

MY1380
CLT TMP

PS IGN
OIL GAG

FUEL PUMP
FUEL PUMP
GND-14
PS IGN

PS IGN
HR MTR

FP PWR

GND-14
FP RLY

FP RLY
PS IGN

PS IGN
GP SW

GND-6
C
A

85
86
87
30
87A
B

B
1

1
2

2
M

FUEL
OIL WATER SOLENOID
PRESSURE TEMP. FUSE FUEL PUMP FUEL PUMP
OIL COLD START
SENDER SENDER PRESSURE SWITCH 7.5 AMP RELAY
ADVANCE
5 PSI SOLENOID

9-24 G6-42A, G9-43A, G10-43A

 Electrical System

TRANSMISSION
TEMPERATURE SWITCH

GND-13 TR LT SW

DANA TRANSMISSION 250°F

(RISING)

TRANS-B
A
GND-9
B

ZENER DIODE

DIODE
B A
TRANS-A TRANS-A 1
TRANS-B 2
GND-9
B TRANS-C 3
TRANS-D 4
TRANS-E 5 TO ENGINE
A
TRANSMISSION

ZENER DIODE TR LT SW
6
HARNESS
7
GND-9 8
GND-10 9
GND-11 10
TRANS-C GND-12
A 11
C B
GND-10
GND-13 12

ZENER DIODE
D
TRANS-D
A
GND-11
B

E
ZENER DIODE

TRANS-E
A
GND-12
B

ZENER DIODE
DANA SHIFTER
1
2
3
4

F 1
N 2
R 3
4

1
2
3
4
1
2
3

7
8
4

6
TRANS-E
TRANS-C

TRANS-D
TRANS-A

SHFT PWR 2
SHFT PWR 1

SHIFT-B
SHIFT STRT

CAB INSTRUMENT
PANEL HARNESS
SHEET 1 MY1411

G6-42A, G9-43A, G10-43A 9-25

 Electrical System

DASH PANEL

PARK
BRAKE
LIGHT

HOUR METER
DATCON
P/N 56458-10

OIL FUEL
12 UDC
2
1
PARK BRAKE
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 GND 12V
8 7

GND 1 4

2 5
G TEMP

3 6
3

4 IN 1 GAGE
BEEDE

STEER
LIGHT

HORN
LIGHT

STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
CARLING SWITCH
P/N V2D1S00BAZC00-000
8 7
8 7 GND 85
1 4 MAST 1 4 SW1-86
8 7
SW1-87a 2 5 SW1-87a 8 7 GND 85
2 5
1 4 SIDESHIFT 3 6 SW1-86 SWING 1 4 SW2-86
5
3 6 SW2-87a 2 5 SW2-87a
2
EXTRA 3 6 SW2-86
6
3
MAST

SWING

TRANS
TEMP
WARN
LIGHT

SW1-87a
SW1-86
SW2-87a
SW2-86

MAST A BLACK
SIDESHIFT B RED
GND 85 C WHITE
SWING D GREEN
EXTRA E ORANGE
PLUG F PLUG

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

O
A P
B Q

ORANGE
C R

GREEN
WHITE
BLACK

PLUG
RED
E S
D1 T
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3
R1
C
A

D
E
B

F
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
WHITE

ORANGE

REV
GREEN
RED

PLUG
BLACK
OPT-1

OPT-2

30 30 30 30 30
OPT-3

ALARM WARN AUX AUX

F LT CK ELEC2 OPT
ELEC1
G
GND1 GND2 GND3
SL
SWB
U
WL2 WL D7 D8 D9 V
SWB D6

87 87 87 87

HTR FAN 86
87a
85 86
87a
85 86
87a
85 86
87a
85
SW SW 30 30 30 30 "TM" EXTRA (ORANGE)
FAN/HTR W/W LIGHTS ACC
"A" OPEN

GROUND (YELLOW)

H
W
X "S" MAST (BLACK)
I
"LT" SIDESHIFT (RED)
J "RT" SWING (BLUE)
K
L
Y

M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT

WL_SWA SL_SWA

W/W_SW SPARE_BAT

AUX ELECTRIC OPTION MY1420

9-26 G6-42A, G9-43A, G10-43A

 DASH PANEL

FRONT FRONT
WORK GND L1 WORK
LIGHT PARK WORK LIGHT
BRAKE LIGHT IND LT

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

(ON CAB) LIGHT INDICATOR (ON CAB)
HOUR METER
DATCON
P/N 56458-10
WORK LIGHT
OIL FUEL CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1
PARK BRAKE 8 7
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 1 4 GND 12V
8 7
5
GND 2
1 4
6
2 5 3
G TEMP

3 6
3

4 IN 1 GAGE
BEEDE

WORK LT

LIGHT SW
A B A B

STEER
LIGHT
HORN
LIGHT

STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000

DEUTSCH P/N HD-36-24-18-PN

DEUTSCH P/N HD-34-24-18-SN
CARLING SWITCH
8 7
P/N V2D1S00BAZC00-000

1 4
8 7 REV AL REV AL
18

GND L
GND L

LIGHT-1
LIGHT-2
2 5 TRANS-E TRANS-E
1 4 17
TRANS-D 16 TRANS-D
3 6
5 TRANS-C TRANS-C
2 15
TRANS-A TRANS-A
6 14
3 TRANS-B TRANS-B
13
STR CRB STR CRB
12
STR AW STR AW
11
SP-3 SP-3
10
TRANS ALT EXC ALT EXC
9
TEMP SP-2 SP-2
WARN 8
LIGHT SP-1 SP-1
7
FRONT
BAT-2 BAT-2
6 WORK
ST RLY ST RLY LIGHT
5
FUL GAG FUL GAG
4
HORN HORN
3
HR MTR HR MTR
2
BAT-1 BAT-1
1
GND

MIRROR-LT

CAB FIREWALL

LIGHT SW LIGHT-2 A B
18
17

GND L
GND L
GND L1 16

IND LT 15
14
TR LT SW TR LT SW
13 REV AL
BRK SOL BRK SOL
12
GND

BACK-UP

WORK LT
CLT TMP CLT TMP

LIGHT SW
11 GND 1 ALARM
OIL GAG OIL GAG
MIRROR-LT

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL 10

PS IGN PS IGN
9 GND 2
STOP LT STOP LT
O 8
GND-2 GND-2
A 7 WORK LT
P GND-5
WORK LT WORK LT
B Q 6 C
C R 5 STOP LT GROUND
D 4 B (AT
S 3 BACK LT STARTER
E MOTOR)
T BACK LT BACK LT
2 A
D1 GND-1 GND-1
1
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3
R1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
30 REV 30 30 30 30
ALARM WARN AUX AUX
F LT CK ELEC2 OPT

OPT-1
OPT-2
OPT-3
ELEC1
BACK LT
STOP LT
TAIL LT

GND L1
GND L
GND L
G
GND1 GND2 GND3
SL
SWB GND L A B C
DEUTSCH P/N HD-36-24-18-SN
DEUTSCH P/N HD-34-24-18-PN

U
WL V

STOP LT
LIGHT-1 WL2 SWB D7 D8 D9
D6

87 87 87 87

GND DL
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30

FAN/HTR W/W LIGHTS ACC

H BACK-UP STOP TAIL

LIGHT LIGHT LIGHT
(GREEN) (RED) (BLACK)
W
X REAR TAIL LIGHT
I ASSEMBLY

J
K
L
Y

M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT

WL_SWA SL_SWA GND DL

IND LT

W/W_SW SPARE_BAT

DOME LT DOME LT

DOME
WORK LT LIGHT
DOME
STOP SW LIGHT
SWITCH

STOP LT
STOP SW
WORK LIGHT OPTION

MY1440
STOPLT SW
Electrical System

9-27
9-28
DASH PANEL

BEACON
LIGHT GND L1
(ON CAB) PARK BEACON
BRAKE LIGHT IND LT
LIGHT INDICATOR

HOUR METER
DATCON
P/N 56458-10
BEACON LIGHT
OIL FUEL CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1
PARK BRAKE 8 7
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 1 4 GND 12V
8 7
5
GND 2
1 4
6
2 5 3
G TEMP

3 6
3

4 IN 1 GAGE
BEEDE

A B

BEACON-1

BEACON SW
STEER
LIGHT

HORN
LIGHT
Electrical System

STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
CARLING SWITCH
8 7
P/N V2D1S00BAZC00-000

1 4
8 7

GND L
2 5

BEACON SW
1 4

3 6
5
2
STAB-SW1 STAB-SW2
6
3

STAB-PWR

GND-8
TRANS
TEMP
WARN
LIGHT

A B C D A B

OIL
GND-7

PRESSURE SWITCH
(ON ENGINE)

DIODE

BLUE
RED

WHITE
BLACK

ORANGE

+ -
N.O.

N.C.

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

STABILIZER STABILIZER
O PROXIMITY VALVE
A P SENSOR
B Q
C R
D
E S TO COMMON GROUND
D1 T ON ENGINE
10 OHM (10A) (15A) BELL HOUSIING
D2 D3 D4 D5 (15A)
30W OPT-1 OPT-2 OPT-3
R1

BEACON-1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
30 REV 30 30 30 30
ALARM WARN AUX AUX
F LT CK ELEC2 OPT

OPT-1
OPT-2
OPT-3
ELEC1
G REAR AXLE
GND1 GND2 GND3
SL
SWB GND L STABILIZER
U
WL V
D8
WL2 SWB D6 D7 D9
OPTION
87 87 87 87

HTR FAN 87a 87a 87a 87a

86 85 86 85 86 85 86 85
SW SW 30 30 30 30

FAN/HTR W/W LIGHTS ACC

H
W
X
I
J
K
L
Y

M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT

WL_SWA SL_SWA

W/W_SW SPARE_BAT

MY1450
BEACON LIGHT OPTION

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

 Electrical System

JOYSTICK
RED BLUE

TILT SPEED
CONTROL

BLACK

GRAY
ADJUSTABLE TILT ON JOYSTICK OPTION
A B C D E F

YELLOW
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

RED
O
A P DEUTSCH 6-PIN

TILT DWN
B Q

TILT PWR 1

TILT PWR 2
DT 06-65

TILT UP
C R
D
E S
D1 T
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3

TILT PWR
R1

TILT PWR 2
TILT PWR 1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
REV

OPT-1

OPT-2
30 30 30 30 30

OPT-3
ALARM WARN AUX AUX
F LT CK ELEC2 OPT
ELEC1
TILT PWR
G
GND1 GND2 GND3
SL
SWB
U
WL V
WL2 SWB D7 D8 D9
D6

87 87 87 87

HTR FAN 87a 87a 87a 87a

TILT DWN
86 85 86 85 86 85 86 85
SW

TILT UP
SW 30 30 30 30

FAN/HTR W/W LIGHTS ACC

A
B
H
W

TILT DWN
TILT UP
X
I
J
K
L
Y

M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT

WL_SWA SL_SWA

W/W_SW SPARE_BAT

TILT DWN TILT UP

GND-15 GND-16

A B A B
GND-15

GND-16

DIODE DIODE

MAIN CONTROL MAIN CONTROL

VALVE VALVE MY1460

G6-42A, G9-43A, G10-43A 9-29

 Electrical System

JOYSTICK
RED BLUE

BLACK

GRAY
TILT ON JOYSTICK OPTION
A B C D E F

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

O
A P DEUTSCH 6-PIN

TILT DOWN
TILT PWR1

TILT PWR2
B Q DT 06-65

TILT UP
C R
D
E S
D1 T
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3
R1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
REV

OPT-1

OPT-2
30 30 30 30 30

OPT-3
ALARM WARN AUX AUX
F LT CK ELEC2 OPT
ELEC1
G
GND1 GND2 GND3
SL
SWB
U
WL V
WL2 SWB D7 D8 D9
D6

GND-15

GND-16
87 87 87 87

HTR FAN 86
87a
85 86
87a
85 86
87a
85 86
87a
85
SW SW 30 30 30 30

FAN/HTR W/W LIGHTS ACC

H
W
X
I
J
K
L
Y

M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT

WL_SWA SL_SWA
TILT DOWN

W/W_SW SPARE_BAT
TILT UP

TILT DWN TILT UP

GND-15 GND-16

A B A B

DIODE DIODE

MAIN CONTROL
VALVE
MAIN CONTROL
VALVE
MY1470

9-30 G6-42A, G9-43A, G10-43A

G6-42A, G9-43A, G10-43A
BAT HSW
GND HSW

SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL

O
A P

HIG WSW

WAS WSW
LOW WSW
B Q

PAR WSW

BAT HSW
GND HSW
C R
D
E S
D1 T
10 OHM (10A) (15A)
THERMOSTATIC PRESSURE SWITCH CLUTCH ON
D2 D3 D4 D5 (15A)
30W OPT-1 OPT-2 OPT-3 A B C D E F SWITCH A/C (IN CAB) COMPRESSOR
R1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
30 REV 30 30 30 30 4A
ALARM WARN AUX AUX
F LT CK ELEC2 OPT

OPT-1
OPT-2
OPT-3
ELEC1

BAT HSW
GND HSW
G

PAR WSW
LOW WSW
WAS WSW
HIG WSW
GND1 GND2 GND3
SL
GND HSW
SWB
U ON ENGINE
WL V
WL2 SWB D7 D8 D9
D6

87 87 87 87
BAT HSW FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85 CONDENSER FANS
SW 30 30 30 30
HTR (ON ROOF)
SW FAN/HTR W/W LIGHTS ACC

A/C SWITCH IN M
H
RH CONSOLE
W
17A
X
I
M
J
K
L
Y

M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
BAT

BAT HSW
N
BAT
"C" 86 87a 87
WL_SWA SL_SWA HEATER
SPARE_BAT SWITCH
W/W_SW
RELAY

85 30
HIG HSW
MED HSW
LOW HSW
GND HSW

3-FRONT

A B C D

AIR CONDITIONING OPTION

A/C AND
(JOHN DEERE ONLY) HEATER
MOTOR

MY1490
Electrical System

9-31
G6-42A, G9-43A, G10-43A 9-32
MY6300 B
KEY BAT PWR
1
KEY/IGN

KEY START
4

KEY IGN
2

(SHIELD/020)
C
KEY ACC (CAN L/905,GREEN)
(SHIELD/020)

B
SHIELD (SHIELD/020) (CAN H/904, YELLOW)
C A
(CAN L/905, GREEN)

CAN L (CAN L/905)

(CAN H/904, YELLOW)

B (SHIELD/020)
CAN H (CAN H/904) C
3 31 30 29

A (CAN L/905,GREEN)
SHIELDED B
(CAN H/904, YELLOW)
CABLE A
(D BLU, 18 GA GXL)
FUL LVL FUL LVL
12
1
GAUGE
STONERIDGE

DASH GND DASH GND (BLK, 18 GA GXL)

5
2
3 2

GAGE PWR GAGE PWR (RED, 18 GA GXL)

5 4

ENG STOP LT ENG STOP LT (ORG, 18 GA GXL)

TRANS TMP SW (D BLU, 18 GA GXL)
3 4 5

TRANS TMP SW
6 22 13

ENG WARN LT ENG WARN LT (ORG, 18 GA GXL)

WAIT TO START LT WAIT TO START LT (WHT, 18 GA GXL)
21 20

PLUGGED PLUGGED
6 7 8

HD34-24-31ST
DASH PANEL HARNESS

HORN PWR HORN PWR

HORN HORN
7 11
3
(RED, 18 GA GXL)

HORN
2
(RED, 18 GA GXL)
(RED, 18 GA GXL)
(RED, 18 GA GXL)

GND FAULT
17

PK BRK SOL PK BRK SOL

ENG STOP

16
ENG WARN
MAIN DASH PANEL

STR CRB STR CRB

TRANS TMP WRN
WAIT TO START

STEER/SWAY PWR
STR AW STR AW
10 8 9

TRAN/BRK PWR TRAN/BRK PWR

23

DCLUTCH IN
ST RLY ST RLY
14
7

STEER/SWAY PWR
4
3

6
1

7
4
3

6
1

SHIFT PWR 1 SHIFT PWR 1

TILT UP
2

TILT DN
PARK BRAKE

DCLUTCH
STEER MODE

AUX A
AUX B
ACC MOD GND DASH GND
15 25 26 27 18 19 24
120 OHM

A
B

A
B
C

C
CAN TERMINATOR

AUX A
AUX B
TILT UP
TILT DN
KEY IGN

DCLUTCH

GND FAULT
PK BRK SOL
DCLUTCH IN

ACC MOD GND

A
B
C
(SHIELD/020)

(CAN L/905,GREEN)
(CAN H/904, YELLOW)
N
F4
F3
F2
F1

R3
R2
R1
GEAR
CAB
TURNER

E4, E3
E4, E2
E4, E1
E6, E3
E5, E3
E5, E2
E5, E1

SEE SHEET 3
NO SOLENOIDS INGAUGED
TRANSMISSION LEGEND

ACTIVATED TRANS SOLENOIDS

SW3

CAB BULK HEAD

SW1
F

1
4
N

TRANS SOL Y1
2
3

TRANS SOL
TRANS SOL Y3
TRANS SOL Y6
SHIFT PWR 2
HOBBS

REVERSE SOL
PLUGGED
TRANS SOL Y5
2
3

1
4
N

KEY START
F

SHIFT PWR 1
TRANSMISSION SHIFTER

PLUGGED
SW4

PLUGGED
SW2

1 2 3 4 5 6 7 8 9 10 11 12

PLUGGED
SW3
SW1

PLUGGED

26 27
F

1
4
N

TRANS SOL Y1 TRANS SOL Y1

2
3

TRANS SOL Y3 TRANS SOL Y3

TRANS SOL Y5 TRANS SOL Y5
TRANS SOL TRANS SOL
SHIFT PWR 1 SHIFT PWR 1
HOBBS

KEY START KEY START

REVERSE SOL REVERSE SOL
SHIFT PWR 2
2
3

SHIFT PWR 2

1 3 5 4 8 7 2 9
1 2 3 4 5 6 7 8
1
4
N
F

TRANS SOL Y6

6
TRANSMISSION SHIFTER

SW4
SW2

ON-IDLE
IVR
THR SGN/915 THR SGN/915
THR RTN/914 THR RTN/914

HD34-24-31PT
THR SUP/911 THR SUP/911
IVS IVS
SHIFTER GND ON-IDLE
WILLIAMS
(SUSPENDED)

SP ACCY PWR IVR

A B C D E F
THROTTLE

CAB CONTROL HARNESS

SP CAB GND 1
SP CAB GND 2

30 31 14 15 13 29 12 17 18 19
PLUGGED 3 87a
TWIST
12 TURNS
PER FOOT

TRAN/BRK PWR TRAN/BRK PWR 1 30

REVERSE REVERSE 4 87
RELAY

REVERSE SOL 5 86
SP-1
REVERSE

SHIFTER GND 2 85
SP-2
SP-3

11 10 20 21 22
PLUGGED PLUGGED 3 87a

25
SHIFTER GND 1 30
TRANS TMP SW TRANS TMP SW 4 87
SP BAT PWR KEY START 5 86
SP BAT PWR SHIFTER GND 2 85
TEST RELAY
WARN LIGHT

23 16 28
AC CLUTCH

24
F4
F3
F2
F1

N4
N3
N2
N1
R4
R3
R2
R1
GEAR

SP-3
SP-2
SP-1

SP BAT PWR

AC CLUTCH
SP CAB GND 2
SP CAB GND 1
SP ACCY PWR
Y2,Y6
Y1,Y6

Y2,Y3,Y6
Y1,Y3,Y6

Y2,Y3,Y5,Y6
Y2,Y3,Y4,Y6
Y1,Y3,Y5,Y6
Y1,Y3,Y4,Y6

SEE
Y6 (ONLY IF PARK BRAKE OFF)
Y6 (ONLY IF PARK BRAKE OFF)
Y6 (ONLY IF PARK BRAKE OFF)
Y6 (ONLY IF PARK BRAKE OFF)
ACTIVATED TRANS SOLENOIDS
TRANSMISSION LEGEND ZF

SHEET 2
G9-43A/G10-43A - S/N 0160040465 & After including 0160040468 & 0160040672
G6-42A - S/N 0160040678 & After 9.5.4
Electrical System
 BEACON WORKLIGHTS
OPTIONS 1
2 2
3 3 STOP LT
OPTIONS VEC WORKLIGHT/
BEACON 4 STOPLIGHT
WIPER HEATER/BLOWER
S/W LT PWR SWITCH
F1 20 WIPER PWR OPTION
A
F5 20 HEATER PWR 6 5 DOME/BCN GND

30
87
86
85
30
87
86
85
B

87a
87a

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

KEY ACC STOP LT STOP LT
AUX ELECTRICS C
BCN PWR BCN PWR BCN PWR

1 3
F7 10
D
F8 10 D FAN PWR DOME
E
F6 20 DOME LT DOME LT DOME LT DOME LT LIGHT
1 1 LIGHTS BCN/FAN
A

GREEN-4
F
CAB LT PWR CAB LT PWR CAB LT PWR
2 2 G

30
87
86
85
30
87
86
85

87a
87a
S/W LT PWR S/W LT PWR

4 6 2
H S/W LT PWR
3 3 BCN LT
AUX ELEC1
SW1 86 WORK LT WORK LT DOME/BCN GND

8
BEACON
A B

30
87
86
85

87a
4 4 OPTION (15A) OPTION (25A)
HEATER GND
B
CAB LT GND CAB LT GND CAB LT GND
C CAB LTS

30
87
86
85
30
87
86
85

87a
87a
DOME/BCN GND DOME/BCN GND DOME/BCN GND

7 5
5 5 D CAB LT GND LEFT
AUX ELEC2
A B

6 6 AUX ELEC PWR

E
SW1 87A CAB LIGHTS

BLUE-3

30
87
86
85
F

87a
7 7

F4
F3
F2
SW2 86 CAB LTS
G
SW2 87A CAB LT GND RIGHT
A B

25
15
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
OPTIONS
FUSE LEGEND
F1 20A WIPER PWR
WINDSHIELD
F2 5A 5A ROOF WIPER PWR WASHER
DASH BLOWER HEATER M WIPER MOTOR
F3 15A 15A OPTION PWR 2 FAN MOTOR VALVE MOTOR
F4 25A 25A OPTION PWR M
F5 20A HEATER/BLOWER PWR M M M
WIPER
F6 20A LIGHT PWR 1 2 3 4 5 6 7 8 9 10

25A OPT
PLUGGED
QC GND
F7 10A BEACON PWR H

15A OPT 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
D FAN GND

AUX SW GND

MAST
LW

25A OPT GND

B

SWING
EXTRA
F8 10A DASH FAN PWR

SW2 86
SW1 86
15A OPT 2 GND

SW2 87A
SW1 87A
PLUGGED
PLUGGED
PLUGGED

SIDESHIFT
P

AUX SW GND
5A ROOF WIPER PWR
5A ROOF WIPER GND
A B A B C D
AUX
ELECTRIC 1 2 3 4 5 6 7 8 9 10 11 12

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
OPTION

HEATER GND
HEATER PWR

HTR CNTRL B
EMPTY
EMPTY
WASHER

WIPER HI
WIPER LO

WIPER LO
WIPER HI
WIPER PWR

WIPER PARK

WIPER PARK
WASHER

D FAN PWR
D FAN GND
HEATER HI

MAST
HEATER MED
HEATER LOW
HEATER GND

SWING
EXTRA
SW2 86
SW1 86

SW2 87A
SW1 87A
PLUGGED
PLUGGED
PLUGGED

SIDESHIFT
25A OPT
25A OPT GND

AUX SW GND
15A OPT 2
ROOF WIPER

15A OPT 2 GND

MOTOR

A
B

A
OPTION
25 A
M D FAN PWR D FAN PWR
HEATER PWR HEATER PWR
WIPER PWR WIPER PWR
HEATER GND HEATER GND

OPTION 2 B
15 A
8K OHM
D FAN GND D FAN GND
PLUGGED PLUGGED

A B C D E F
HTR TEMP
BLOWER
ENCLOSED CAB A B C

(RED)
M H
OPTION A/C SWITCH RESISTOR LOCATED
L B
C
APPROX 10" BEHIND
HEATER TEMP SWITCH

5A ROOF WIPER PWR

5A ROOF WIPER GND
CONNECTION IN
ENCLOSED CAB
RLY 87 A OPTIONS HARNESS
HTR CNTRL A
HEATER GND

AUX ELEC PWR

HEATER PWR

25A OPT GND B CONDENSER FANS

24 KOHM,1W

FAN SW C

(ON ROOF)
HEATER PWR

M 17A M
A 87
86 85
30
(BLACK)

THERMOSTATIC
(RED/WHITE)

QUICK CONNECT SWITCH A/C PRESSURE SWITCH

1
AC CLUTCH PRS SW AC SW
2

~
SEE SHEET 1
3
AC SW
4

5 87 a
6 A/C
86 85
30 RELAY

AUX RLYS PWR

7

25A OPT
25A OPT GND
25A OPT GND

OPT GND 2

SIDESHIFT
PLUGGED
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1

SWING
MAST

EXTRA
OPT PWR 1
QC PWR 1
QC GND 5
QC PWR 2
QC GND 7
KEY ACC
WORK LT
STOP LT

AUX RLYS PWR

6 5 19 17 15 8 10 12 14 16 18 7 9 11 13 2 1 4 3

OPTIONS HARNESS
HD36-24-19PE

TO CHASSIS ASSEMBLY

MY6310 B
Electrical System

9-33
9-34
ACCESSORY MODULE OPTION
Electrical System

CONNECTOR PIN TAGNAME DESCRIPTION TYPE

1 KEY IGN IGNITION POWER INPUT 1 5 EXC TILT +5 ANALOG EXCITATION VOLTAGE POWER OUTPUT
2 ACC MOD GND ACCESSORY MODULE GROUND POWER INPUT 2 TILT SIG A FORK TILT SIGNAL A ANALOG INPUT
3 TRIG JOYSTICK TRIGGER FOR DE-CLUTCH DIGITAL INPUT 3 TILT GND ANALOG GROUND POWER OUTPUT
4 DCLUTCH IN TRANSMISSION DE-CLUTCH INPUT DIGITAL INPUT 4 5 EXC AUX +5 ANALOG EXCITATION VOLTAGE POWER OUTPUT
5 DI2 SPARE DIGITAL INPUT DIGITAL INPUT 5 AUX SIG A AUX HYD SIGNAL A ANALOG INPUT
6 ROLLER SEL ROLLER / JOYSTICK SELECT DIGITAL INPUT 6 AUX GND ANALOG GROUND POWER OUTPUT
J1 (BLACK) J2 (GREY)
7 TILT UP TILT UP VALUE DIGITAL OUTPUT 7 TILT SIG B FORK TILT SIGNAL B ANALOG INPUT
8 TILT DN TILT DOWN VALVE DIGITAL OUTPUT 8 AUX SIG B AUX HYD SIGNAL B ANALOG INPUT
9 AUX A AUX HYD VALVE A DIGITAL OUTPUT 9 CAN H/904 CANBUS HIGH SERIAL I/O
10 AUX B AUX HYD VALVE B DIGITAL OUTPUT 10 CAN L/905 CANBUS LOW SERIAL I/O
11 DCLUTCH TRANSMISSION DE-CLUTCH OUTPUT DIGITAL OUTPUT 11 TX RS-232 TRANSMIT SERIAL OUTPUT
12 GND FAULT GND RLY FAULT SIG DIGITAL OUTPUT 12 RX RS-232 RECEIVE SERIAL INPUT

CAN SHIELD
CAN L/905 1
DCLUTCH IN SEE SHEET 1
CAN H/904 IGN
2
DCLUTCH IN TILT UP
1 3
KEY IGN 4 TILT DN NOTE: FOR BASE MACHINE
2 DCLUTCH
3
TILT UP 5 OR FAILED ACCESSORY
TILT DN 6 AUX A
4 SEE SHEET 1 MODULE ONLY
DCLUTCH AUX B
7
5 ACC MOD GND
6 AUX A 8
AUX B 9
PK BRK SOL
7 PLUGGED
ACC MOD GND 10
8 GND FAULT
PLUGGED PK BRK SOL 11
9 PLUGGED
PLUGGED 10 PLUGGED 12
GND FAULT 11
GND FAULT
PLUGGED 12
PLUGGED

KEY IGN KEY IGN G SERIES

1
5
ACC MOD GND
TRIG TRIG 6
DCLUTCH IN TILT SIG A
3 OPTIONAL FORK TILT ON
DI2 TILT GND JOYSTICK W/ DE-CLUTCH TRIGGER
2
ROLLER SEL TILT SIG B 4
TILT UP 5 EXC TILT

J1 (BLACK)
TILT DN 1
AUX A PLUGGED
7
AUX B PLUGGED
8
DCLUTCH
GND FAULT

2 3 4 5 6 7 8 9 10 11 12
5 EXC TILT OPTIONAL
TILT SIG A PROPORTIONAL AUX.
PADDLE
TILT GND
5 EXC AUX 5 EXC AUX
1

ACCY. MODULE
AUX SIG A AUX SIG A 3
AUX GND AUX GND 2
TILT SIG B
AUX SIG B

J2 (GREY)
AUX SIG B 4
CAN H/904 KEY IGN 5
CAN L/905 ROLLER SEL NEUTRAL SWITCH
6
TX
RX

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4

JLG ANALYZER

MY6320 B

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

 1
TO CAB ASSEMBLY 2

(OPT)

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

REVERSE (OPT)
TAIL LIGHT HORN
ALARM A/C QC DIVERTOR (OPT)
BU STOP TAIL TO DASH PANEL HARNESS TO CAB CONTROL HARNESS TO OPTIONS HARNESS COMPRESSOR A B C D E F VALVE
AUXILIARY
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M ELECTRIC
NEGATIVE CABLE
TO CAB FIREWALL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 A S LT RT TM
A B

BLK
RED
YEL
BLU
ORG

(-)

GRN
RED
BLK
PLUGGED
A B C D
A B C D E F

MAST
BLK
YEL
BLU

RED
ORG

SP-3
SP-2
SP-1

HORN
TILT DN

HORN
SP-1
SP-2
SP-3
TILT UP

LT GND
QC GND 5
QC GND 7
SP GND 1

REVERSE
STR AW
ST RLY
AC CLUTCH

GND FAULT
AUX A
AUX B

KEY IGN
KEY ACC
STR CRB
FUL LVL
TILT UP
TILT DN
DCLUTCH
PLUGGED
CAN H/904
CAN L/905
SHIELD /020
REVERSE
IVS
ON-IDLE
IVR
KEY ACC
STOP LT
WORK LT
EXTRA
SWING
SIDESHIFT
SP BAT PWR

QC PWR 1

DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR

KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR 2
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2

PK BRK SOL
SHIFT PWR 2
SP BAT PWR
SP BAT PWR

ACC MOD GND

KEY BAT PWR

SHIFT PWR 1
ENG WARN LT
SHIFT PWR 1
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP ACCY PWR

TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
REVERSE SOL
TRANS SOL Y3
TRANS SOL
TRANS SOL Y5
TRANS SOL Y6
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
AUX ELEC GND

WAIT TO START
STAB/TILT PWR

STEER/SWAY PWR
AC CLUTCH GND
CABLE
+ -

LT GND

REVERSE
STOP LT
WORK LT
12 VDC
QC GND 7
QC GND 5
PLUGGED

QC PWR 2
QC PWR 1
BATTERY

POSITIVE CABLE AUX ELEC GND

PLUGGED

TO STARTER
AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK

BAT GND
BAT GND
BAT POS
BAT POS
A B C D E F
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
A C A C POWER DIST
BLACK-6 GRAY-5 VEC
DASH GND
A
F2 5 ALT EXC
B
ACCY-2 IGNITION-2
MAST

F5 15 SP ACCY PWR
EXTRA
SWING

C
AUX RLYS PWR
PLUGGED

F6 10
SIDESHIFT

30
87
86
85
30
87
86
85
D

87a
87a
OPT GND 1
E
AUX ELEC GND

KEY ACC

GREEN-4
F
F1 15 TRAN/BRK PWR
G
IGNITION-1 ACCY-1
OPT GND 2
H

30
87
86
85
30
87
86
85

87a
87a
SP CAB GND 1
A
SP CAB GND 2
B
SP GND 1
C
AC CLUTCH GND
D
AUX ELEC GND
E

F8
F3
F4
F9
F7
LT GND

BLUE-3

CB4
CB3
CB1
F10
CB2
F11
F12
F
STR/FUL GND

20
20
20
20
G

25
10
10
25
15
10
10
15
ACC MOD GND
H

SHIFT PWR 2
BLACK-1 GRAY-2 DCLUTCH
H G F E D C B A H G F E D C B A

A 87
TRANSMISSION DECLUTCH
86 85 RELAY
30

KEY IGN
ENG GND

GAGE PWR
HORN PWR

OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4

SP BAT PWR

SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050

STAB/TILT PWR

STEER/SWAY PWR
STR/FUL GND

PK BRK SOL

12 TURNS
2
VLV GND PER FOOT POWER DISTRIBUTION
AUX A TWIST FUSE/BREAKER LEGEND
PROPORTIONAL 1
HYDRALIC AUX. 2 VLV GND CABLE
VALVE FUSE 20A OPTION POWER 3
1 AUX B
FUSE 20A OPTION POWER 4
2
VLV GND
FUSE 20A OPTION POWER 1
TILT-ON TILT UP
1
JOYSTICK VLV GND FUSE 20A OPTION POWER 2
2
VALVE TILT DN F1 15A TRANS/PARK BRK PWR
1
F2 5A ALTERNATOR EXCITE
ALL WHEEL STR AW F3 10A ENGINE ECU IGN PWR
1
IVS
ON-IDLE
IVR

THR SUP/911
THR SGN/915
THR RTN/914

STEER STR/FUL GND

PK BRK SOL

TRANS SOL Y1

2
REVERSE SOL
TRANS SOL
TRANS SOL Y3
ECU GND/050
TRANS SOL Y5
PLUGGED

TRANS SOL Y6
PLUGGED

SHIELD /020

CAN H/904
CAN L/905
F4 10A GAGE (INST PANEL) PWR

ST RLY
ENG GND

PLUGGED
MODE
PLUGGED

PLUGGED

ENG WARN LT
ENG STOP LT
ALT EXC

WAIT TO START LT
TRANS TMP SW

ECU IGN/012
ECU BAT/022
VALVE STR CRB
CRAB 1 F5 15A SPARE ACCESSORY PWR
STR/FUL GND
2 F6 10A AUX ELECTRIC PWR
STR/FUL GND F7 15A HORN PWR
FUEL B
SNDR FUL LVL 20 7 8 1 2 13 5 14 15 16 4 19 21 22 25 26 3 28 6 10 11 12 23 24 9 17 27 29 18 23 24 F8 25A SPARE BATTERY PWR
A
CHASSIS HARNESS F9 25A ENGINE ECU BAT PWR
HD34-24-29PE
F10 10A STEER/SWAY PWR
TO POWER UNIT ASSEMBLY F11 10A R. AXLE STAB/TILT
F12 15A KEY BATTERY PWR

VLV GND

GND FAULT
ACC MOD GND
A 87
GROUND FAULT
85 86 RLY
30

MY6330 B
Electrical System

9-35
9-36
TO BATTERY
POSITIVE ECM PWR
TO BATTERY
FUSE NEGATIVE
X10
POWER UNIT 30A X02
X44 X11 BLK ECM GND BLK ECM GND BLK ECM GND
1
TO ENGINE S12 BLK ECM GND BLK ECM GND
BLOCK 2
RED ECM PWR - RED ECM PWR RED ECM PWR
3

1
2
S09 RED ECM PWR RED ECM PWR
4

FC37
ECM POWER
BLK ECM GND
RED ECM PWR -
RED ECM PWR - X03
YEL CAN H/904
1
29 2
BRN TRANS SOL 6
28 3
27 4
BRN TRANS SOL 5
26 5
BRN TRANS SOL
25 6
BRN IVR
24 7
BLU ON-IDLE
23 8
BRN TRANS SOL 3
22 9
BRN REVERSE SOL
21 10
YEL WAIT TO START LT
20 11
BRN TRANS SOL 1
19 12
WHT IVS
18 13
BLU TRANS TMP SW
17 14
BRN CAN SHIELD/020 WHT IVS
16 15
GRN CAN L/905 S16
15 16
YEL CAN H/904 S15
14 17
RED STRT RLY S17 S26
13
Electrical System

18
YEL THR RTN/914
12 19
GRN THR SGN/915
11 20
BRN THR SUP/911 GRN CAN L/905
10 21

HD36-24-29PE
RED ALT EXC S25
9 22
YEL ENG STOP LT
8 23

ENGINE HARNESS
YEL ENG WARN LT BLU ON-IDLE
7 24
VIO PK BRK SOL
6 25

TO CHASSIS ASSEMBLY
5 26
BLK ENG GND BRN THR SUP/911

GRN CAN L/905

4 27

BRN CAN SHIELD/020

YEL CAN H/904

BLK ECM GND/050 YEL THR RTN/914
3 28
RED ECM BAT/022
2 29
RED ECU IGN/012
1 30
S41
X04 31
4 32
BLK SPARE GND -
3 33
RED SPARE BAT -
2 34

S42
RED SPARE IGN - GRN THR SGN/915
1 35

BRN CAN SHIELD/020

X40 36
37
BLK ENG GND BLK ENG GND
12 38
BLK ENG GND S06
11 39
CUMMINS ENGINE ECM CONNECTION (60 PIN)

VIO PK BRK SOL

BLU TRANS TMP SW
10 40
BRN IVR
9 41
VIO PK BRK SOL VIO PK BRK SOL
8 42
S07 YEL ENG WARN LT
7 43
BRN TRANS SOL 6 BLK GRID HTR RTN
6 44
BRN TRANS SOL 5 RED ECU IGN/012
5 45

CONNECTION
BRN TRANS SOL
4 46
BRN TRANS SOL 3 YEL ENG STOP LT
3 47
BRN REVERSE SOL
2 48

TRANSMISSION HARNESS
BRN TRANS SOL 1
1 49
X05 50
51
52
PARK BRAKE BLK ENG GND YEL WAIT TO START LT
2 53
VIO PK BRK SOL
SOL 1 54
X13 WHT GRID HTR
1 55
2 56

DIODE
MS32 57

MOLDED
BRN CAN SHIELD/020
NC 58
9 59
8 60
BRN CAN SHIELD/020
7 NC
S24
6
5
GRN CAN L/905
4
YEL CAN H/904
3
RED ECM BAT/022

DIAGNOSTIC
CONNECTOR
2
BLK ECM GND/050
1
S39
X21

BLK SPARE GND - ALT PWR

FUSE
FC22
RED ECM BAT/022 150A
2
RED ECM BAT/022
1

30A

DIAGNOSTIC
POWER FUSE
1
1
FC36-1
FC36-2
CUMMINS ENGINE

RED ALT PWR RED ALT PWR X28

RED ALT PWR RED ALT PWR
1 1
M X27

1 RED STRT SOL -

X29

3
RED ALT EXC
ALTERNATOR 2
IP35 RED STRT PWR -
1 1
X34 X43
RED STRT RLY

BLK ENG GND

BLK ENG GND

MS33
TRANSMISSION LEGEND
2

DIODE
1 GEAR ACTIVATED TRANS SOLENOIDS

MOLDED
RED STRT RLY

TRANS SOL Y1 FC30-2 F1 Y1,Y3,Y4,Y6

RED STRT PWR -
Y1 1
ENG GND

A B
FC30-1

FUSE
RED STRT PWR F2 Y1,Y3,Y5,Y6
1

80A
TRANS SOL Y2

START SOL
Y2 ENG GND 1

A B
F3 Y1,Y3,Y6
2
BLK GRID HTR RTN

TRANS SOL Y3 3
WHT GRID HTR

Y3 ENG GND F4 Y1,Y6

BRN CAN SHIELD/020

A B
GRN CAN L/905
YEL CAN H/904

4
X23

TRANS SOL Y4 5 R1 Y2,Y3,Y4,Y6

1
1
1
1
3
2
1

RED STRT SOL -

RED STRT PWR

RL18-86
RL18-30
RL18-87

RL18-85

Y4 ENG GND 6

A B
RL20

2
1
1
1
RL20-2
RL20-1

R2 Y2,Y3,Y5,Y6
85
86
30
87

7
TRANS SOL Y5
Y5 8
ENG GND R3 Y2,Y3,Y6

A B
9
PRK BRK SOL 10
120 OHM

Y6 ENG GND GRID HEATER R4 Y2,Y6

11

A B

ZF TRANSMISSION
START RELAY
12 RELAY N1 Y6 (ONLY IF PARK BRAKE OFF)
TRANS TMP SW

250 F
ENG GND

A B
N2 Y6 (ONLY IF PARK BRAKE OFF)

N3 Y6 (ONLY IF PARK BRAKE OFF)

N4 Y6 (ONLY IF PARK BRAKE OFF)

TRANS SOL E1
E1 ENG GND TRANSMISSION LEGEND

A B
TRANS SOL E2
TURNER
E2 ENG GND 1 GEAR ACTIVATED TRANS SOLENOIDS

A B
2
TRANS SOL E3 3
E3 F1 E5, E1
ENG GND

A B
4
TRANS SOL E4 5 F2 E5, E2
E4 ENG GND 6

A B
7 F3 E5, E3
TRANS SOL E5
E5 8 F4 E6, E3
ENG GND

A B
9
TRANS SOL E6 10 R1 E4, E1
E6 ENG GND 11

A B
12 R2 E4, E2
TRANS TMP SW

250 F
R3 E4, E3

TURNER TRANSMISSION
N NO SOLENOIDS INGAUGED

MY6340 B

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

G6-42A, G9-43A, G10-43A
G 9-43A & G10-43A (ONLY) VARIABLE DISPLACEMENT PUMP SCHEMATIC

X04
* NOTE: CAN TERMINATING RESISTOR ON X05 WAS THE 1
CAN TERMINATING RESISTOR ON (X23) OF THE ENGINE 2
HARNESS, PRIOR TO MATING OF X02 AND (X23). 3
BRN CAN SHIELD
3 4
120 OHM GRN CAN L/905
2 5
YEL CAN H/904
1 6
X05 7
J2
(GREY)

8
YEL CAN H/904 YEL CAN H/904
1 9
X02 MATES WITH CONNECTOR (X23) GRN CAN L/905 S08 GRN CAN L/905
2 10
BRN CAN SHIELD S09
OF THE ENGINE HARNESS. (1001125280) 3 11
X02 12
BRN CAN SHIELD
N/C
S10
X03
RED MOD IGN PWR
1
BLK MOD PUMP GND
2
3
4
VARIABLE DISPLACEMENT BLK MOD PUMP GND
2 5
PUMP SOLENIOD WHT PUMP VAL SIG
1 6
WHT PUMP VAL SIG
X06 7
8
4 9
J1
(BLACK)

BLK MOD PUMP GND

3 10
X01 MATES WITH CONNECTOR (X40) S07
2 11
ON THE ENGINE HARNESS. (1001125280) RED MOD IGN PWR
1 12
X01

MY6350 B
Electrical System

9-37
 Electrical System

9.6 CIRCUIT BREAKDOWNS

9.6.1 Constant Power Circuit from Battery

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

G9-43A/G10-43A - Before S/N 0160040465 excluding 0160040468 & 0160040672

30 86
ENGINE HARNESS

ST RLY PWR
87 85

STARTER
RELAY

STRT SOL STARTER

BAT-2 MOTOR
BAT-1
SNSR
ALT BAT

- + GROUND

BATTERY
12VDC
GROUND
(AT ENGINE
POD)

SNSR SNSR

#1

BATT #2 ALTERNATOR

TO PCB
BAT-2

BAT-1

DEUTSCH P/N HD-34-24-18-SN ALT BAT

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

PCB D9 D5 D8 D7 D6
BATT
AA

DEUTSCH P/N HD-36-24-18-PN

87 87 87 87 87

87a 87a 87a 87a 87a

86 85 86 85 86 85 86 85 86 85
30 30 30 30 30
ACC OPT LIGHTS W/W FAN/HTR

SPARE
BAT

(30A) (10A) (15A) (25A) (25A) (25A) (25A)

OPT_PWR HORN KEY SPARE LIGHTS W/W FAN/HTR
BAT

K
L

TO DASH PANEL

DASH PANEL
IGNITION SWITCH HORN
POLLACK P/N 31-610 CARLING SWITCH
P/N V2D1S00BAZC00-000

8 7
BAT ACC

1 4

STRT 5
2

6
3
IGN
HORN PWR

KEY PWR

MY0810

9-38 G6-42A, G9-43A, G10-43A

 OPTIONS VEC
WIPER HEATER/BLOWER

30
87
86
85
30
87
86
85

87a
87a
NEGATIVE CABLE
LIGHTS BCN/FAN

30
87
86
85
30
87
86
85

87a
87a
MAIN DASH PANEL
+ - OPTION (15A) OPTION (25A)

BAT POS
BAT POS
CAB CONTROL HARNESS

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

12 VDC

30
87
86
85
30
87
86
85

87a
87a
BATTERY

POSITIVE CABLE
TO STARTER A C
AND ALTERNATOR GRAY-5 HORN
2 BLACK-1
H G F E D C B A
KEY/IGN 3

ACCY-2 IGNITION-2

30
87
86
85
30
87
86
85

87a
87a
TO CHASSIS HARNESS TO CHASSIS HARNESS

OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4

POWER DIST TO CHASSIS ASSEMBLY

DASH PANEL HARNESS DASH PANEL HARNESS

SP BAT PWR
SP BAT PWR
IGNITION-1 ACCY-1 VEC OPTIONS HARNESS

HORN PWR

KEY BAT PWR

HD34-24-31ST HD36-24-31PT HD36-24-19PE

30
87
86
85
30
87
86
85

87a
87a
b. G6-42A - S/N 0160040678 & After

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

F8
F9
F7

CB4
CB3
CB1
CB2
F12
TO DASH PANEL HARNESS TO CAB CONTROL HARNESS TO OPTIONS HARNESS

20
20
20
20
CHASSIS HARNESS

25
25
15
15
CHASSIS HARNESS CHASSIS HARNESS
HD36-24-31PT HD36-24-31ST HD34-24-19SE

BLACK-1 GRAY-2

HORN PWR
H G F E D C B A H G F E D C B A
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4

SP BAT PWR
SP BAT PWR

KEY BAT PWR

(OPT)
A/C
COMPRESSOR

HORN PWR

OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4

SP BAT PWR
ECU BAT/022
KEY BAT PWR
SP BAT PWR

ECU BAT/022
TO POWER UNIT ASSEMBLY CHASSIS HARNESS HD34-24-29PE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
G9-43A/G10-43A - S/N 0160040465 & After including 0160040468 & 0160040672

X04 TO CHASSIS ASSEMBLY ENGINE HARNESS HD36-24-29PE

TO BATTERY ECM PWR
POSITIVE FUSE
FC22
30A X02 S42 RED ECM BAT/022
X10 1 30A DIAGNOSTIC
1 RED ECM BAT/022 POWER FUSE
2
4

2
S09 RED ECM PWR ECM POWER
3

1
2
RED ECM PWR RED SPARE BAT
2

4
FC37
1

RED ECM PWR - X40

MY6360 B
POWER UNIT X21

1 2 3 4 5 6 7 8 9 NC
DIAGNOSTIC
Electrical System

CONNECTOR

9-39
 Electrical System

9.6.2 Start Circuit

JOHN DEERE

ENGINE HARNESS ST RLY

30 86

ST RLY PWR
87 85

STARTER
RELAY

STRT SOL STARTER

PS IGN BAT-2 MOTOR
FUL SOL BAT-1
SNSR
ALT BAT
2 AMPS HR MTR

FUEL - + GROUND
SOLENOID

OIL BATTERY
PRESSURE SWITCH 12VDC
(ON ENGINE) GROUND
(AT ENGINE
POD)

SNSR SNSR
ALT EXEC

#1

BATT #2 ALTERNATOR

ALT EXEC

HR MTR
PS IGN

ST RLY
BAT-2

BAT-1
ALT BAT
DEUTSCH P/N HD-36-24-18-PN DEUTSCH P/N HD-34-24-18-SN

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DEUTSCH P/N HD-34-24-18-SN
DEUTSCH P/N HD-36-24-18-PN
ALT EXEC
PS IGN

HR MTR
ST RLY
AA

BATT
ST RLY
HR MTR PCB
D2

TR LT SW
Q

87 O D9

87a 10 OHM
F-N-R AND 86 85 30W
GEAR SELECTOR 30 R1

87
WARN G
DEUTSCH
P/N DT06-8S LT CK (15A) 87a
TO 86 85
LOCKING WEDGE KEY
TRANSMISSION W8S 30
TEMPERATURE 1 2 3 4 5 6 7 8
SWITCH DEUTSCH KEY PWR ACC
P/N DT04-8P E KEY ACC
LOCKING WEDGE SHIFT STRT
B
W8P D

DASH PANEL HOUR METER

DATCON
P/N 56458-10

KEY STRT
GND 12V KEY ACC
ST RLY

IGNITION SWITCH
POLLACK P/N 31-610
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
HR MTR
TR LT

8 7

1 4
BAT ACC
KEY PWR
2 5

3 6 TRANS
TEMP
WARN STRT
LIGHT
PS IGN BR SW PWR

IGN

BR SW PWR

MY1640

9-40 G6-42A, G9-43A, G10-43A

 Electrical System

PERKINS

ENGINE HARNESS PS IGN

ST RLY

FUL SOL
30 86
HR MTR

ST RLY PWR
FUEL PUMP
FUEL PUMP

HR MTR
PS IGN
GP SW
PS IGN

FP PWR
PS IGN

PS IGN

FP RLY

FP RLY
PS IGN
87 85

STARTER

C
A
B
RELAY
A

85
86
87
30
87A
B
1

1
2

2
M
FUEL
STRT SOL STARTER
OIL GP PWR MOTOR
SOLENOID FUEL PUMP FUEL PUMP BAT-2
FUSE PRESSURE SWITCH
COLD START RELAY 5 PSI BAT-1
ADVANCE 7.5 AMP SNSR
SOLENOID ALT BAT
GP SW

FUSE, 50 AMP GLOW PLUGS - + GROUND

SLOW BLOW
GP PWR GP RLY
FP PWR

GP SIG 86 30
BATTERY
12VDC
GROUND
GLOW PLG (AT ENGINE
85 87 POD)
GLOW PLUG
RELAY

SNSR SNSR
ALT EXEC

#1

BATT #2 ALTERNATOR

ALT EXEC

HR MTR
GP SIG

ST RLY
PS IGN
GP SW

BAT-2

BAT-1
ALT BAT

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

ALT EXEC
PS IGN

HR MTR
ST RLY
AA

BATT
ST RLY
HR MTR PCB
D2

TR LT SW
Q

87 O D9

87a 10 OHM
F-N-R AND 86 85 30W

TO GEAR SELECTOR 30 R1

87
TRANSMISSION G
TEMPERATURE DEUTSCH
WARN
P/N DT06-8S LT CK (15A) 87a
SWITCH 86 85
LOCKING WEDGE KEY
W8S 30
1 2 3 4 5 6 7 8

DEUTSCH KEY PWR ACC

P/N DT04-8P E KEY ACC
LOCKING WEDGE SHIFT STRT
B
W8P D

DASH PANEL HOUR METER

DATCON
P/N 56458-10

KEY STRT
GND 12V KEY ACC
ST RLY

IGNITION SWITCH
POLLACK P/N 31-610
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
HR MTR
TR LT

8 7

1 4
BAT ACC
KEY PWR
2 5

3 6 TRANS
TEMP
WARN STRT
LIGHT
PS IGN BR SW PWR

IGN

BR SW PWR

MY1630

G6-42A, G9-43A, G10-43A 9-41

 Electrical System

CUMMINS

MAIN DASH PANEL STEER MODE

1
STONERIDGE WAIT TO START
GAUGE 2
(RED, 18 GA GXL)
3
6 5 4 TRANS TMP WRN
4
(RED, 18 GA GXL)
3 2 1
5
6
ENG WARN
(RED, 18 GA GXL) 7
TO CHASSIS ASSEMBLY
ENG STOP STEER/SWAY PWR OPTIONS HARNESS
(RED, 18 GA GXL) HD36-24-19PE
TRANSMISSION SHIFTER TRANSMISSION SHIFTER
PARK BRAKE F HOBBS F
SW2
F HOBBS F
SW2
SW1 SW1
1 N N N N
OPTIONS VEC
2

(RED, 18 GA GXL)
R R WIPER HEATER/BLOWER
KEY/IGN R R
3
HORN

87a

87a
30

87
86
85

30

87
86
85
4 SW4 4

TRAN/BRK PWR
4 4
2

GREEN-4
4 SW3
3 3 SW4
3 SW3 3
3
6 5 2 2 LIGHTS BCN/FAN

DCLUTCH IN
2 2
1 1 1
1
7

87a

87a
30

87
86
85

30

87
86
85
ST RLY
AUX ELEC1

1 2 3 4 5 6 7 8

87a
30

87
86
85
OPTION (15A) OPTION (25A)

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8

87a

87a
30

87
86
85

30

87
86
85

BLUE-3
AUX ELEC2

GAGE PWR

SHIFT PWR 1
WARN LIGHT

SHIFT PWR 1
SHIFT PWR 1

KEY START
HORN PWR

KEY START

87a
30

87
86
85
TEST RELAY REVERSE
RELAY
KEY BAT PWR

KEY START

KEY ACC
KEY IGN

87a
30

87
86
85
BLACK-1 GRAY-2

87a
30

87
86
85
H G F E D C B A H G F E D C B A

3
1
4
5
2

3
1
4
5
2
KEY START

SP BAT PWR
25

TRAN/BRK PWR

SP ACCY PWR
7

PLUGGED
SP BAT PWR

SP BAT PWR
SHIFT PWR 1
KEY START

OPT PWR 3
OPT PWR 1

OPT PWR 4
OPT PWR 2
CAB CONTROL HARNESS 2 1 4 3 OPTIONS HARNESS
DASH PANEL HARNESS

1
DCLUTCH IN
2
KEY IGN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 M
3
4 CHASSIS HARNESS CHASSIS HARNESS
(OPT)
CHASSIS HARNESS A/C
HD36-24-31ST

STEER/SWAY PWR

SP ACCY PWR
5 HD36-24-31PT HD34-24-19SE

SP BAT PWR
COMPRESSOR

TRAN/BRK PWR

TRAN/BRK PWR

AUX RLYS PWR

SP ACCY PWR
KEY BAT PWR

STAB/TILT PWR
HORN PWR
GAGE PWR
BAT POS
BAT POS

SP BAT PWR

SP BAT PWR
SHIFT PWR 1

SHIFT PWR 1

OPT PWR 1

OPT PWR 2

OPT PWR 3

OPT PWR 4
KEY START

KEY START
6

KEY ACC

KEY ACC
KEY IGN

ST RLY
7 NEGATIVE CABLE
8 + -
9 12 VDC
10 BATTERY A C A C POWER DIST
11 POSITIVE CABLE BLACK-6 GRAY-5 VEC
TO STARTER
12 AND ALTERNATOR
A
F2 5 ALT EXC
B
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR
C
AUX RLYS PWR
GREEN-4

F6 10
D
87a

87a
30

87
86
85

30

87
86
85

E
KEY ACC
F
F1 15 TRAN/BRK PWR
G
KEY IGN
1

IGNITION-1 ACCY-1 H
2 3 4 5 6 7 8 9 10 11 12

87a

87a
30

87
86
85

30

87
86
85

A
KEY IGN

KEY IGN

DCLUTCH IN B
J1 (BLACK)

C
BLUE-3

D
E
CB4

CB3

CB1

CB2
F10

F12
F11
F8
F3

F4
F9

F7
ACCY. MODULE

F
20

20

20

20

G
25
10

10
25

15
10

10
15

H
2

1
4

6
5

5
6

2
8

BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
1 2 3 4 5 6 7 8 9 10 11 12

STEER/SWAY PWR

KEY BAT PWR

STAB/TILT PWR
HORN PWR
GAGE PWR
SP BAT PWR
OPT PWR 2

OPT PWR 1

ECU BAT/022

OPT PWR 3

OPT PWR 4
NEUTRAL SWITCH

ECU IGN/012
KEY IGN
J2 (GREY)

OPTIONAL FORK TILT ON

JOYSTICK W/ DE-CLUTCH TRIGGER

OPTIONAL
1 2 3 4
PROPORTIONAL AUX.
PADDLE
JLG ANALYZER
ST RLY

ALT EXC
ECU BAT/022
ECU IGN/012

TO POWER UNIT ASSEMBLY

CHASSIS HARNESS
HD34-24-29PE

RED MOD IGN PWR

X04
X03

X01 X40
N/C
12
11
10
9
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1
2
3
4

X04 TO CHASSIS ASSEMBLY

ENGINE HARNESS
J1 J2
(BLACK) (GREY) POWER UNIT HD36-24-29PE
RED MOD IGN PWR
RED SPARE IGN -

RED ECU IGN/012

RED ECM BAT/022

RED STRT RLY

RED SPARE BAT -

RED ALT EXC

M

S41

DIAGNOSTIC
POWER FUSE
30A DIAGNOSTIC
CONNECTOR
NC
1
2

1
2
3
4
5
6
7
8
9
FC22

X21
ALTERNATOR

RED ECM BAT/022

RED ECM BAT/022

RED ECM BAT/022
1
2
3

1
X34

X29

X27
RED STRT SOL -

RED ALT PWR

RED ALT EXC

S42
IP35
POSITIVE
TO BATTERY

G 9-43A/G10-43A (ONLY) VARIABLE DISPLACEMENT PUMP SCHEMATIC

X10

150A

ALT PWR
RED ECM PWR -

1
FUSE

FC36-1
1
FC30-2
START SOL

RED STRT PWR - RED STRT PWR - FC36-2

1 1
RED ALT PWR
FUSE

FC30-1 X43
RED STRT PWR
80A

1
ECM PWR
30A

1
FUSE

2
FC37
X28
MOLDED

MS33
DIODE

2
RED ECU IGN/012

1
RED STRT RLY
S09

2
RED STRT RLY
1
RELAY
START

RL20
RED ECM PWR
RED ECM PWR

RED STRT PWR

1
RL20-2
1 RED STRT SOL -
RL20-1

X02 X03

4 3 2 1
NC
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

ECM POWER
CUMMINS ENGINE ECM CONNECTION (60 PIN) MY6400

9-42 G6-42A, G9-43A, G10-43A

 Electrical System

9.6.3 Charging Circuit

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

G9-43A/G10-43A - Before S/N 0160040465 excluding 0160040468 & 0160040

ENGINE HARNESS
STRT SOL STARTER
MOTOR

SNSR
ALT BAT

- + GROUND

BATTERY
12VDC
GROUND
(AT ENGINE
POD)

SNSR SNSR
ALT EXC ALT EXC

#1

BATT #2 ALTERNATOR
ALT EXC

ALT BAT
TO PCB
DEUTSCH P/N HD-34-24-18-SN

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

PCB
DEUTSCH P/N HD-36-24-18-PN
D9
O

10 OHM
30W 87
R1 (10A)
87a GAGES
G 86 85
30

ACC
J

TO DASH PANEL

DASH PANEL

GAG PWR

OIL FUEL
12 UDC
2
1

B+

GND

G TEMP

4 IN 1 GAGE
BEEDE

MY0800

G6-42A, G9-43A, G10-43A 9-43

 Electrical System

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

G9-43A/G10-43A - S/N 0160040465 & After including 0160040468 & 0160040672

MAIN DASH PANEL

STONERIDGE
GAUGE

6 5 4

3 2 1

(RED, 18 GA GXL)

1 2 3 4 5 6 7 8

KEY/IGN

GAGE PWR
KEY BAT PWR

GAGE PWR
KEY IGN

NEGATIVE CABLE HD36-24-31PT

TO CAB FIREWALL
DASH PANEL HARNESS
BAT POS

BAT POS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

+ - TO DASH PANEL HARNESS

12 VDC CHASSIS HARNESS
KEY BAT PWR

GAGE PWR

BATTERY HD34-24-31ST
POWER DIST
KEY IGN

A C
POSITIVE CABLE
TO STARTER
BLACK-6 GRAY-5 VEC
AND ALTERNATOR
A
F2 5 ALT EXC
B
IGNITION-2
C
GREEN-4

D
87a
30

87
86
85

E
F
G
IGNITION-1 H
87a
30

87
86
85

A
B
C
BLUE-3

D
E
F12
F3

F4
F9

F
G
10

10
25

15

BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
KEY BAT PWR
GAGE PWR
ECU BAT/022
ECU IGN/012
KEY IGN

ECU BAT/022
ECU IGN/012

CHASSIS HARNESS
ALT EXC

DIAGNOSTIC HD34-24-29PE
ALTERNATOR

POWER FUSE TO POWER UNIT ASSEMBLY

M

30A DIAGNOSTIC
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1
2
3
4
X40

X04
NC
1
2

1
2
3
4
5
6
7
8
9
FC22

RED ALT EXC

X21

RED SPARE IGN -

RED SPARE BAT -

RED ECU IGN/012

RED ECM BAT/022

TO CHASSIS ASSEMBLY
ENGINE HARNESS
RED ECM BAT/022

RED ECM BAT/022

HD36-24-29PE
RED ECM BAT/022
1
2
3
X34

RED ALT PWR

S41
IP35
RED ALT EXC

1
X27

S42
POSITIVE
TO BATTERY
X10
RED ECM PWR -
150A

ALT PWR

1
FUSE

FC36-1
1
FC36-2
RED ALT PWR

ECM PWR
30A

1
FUSE

2
FC37
X28

S09
1

RED ECU IGN/012

RED ECM PWR

RED ECM PWR

1
FC30-2 X43 2
START SOL

RED STRT PWR -

1 1
FUSE

RELAY
START

FC30-1 RL20
RED STRT PWR
80A

X03

X02

1 1
RL20-2
NC
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

4
3
2
1

1
CUMMINS ENGINE ECM CONNECTION (60 PIN) ECM POWER
RL20-1
MY6440B

9-44 G6-42A, G9-43A, G10-43A


9.7 ENGINE START CIRCUIT
9.7.1 Starter
a. Testing the Starter on the Engine
If the starter does not engage when the ignition key
switch is turned, check the following:
1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
2. There may be a defect in the ignition key switch,
ignition wiring or starter solenoid.
3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten
all connections.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
b. Starter Circuit Checks
1. Check wires and connections for looseness,
corrosion, damage, etc.
2. If a “whirring” noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.5, “Electrical System Schematics.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
G6-42A, G9-43A, G10-43A
Electrical System
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the wires from the solenoid stud. Remove
the positive (+) battery cable from the starter. Label
and disconnect the wire from the starter solenoid
housing stud. Record how the wires are installed to
ensure correct installation later.
6. Loosen, but DO NOT remove, the three fasteners
securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
fall if not supported.
7. Support the starter and remove the fasteners
securing the starter to the engine. Remove the
negative (-) ground cable from its starter mounting
bolt.
8. Remove the starter from the machine.
d. Starter Installation
1. Position the starter in its mounting opening on the
flywheel housing. Position the ground cable over the
correct starter mounting bolt. Secure the starter with
the three fasteners.
2. Connect the positive (+) battery cable to the upper
solenoid stud. Install the wires to the upper solenoid
stud, and secure with lock washer and nut.
3. Connect the wire to the solenoid mounting stud.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9-45
 Electrical System

9.8 CHARGING CIRCUIT 9. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
Before using a battery charger, an attempt can be made the upper alternator mount. Remove the alternator
to recharge the battery by jump-starting the machine from the machine.
(Refer to the appropriate Operation & Safety Manual).
Allow the engine to run, which will enable the b. Alternator Installation
alternator to charge the battery.
1. Position the alternator and align with the upper
If the engine alternator charging warning indicator alternator mount on the engine bracket. Insert the
illuminates, perform the following checks: upper (longer) mounting hardware through the
1. Check all battery cable connections at the battery, alternator mount. Thread the longer capscrew into
and verify that they are clean and tight. the alternator front mount. DO NOT tighten
completely at this time.
2. Check the external alternator wiring and
connections, and verify that they are in good 2. Align the lower alternator mount hole with the lower
condition. mounting bracket on the engine, and insert the lower
mounting capscrew. Tighten the lower capscrew and
3. Check the fan belt condition and tension.
upper capscrew securely.
4. Run the engine and check the alternator for noise. A
3. Place a drive ratchet into the square hole on the
loose drive pulley, loose mounting hardware, worn or
serpentine belt tensioner bracket. Apply pressure
dirty internal alternator bearings, a defective stator
against the tensioner bracket and route the
or defective diodes can cause noise. Replace a worn
serpentine belt onto the alternator and engine
or defective alternator.
pulleys. Release and check the tensioner pulley to
verify that it is pivoting freely in order to provide the
9.8.1 Alternator proper tension on the belt. Check for proper belt
alignment. (Refer to the appropriate Operation &
a. Alternator Removal
Safety Manual.)
1. Park the machine on a firm, level surface, level the 4. Connect the previously labeled wire leads to the
machine, fully retract the boom, lower the boom, alternator.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 5. Properly connect the battery.
engine OFF. 6. Close and secure the engine cover.
2. Place a Do Not Operate Tag on both the ignition key 7. Remove the Do Not Operate Tags from both the
switch and the steering wheel. ignition key switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool
4. Properly disconnect the battery.
5. Install a drive ratchet into the square hole in the
serpentine belt tensioner bracket.
6. While lifting the automatic belt tensioner away from
the belt, remove the fan serpentine belt.
Note: Record how the alternator is installed to ensure
correct installation later.
7. Label and disconnect the wire leads attached to the
alternator.
8. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.

9-46 G6-42A, G9-43A, G10-43A

 Electrical System

9.9 WINDOW WIPER/WASHER DO NOT disassemble the motor. The motor is not
WINDSHIELD WIPER MOTOR serviceable. Replace motor if found to be defective.

c. Inspection and Replacement

a. Removal
Note: It may be necessary to remove several hydraulic
hoses from behind the dash in order to remove and
install the wiper motor housing. (Refer to Section 4.3.1,
“Steering Column and Orbitrol Valve.”)
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
3
MY0440
Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
d. Installation and Testing
1. Install all required hardware to the motor assembly.
2. Align motor with the mounting holes and bolt the
motor to the mounting bracket.
3. Connect the wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with the flat on the
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
4. Connect the cab harness connectors to windshield
wiper motor connectors.
5. Replace the main dash panel to its original
orientation. Secure with the previously used screws.
6. Properly connect the battery.
7. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
wiper travel is achieved.
8. If previously removed, install hydraulic hoses under
the dash. (Refer to Section 4.3.1, “Steering Column
and Orbitrol Valve.”)
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

5. Remove the screws that secure the main dash

panel. Pull out the dash panel to gain access to the
wiper motor (3).
6. Disconnect the cab harness connectors from the
wiper motor.
7. Remove the linkage attached to the wiper motor.
8. Loosen and remove the four bolts holding the wiper
motor to the mounting bracket.
Note: Retain all hardware removed from the wiper
assembly for possible reuse on the replacement motor
housing.
9. Remove the motor from the inside of the cab.

b. Disassembly

G6-42A, G9-43A, G10-43A 9-47

 Electrical System
9.9.1 Windshield/Rear Window Washer
Reservoir
4 5. Fill the washer fluid reservoir with washer fluid.
MY0420
The windshield washer motor and reservoir (4) is located
in the cab behind the seat. It is labeled as a unit and
cannot be serviced separately.
a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the nuts and the lock washers from the
washer mounting bolts.
6. Pull the washer reservoir out and away from the
mounting bracket.
7. Rotate the washer reservoir, label and remove the
cab harness connectors from the washer reservoir
connectors.
8. Remove the windshield washer hoses from the
reservoir.
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
c. Installation and Testing
1. Connect the windshield washer hoses to the
reservoir.
9-48
2. Connect the cab wiring harness connectors to the
reservoir connectors.
3. Install the reservoir tank onto the mounting bracket.
Note: Attach the ground strap to the lower right bolt hole
of washer bottle.
4. Install the lock washers and nuts and secure.
6. Properly connect the battery.
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on both the windshield and rear glass.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9.10 CAB HEATER AND FAN
9.10.1 Cab Heater Controls
Note: If the suspect component is found to be within the
heater box, the heater box must be removed as a
complete unit and replaced.
a. Cab Heater Controls Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5
5
MY6170
G6-42A, G9-43A, G10-43A
 Electrical System

5. Remove the screws from the cab heater and fan 9.11 SOLENOIDS AND SENDERS
control panel (5).
6. Pull the control panel out from the panel and 9.11.1 Fuel Shut-off Solenoid
disconnect the variable speed fan control cab
harness connector and disconnect the temperature a. Fuel Shut-off Solenoid Removal
cable.
1. Park the machine on a firm, level surface, level the
7. Remove the control from the panel. machine, fully retract the boom, lower the boom,
place the transmission control lever in
b. Disassembly (N) NEUTRAL, engage the park brake and shut the
DO NOT disassemble the cab heater and fan controls. engine OFF.
The controls are not serviceable. Replace controls if 2. Place a Do Not Operate Tag on both the ignition key
found to be defective. switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
c. Installation and Testing
cool.
1. Check that the variable speed fan control is in the 4. Properly disconnect the battery.
OFF position. JOHN DEERE
2. Install the temperature control cable to the back of
the control.
3. Install the hex locknut on the shaft and tighten.
4. Connect the cab harness connector to the variable
speed fan control.
5. Install the screws securing the control panel to the
dash panel.
6. Properly connect the battery.
7. Turn the ignition key to the ON position and check
the fan speeds. If further repair is needed, refer to
Section 9.5, “Electrical System Schematics.” 6
8. Start the machine and allow engine to warm to MY0450
operating temperature. Check heat control at
different levels.
PERKINS
6
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

MY1620

5. Disconnect the wiring connector at the fuel shut-off

solenoid (6) lead.
6. Remove the fuel shut-off solenoid from the fuel
injector pump.

G6-42A, G9-43A, G10-43A 9-49

 Electrical System

b. Fuel Shut-off Solenoid Disassembly 5. Disconnect the wiring connector at the park brake
solenoid lead.
DO NOT disassemble a fuel shut-off solenoid. Replace a
defective fuel shut-off solenoid with a new part.
7
c. Fuel Shut-off Solenoid Inspection and
Replacement
Use a 12-volt DC source and ground to test the solenoid.
Energize the solenoid, and watch for the plunger to
retract. If the plunger does not retract, replace the fuel
shut-off solenoid with a new part. 8

d. Fuel Shut-off Solenoid Installation

1. Clean the exterior of the fuel injector pump.
2. Install the fuel shut-off solenoid on the fuel injection
pump. Do Not Over Tighten.
3. Connect the wiring connector at the fuel shut-off
solenoid lead.
4. Properly connect the battery.
5. Start the engine. If the engine starts, the fuel shut-off
solenoid is functioning. If the engine fails to start, the
fuel shut-off run solenoid may have a poor ground
connection. Visually check the wiring at the fuel
shut-off solenoid leads and/or check for continuity
with a voltmeter as required.
6. Check for fuel and/or oil leakage around the solenoid.
7. Close and secure the engine cover.
8. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9.11.2 Park Brake Solenoid Valve
G6-42A - All
G9-43A/G10-43A - Before S/N 0160040675 excluding
0160040468 & 016040672
a. Park Brake Solenoid Valve Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
MY0470
6. Remove the nut on the end of the park brake coil (7).
7. Remove the park brake coil.
8. Remove the park brake solenoid (8). (Remove only if
the electrical coil is found to not be faulty.)
b. Disassembly
DO NOT disassemble the solenoid. The solenoid is not
serviceable. Replace solenoid if found to be defective.
c. Park Brake Solenoid Valve Installation
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
1. If necessary, install the park brake solenoid in its
original orientation.
2. Slide the park brake coil over the solenoid. Tighten
the nut to secure the solenoid. DO NOT overtighten.
3. Connect the wiring connector to the park brake coil
lead.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

9-50 G6-42A, G9-43A, G10-43A

 Electrical System

G9-43A/G10-43A - S/N 0160040675 and After including b. Disassembly

0160040468 & 016040672
DO NOT disassemble the solenoid. The solenoid is not
serviceable. Replace solenoid if found to be defective.
a. Park Brake Solenoid Valve Removal
1. Park the machine on a firm, level surface, level the c. Park Brake Solenoid Valve Installation
machine, fully retract the boom, lower the boom,
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
place the transmission control lever in
with new parts to help ensure proper sealing and
(N) NEUTRAL, engage the park brake and shut the
operation. Lubricate seals and o-rings with clean
engine OFF.
hydraulic oil.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel. 1. If necessary, install the park brake solenoid in its
original orientation.
3. Open the engine cover. Allow the system fluids to
cool. 2. Slide the park brake coil over the solenoid. Tighten
the nut to secure the solenoid. DO NOT overtighten.
4. Properly disconnect the battery.
3. Connect the wiring connector to the park brake coil
5. Disconnect the wiring connector at the park brake lead.
solenoid lead.
4. Properly connect the battery.
7 5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

MY1140

6. Remove the nut on the end of the park brake coil (7).
7. Remove the park brake coil.
8. Remove the park brake solenoid (8). (Remove only if
the electrical coil is found to not be faulty.)

G6-42A, G9-43A, G10-43A 9-51

 Electrical System
9.11.3 Transmission Solenoid Valves
The transmission should be checked, serviced and
repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.
Note: If the transmission is not shifting properly, the
transmission shift control switch (travel select lever),
wiring harness or transmission shift solenoids (9) should
be checked in order to determine which component is
defective. Specific information to determine which travel
position and corresponding component is not responding
can be found in the detailed transmission service
instructions (covering repair, disassembly, reassembly
and adjustment information) are provided in the Dana-
Spicer T12000 Transmission Repair Manual,
(JLG P/N 31200163) or the ZF Powershift Transmission
4WG-92/98 Repair Manual, (JLG P/N 31200241) and
can be obtained by calling your local JLG Service
distributor.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
DANA
9
MY6180
9 ZF
9 1. Thread the transmission temperature sender into the
9
9 3. Check for proper fluid level.
MY6200
9-52
9.11.4 Transmission Temperature Sender
a. Transmission Temperature Sender Removal
ZF DANA
MY6210
10 10
The transmission temperature sender (10) is located on
the left side of the transmission housing.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Unplug the transmission temperature sender
connector from the wiring harness connector.
6. The sender is threaded into the transmission
housing. Remove the sender.
b. Transmission Temperature Sender Inspection and
Replacement
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new part.
c. Transmission Temperature Sender Installation and
Testing
transmission housing snugly, then connect the sender
connector to the wiring harness connector.
2. Properly connect the battery.
G6-42A, G9-43A, G10-43A
 Electrical System

4. Start the engine, allow it to reach operating

temperature and observe the operator’s display 1 PERKINS
cluster for warning indication. If the sender is not
defective, the problem could be elsewhere; possibly
in a shorted wire, damaged transmission, improper
or low fluid, etc.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

9.11.5 Engine Coolant Temperature

Sender / Switch
2 MY1580

a. Engine Coolant Temperature Sender Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Unplug the engine coolant temperature sender /
switch connector from the wiring harness connector.
JOHN DEERE
1 3. Check for proper coolant level.
2 5. Close and secure the engine cover.
MY0450
6. The Engine Coolant Temperature sender (1) is
threaded into the engine block. Remove the sender.
b. Engine Coolant Temperature Sender / Switch
Inspection and Replacement
Inspect the sender / switch and the wiring harness
connector terminals for continuity. Replace a defective or
faulty sender with a new part.
c. Engine Coolant Temperature Sender Installation
and Testing
1. Thread the engine coolant temperature sender into
the engine block snugly, then connect the sender
connector to the wiring harness connector.
2. Properly connect the battery.
4. Start the engine, allow it to reach operating
temperature and observe the operator’s instrument
cluster for warning indication. If the sender is not
defective, the problem could be elsewhere; possibly
in a shorted wire, improper-running engine, improper
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument display,
etc.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

G6-42A, G9-43A, G10-43A 9-53

 Electrical System
9.11.6 Engine Oil Pressure Sender
a. Engine Oil Pressure Sender Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow system fluids to cool.
4. Properly disconnect the battery.
5. The engine oil pressure sender (2) is threaded into
the engine block. Remove the sender.
b. Engine Oil Pressure Sender Inspection and
Replacement
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new part.
c. Engine Oil Pressure Sender Installation and
Testing
1. Thread the engine oil pressure sender into the
engine block snugly, then connect the sender
connector to the wiring harness connector.
2. Properly connect the battery.
3. Check for proper oil level.
4. Start the engine, and observe the operator’s display
for warning indication. If the sender is not defective,
the problem could be elsewhere; possibly in a
shorted wire, improper-running engine, low oil,
obstructed or faulty oil pump, defective instrument
display.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9-54
9.11.7 Fuel Level Sender
a. Fuel Level Indicator Testing
1. The fuel level sender wiring harness leads can be
accessed from the top of the fuel tank. Disconnect
the fuel level sender wiring harness leads. With the
help of an assistant, touch both harness leads
together.
2. From the operator’s cab, have the assistant turn the
ignition key switch to the RUN position. DO NOT
start the engine. Observe the fuel level indicator
needle on the operator’s instrument cluster. The
reading must be at the FULL mark.
3. Turn the ignition key switch to the OFF position. The
fuel level indicator needle should return to the
EMPTY position.
b. Fuel Level Circuit Tests
MY4340
3
If the fuel level sender (3) is suspected of giving a false
reading, perform the following checks:
1. If the fuel level indicator needle does not move,
check the fuel tank for fuel.
2. Check for loose or defective wiring, faulty ground
connections, and corrosion on the fuel tank sender
and wiring lead.
3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level
sender.
G6-42A, G9-43A, G10-43A

4. If the fuel level indicator does not move and a faulty
or defective fuel level sender in the fuel tank has
been ruled out, and in addition, wiring and
connectors have been checked and ruled out, the
fuel level indicator is defective and must be
replaced.
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key
switch, and from the fuel level sender on the fuel
tank through the wiring in the cab.
7. Check the fuel level sender. A defective fuel level
sender in the fuel tank may also prevent the fuel
level indicator from moving. Refer to Section 9.5,
“Electrical System Schematics,” for further
information.
G6-42A, G9-43A, G10-43A
Electrical System
9.11.8 Front and Rear Axle Proximity
Sensors
The sensors used on each axle allow the steering to be
changed to one of three different settings. The sensors
will not allow the change to be completed unless both
axles are in the central location.
Each sensor is mounted in the center of each steer
cylinder.
a. Removal
1. Open engine cover. Allow system fluids to cool.
2. Properly disconnect the battery.
3. Unplug the axle proximity sensor from the wiring
harness.
4. Remove the bolts holding the sensor to the steering
cylinder barrel.
b. Disassembly
1. Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sensor with a new sensor.
c. Installation and Testing
1. Install the bolts holding the sensor to the steering
cylinder barrel.
2. Connect the axle proximity sensor to the wiring
harness.
3. Properly connect the battery.
4. Close and secure engine cover.
5. Start the machine, select a steering mode, turn the
steering wheel until the display unit shows the
steering has been "locked" into the selected mode.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9.12 DISPLAY MONITOR AND GAUGES
9.12.1 Analog Gauges
a. Gauge Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
9-55
 Electrical System

3. Open the engine cover. Allow the system fluids to b. Disassembly

cool.
DO NOT disassemble the gauge. The gauge is not
4. Properly disconnect the battery. serviceable. Replace the gauge if found to be defective.
Before S/N 0160040675 excluding 0160040468 & 0160040672
c. Gauge Installation and Testing
1. Install the gauge (12) in the dash. Install the gauge
12 11 bracket.
2. Connect the previously labeled wires to the gauge.
3. Install the dash panel with the previously used
hardware (11).
4. Properly connect the battery.
PERKINS 5. Turn the ignition to the ON position to check the
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.
12 11

9.13 DASH SWITCHES

9.13.1 Ignition Key Switch

Note: For information on the front windshield wiper, rear
DEERE window wiper and washer systems, refer to Section 9.9,
“Window Wiper/Washer Windshield Wiper Motor.”
MY1840

a. Ignition Switch Removal

S/N 0160040675 & After including 0160040468 & 0160040672
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
12 (N) NEUTRAL, engage the park brake and shut the
11
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
CUMMINS 4. Properly disconnect the battery.
S/N 0160040678 & AFTER INCLUDING
0160039394 & 0160039397 MY5060 5. Remove the screws securing the dash panel.

5. Remove the screws (11) securing the dash panel.
6. Label and disconnect the wires from the gauge,
remove the gauge bracket.
7. Pull the gauge (12) out from the dash.
6. Remove the hex nut securing the ignition key switch
to the dash.
7. Label and disconnect the ignition switch wires and
remove the switch from the machine.

9-56 G6-42A, G9-43A, G10-43A

 Electrical System

b. Disassembly (N) NEUTRAL, engage the park brake and shut the
engine OFF.
DO NOT disassemble the ignition switch. Replace a
defective switch with a new part. 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering.
c. Inspection and Replacement 3. Open the engine cover. Allow the system fluids to
To determine the proper operation of the ignition key cool.
switch, test the terminals on the back of the switch for 4. Properly disconnect the battery.
continuity with an ohmmeter. 5. There are three frames with three switches in each
BA C frame.
13 T AC
6. Pull the frame out of the dash, disconnect the
harness connector to the switch in question and
push the switch out of the frame.
ACC
BAT

ST b. Disassembly
DO NOT disassemble the dash switch. Replace a
IG defective switch with a new part.
N N
IG
MY0830 c. Inspection and Replacement
Test the ignition key switch for continuity, by checking Inspect the switch terminals for continuity and shorting in
from the BAT terminal (13) to each of the remaining both the engaged and disengaged positions. Replace a
terminals in their corresponding switch position. defective or faulty switch with a new switch.
If all terminals do not show proper continuity, replace the
d. Switch Installation
ignition switch.
1. Connect the switch to the cab harness connector.
d. Ignition Switch Installation 2. Position the switch over the rectangular switch bezel
1. Connect the ignition key switch to the previously and snap into position.
labeled wires. 3. Properly connect the battery.
2. Align the ignition switch in the dash so that when it is 4. Start the machine and check the replaced switch for
in the OFF position, the key slot is positioned vertically proper function.
(straight up and down). Install the hex nut securing
5. Close and secure the engine cover.
the ignition switch to the dash. DO NOT overtighten.
6. Remove the Do Not Operate Tags from both the
3. Install the dash panel with the previously used
ignition key switch and the steering wheel.
hardware.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
Note: If further information is needed, refer to Section
9.5, “Electrical System Schematics.”

9.13.2 Dash Switches

a. Switch Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in

G6-42A, G9-43A, G10-43A 9-57

 Electrical System

9.14 VARIABLE DISPLACEMENT PUMP CONTROL

(G9-43A/G10-43A S/N 0160040675 AND AFTER INCLUDING 0160040468 & 016040672)

3
MY6220

The Variable Displacement Control Pump (1) is equipped

with an electrical solenoid (Anti-Stall Valve) and controls
the mechanical swivel within the pump.
Trouble shooting can be performed by using the JLG
Analyzer (P/N 1001103758) and connecting to the
adaptor (2) near the pump displacement control (3).

9.14.1 Pump Displacement Analyzer Software Version A

TMH PUMP DISPLACEMENT CONTROL

MODULE
ANALYZER STRUCTURE

MENU: MENU: MENU:

HELP: PRESS ENTER DIAGNOSTICS ACCESS LEVEL X

ENGINE SPEED: ENGINE TORQUE: ANTI-STALL COMMAND: ANTI-STALL ACTUAL: CONTROL MODULE: DIAGNOSTICS:
XXXX RPM XXX % XXXXmA XXXXmA VOLTAGE XX.XX VERSIONS

CONTROL MODULE:
SOFTWARE Px.x

ANALYZER:
ANALYZER SW VER
MY6230

9-58 G6-42A, G9-43A, G10-43A

 Electrical System

9.14.2 Diagnostics Menu

MENU SUB-MENU COMMENT

Engine Speed:
Displays the engine speed transmitted by the ECM.
XXXX RPM

Engine Torque:
Displays the engine torque (0-120%) transmitted by the ECM.
XXX%

Anti-Stall Command: Displays the anti-stall valve current corresponding to the present
XXXXmA engine speed and torque.

Anti-Stall Actual:
Displays the actual anti-stall valve current measured by the ECM.
XXXXmA

Control Module
Displays the battery voltage reading for the control module.
Voltage: XX.XV

Control Module
Displays the CM’s software version.
Diagnostics: Software: Px.x
Versions Analyzer:
Displays the JLG Analyzer’s software version.
Analyzer Ver 6.2

G6-42A, G9-43A, G10-43A 9-59

 Electrical System

9.15 HAND HELD ANALYZER

(G9-43A/G10-43A S/N 0160040675 AND AFTER INCLUDING 0160040468 & 016040672)
The hand held analyzer can be used in place of the cab
display panel.

3 4

5 6

MZ6040

1. Cable Connector.
2. Analyzer Display Screen.
3. Escape Key: To return home or access previous
menu.
4. Enter Key: Stores and selects Top Level, Sub Level
and Items Menus.
5. Up/Down Arrow Keys: Change adjustable values.
6. Left and Right Arrow Keys: Used to move between
Top Level, Sub Levels and Item Menus.

9.15.1 Analyzer Usage

Help messages can be viewed using the Analyzer
(P/N 1001103758). The Help messages can be accessed
by pressing the ENTER key while viewing the current
Help message. The Help message shall be
EVERYTHING OK when no fault is present. For more
information, contact the local JLG dealer.

9-60 G6-42A, G9-43A, G10-43A

 9.15.2

The Access Level Menu controls security for Control Module settings. Access Level 2 is the default and allows view access to all menus, except
Calibration. Access Level 1 (33271) provides view, edit and calibration authorization.

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

Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
Analyzer Software - Version A

MAL0890A
Electrical System

9-61
 Electrical System

9.16 JOYSTICK FAULT CODES

(G9-43A/G10-43A S/N 0160040675 AND AFTER INCLUDING 0160040468 & 016040672)

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 & B prevented No

Position At Power Up
• The auxiliary hydraulic joystick must be in the
neutral position (established by Calibration) when
the control system is energized or it is ignored until
is momentarily returns to neutral.
• Active when AUX HYDRAULIC is ENABLED

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 Roller Not In The • Fork Tilt Up & Down prevented No
Neutral Position At Power
• The left roller must be in the neutral position
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 & B prevented Yes

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 0%; closed
beyond ±25%

2357 Auxiliary Hydraulic Joystick - • Auxiliary Hydraulic A & 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 control module issue.
• Active when Machine Setup’s AUX HYDRAULIC is
set to ENABLED

9-62 G6-42A, G9-43A, G10-43A

 Electrical System

DTC Event Comment Latched

2358 Auxiliary Hydraulic Joystick - • Auxiliary Hydraulic A & 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 & 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 & 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 & 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 - • The desired current is greater than 250mA, but the Yes
Open Circuit actual current is less then 75mA
• The fork tilt up digital output was open-circuit. This
fault may be caused by improper wiring or a
control module issue.

33192 Fork Tilt Valve - • Fork Tilt Up & Down, Auxiliary Hydraulics Yes
Short To Battery functionality prevented
• The fork tilt up or down digital output was shorted
to battery. Fork tilt up or down will be prevented
until the next powercycle. This fault may be caused
by improper wiring or a control module issue.
• The desired current is greater than 250mA, but the
actual current is less than 75mA.

33193 Fork Tilt Up Valve - • The actual current is greater than 200mA, PWM is Yes
Short To Ground 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.

G6-42A, G9-43A, G10-43A 9-63

 Electrical System
DTC Event
33194 Fork Tilt Down Valve -
Open Circuit
33195 Fork Tilt Down Valve -
Short To Ground
33196 Auxiliary Function -
A Valve - Open Circuit
33197 Auxiliary Function -
A/B Valve - Short To Battery
33198 Auxiliary Function -
A Valve - Short To Ground
33199 Auxiliary Function -
B Valve - Open Circuit
9-64
Comment Latched
• The desired current is greater than 250mA, but the Yes
actual current is less then 75mA
• The fork tilt down digital output was open-circuit.
This fault may be caused by improper wiring or a
control module issue.
• The actual current is greater than 200mA, PWM is Yes
95%, and the digital 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.
• The desired current is greater than 250mA, but the Yes
actual current is less then 75mA
• The auxiliary hydraulic “A” or “B” digital output was
open-circuit. This fault may be caused by improper
wiring or a control module issue.
• Fork Tilt Up & Down, Auxiliary Hydraulics Yes
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 0mA and the digital output
driver’s diagnostic feedback is low
• Low-Side Fault Relay de-energized
• The actual current is greater than 200mA, PWM is Yes
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 module issue.
• Active when Machine Setup’s AUX HYDRAULIC is
set to ENABLED
• The desired current is greater than 250mA, but the Yes
actual current is less then 75mA
• 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
G6-42A, G9-43A, G10-43A

DTC Event
33200 Auxiliary Function -
B Valve - Short To Ground
441 Battery Voltage Too Low -
System Shutdown
442 Battery Voltage Too High -
System Shutdown
447 Reference Voltage Out Of
Range
998 Eeprom Failure -
Check All Settings
2239 Function Problem -
Joystick Calibration Faulty
G6-42A, G9-43A, G10-43A
Electrical System
Comment Latched
• The actual current is greater than 200mA, PWM is Yes
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
• Fork Tilt Up & Down, Auxiliary Hydraulics & De- No
Clutch functionality prevented
• Battery voltage is less than 8.0V so the control
module has prevented associated functionality.
• Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
Clutch functionality prevented
• Battery voltage is greater than 8.0V so the control
module has prevented associated functionality.
• Low-Side Fault Relay de-energized
• Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
Clutch functionality prevented
• The control module’s +5V reference was
measured greater than 5.4V or less than 4.6V for
1000mS. Since this reference voltage supplies the
joystick(s), fork tilt and auxiliary hydraulic functions
must be prevented.
• Low-Side Fault Relay de-energized
• Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
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
• Fork Tilt Up & Down, prevented No
• 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
9-65
 Electrical System

DTC Event Comment Latched

259 Model Change - Hydraulics • Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
Suspended - Cycle Ems 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

9-66 G6-42A, G9-43A, G10-43A

 Electrical System

9.17 ENGINE INDICATOR LAMPS - PERKINS

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

G6-42A, G9-43A, G10-43A 9-67

 Electrical System

9.18 SAE DIAGNOSTIC TROUBLE CODES AND FAULT CODES - CUMMINS

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

111 629 12 Red Controller #1 Engine Control Module Critical internal failure -
Bad intelligent Device or Component

115 612 2 Red System Diagnostic Engine Speed/Position Sensor Circuit lost both
Code #2 of two signals from the magnetic pickup sensor
- Data Erratic, Intermittent, or incorrect

122 102 3 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit -
Voltage Above Normal, or Shorted to High
Source

123 102 4 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit -
Voltage Below Normal, or Shorted to Low
Source

124 102 16 Amber Boost Pressure Intake Manifold 1 Pressure - Data Valid but
Above Normal Operational Range - Moderately
Severe Level

131 91 3 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor

Position Circuit - Voltage Above Normal, or Shorted to
High Source

132 91 4 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor

Position Circuit - Voltage Below Normal, or Shorted to
Low Source

133 974 3 Red Remote Accelerator Remote Accelerator Pedal or Lever Position
Sensor Circuit - Voltage Above Normal, or
Shorted to High Source

134 974 4 Red Remote Accelerator Remote Accelerator Pedal or Lever Position
Sensor Circuit - Voltage Below Normal, or
Shorted to Low Source

135 100 3 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Voltage Above
Normal, or Shorted to High Source

141 100 4 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source

143 100 18 Amber Engine Oil Pressure Oil Pressure Low - Data Valid but Below Normal
Operational Range - Moderately Severe Level

144 110 3 Amber Engine Coolant Coolant Temperature Sensor Circuit - Voltage
Temperature Above Normal, or Shorted to High Source

145 110 4 Amber Engine Coolant Coolant Temperature Sensor Circuit - Voltage
Temperature Below Normal, or Shorted to Low Source

9-68 G6-42A, G9-43A, G10-43A

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

146 110 16 Amber Engine Coolant Coolant Temperature High - Data Valid but
Temperature Above Normal Operational Range - Moderately
Severe Level

147 91 1 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor

Position Circuit - Abnormal Frequency, Pulse Width, or
Period

148 91 0 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor

Position Circuit - Abnormal Frequency, Pulse Width, or
Period

151 110 0 Red Engine Coolant Coolant Temperature Low - Data Valid but
Temperature Above Normal Operational Range - Most
Severe Level

153 105 3 Amber Intake Manifold #1 Intake Manifold Air Temperature Sensor Circuit
Temp - Voltage Above Normal, or Shorted to High
Source

154 105 4 Amber Intake Manifold #1 Intake Manifold Air Temperature Sensor Circuit
Temp - Voltage Below Normal, or Shorted to Low
Source

155 105 0 Red Intake Manifold #1 Intake Manifold Air Temperature High - Data
Temp Valid but Above Normal Operational Range -
Most Severe Level

187 3510 4 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit - Voltage
Below Normal, or Shorted to Low Source

193 520199 3 Amber Cruise Control Cruise Control (Resistive) Signal Circuit -
Voltage Above Normal, or Shorted to High
Source

194 520199 4 Amber Cruise Control Cruise Control (Resistive) Signal Circuit -
Voltage Below Normal, or Shorted to Low
Source

195 111 3 Amber Coolant Level Coolant Level Sensor Circuit - Voltage Above
Normal, or Shorted to High Source

196 111 4 Amber Coolant Level Coolant Level Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source

197 111 18 Amber Coolant Level Coolant Level - Data Valid but Below Normal
Operational Range - Moderately Severe Level

199 1661 4 Amber Engine Automatic Engine Automatic Start Lamp Driver Circuit -
Start Lamp Voltage Above Normal, or Shorted to High
Source

211 1484 31 None J1939 Error Additional Auxiliary Diagnostic Codes logged -
Condition Exists

G6-42A, G9-43A, G10-43A 9-69

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

212 175 3 Amber Oil Temperature Engine Oil Temperature Sensor 1 Circuit -
Voltage Above Normal, or Shorted to High
Source

213 175 4 Amber Oil Temperature Engine Oil Temperature Sensor 1 Circuit -
Voltage Below Normal, or Shorted to Low
Source

214 175 0 Red Oil Temperature Engine Oil Temperature - Data Valid but Above
Normal Operational Range - Most Severe Level

221 108 3 Amber Barometric Pressure Barometric Pressure Sensor Circuit - Voltage
Above Normal, or Shorted to High Source

222 108 4 Amber Barometric Pressure Barometric Pressure Sensor Circuit - Voltage
Below Normal, or Shorted to Low Source

227 3510 3 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit - Voltage
Above Normal, or Shorted to High Source

231 109 3 Amber Coolant Pressure Coolant Pressure Sensor Circuit - Voltage
Above Normal, or Shorted to High Source

232 109 4 Amber Coolant Pressure Coolant Pressure Sensor Circuit - Voltage
Below Normal, or Shorted to Low Source

233 109 18 Amber Coolant Pressure Coolant Pressure - Data Valid but Below
Normal Operational Range - Moderately Severe
Level

234 190 0 Red Engine Speed Engine Speed High - Data Valid but Above
Normal Operational Range - Most Severe Level

235 111 1 Red Coolant Level Coolant Level Low - Data Valid but Below
Normal Operational Range - Most Severe Level

237 644 2 Amber External Speed Input External Speed Input (Multiple Unit
Synchronization) - Data Erratic, Intermittent, or
Incorrect

238 3511 4 Amber System Diagnostic Sensor Supply Voltage #3 Circuit - Voltage
code #1 Below Normal, or Shorted to Low Source

239 3511 3 Amber System Diagnostic Sensor Supply Voltage #3 Circuit - Voltage
code #2 Above Normal, or Shorted to High Source

241 84 2 Amber Wheel-based Vehicle Vehicle Speed Sensor Circuit - Data Erratic,
Speed Intermittent, or Incorrect

242 84 10 Amber Wheel-based Vehicle Vehicle Speed Sensor Circuit tampering has
Speed been detected - Abnormal Rate of Change

244 623 4 Amber Red Stop Lamp Red Stop Lamp Driver Circuit - Voltage Below
Normal, or Shorted to Low Source

9-70 G6-42A, G9-43A, G10-43A

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

245 647 4 Amber Fan Clutch Output Fan Control Circuit - Voltage Below Normal, or
Device Driver Shorted to Low Source

249 171 3 Amber Ambient Air Ambient Air Temperature Sensor Circuit -
Temperature Voltage Above Normal, or Shorted to High
Source

256 171 4 Amber Ambient Air Ambient Air Temperature Sensor Circuit -
Temperature Voltage Below Normal, or Shorted to Low
Source

261 174 16 Amber Fuel Temperature Engine Fuel Temperature - Data Valid but
Above Normal Operational Range - Moderately
Severe Level

263 174 3 Amber Fuel Temperature AEB15.60 Page 149 of 157 Engine Fuel
Temperature Sensor 1 Circuit - Voltage Above
Normal, or Shorted to High Source

265 174 4 Amber Fuel Temperature Engine Fuel Temperature Sensor 1 Circuit -
Voltage Below Normal, or Shorted to Low
Source

268 94 2 Amber Fuel Delivery Fuel Pressure Sensor Circuit - Data Erratic,
Pressure Intermittent, or Incorrect

271 1347 4 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit -
Pressurizing Voltage Below Normal, or Shorted to Low
Assembly #1 Source

272 1347 3 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit -
Pressurizing Voltage Above Normal, or Shorted to High
Assembly #1 Source

281 1347 7 Amber Fuel Pump High Fuel Pressure Solenoid Valve #1 -
Pressurizing Mechanical System Not Responding Properly
Assembly #1 or Out of Adjustment

284 1043 4 Amber Internal Sensor Engine Speed/Position Sensor (Crankshaft)

Voltage Supply Supply Voltage Circuit - Voltage Below Normal,
or Shorted to Low Source

285 639 9 Amber SAE J1939 Datalink SAE J1939 Multiplexing PGN Timeout Error -
Abnormal Update Rate

286 639 13 Amber SAE J1939 Datalink SAE J1939 Multiplexing Configuration Error-
Out of Calibration

287 91 19 Red Accelerator Pedal SAE J1939 Multiplexing Accelerator Pedal or

Position Lever Sensor System Error - Received Network
Data In Error

288 974 19 Red Remote Accelerator SAE J1939 Multiplexing Remote Accelerator
Pedal or Lever Data Error - Received Network
Data In Error

G6-42A, G9-43A, G10-43A 9-71

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

292 441 14 Red Auxiliary Auxiliary Temperature Sensor Input 1 - Special

Temperature 1 Instructions

293 441 3 Amber OEM Temperature Auxiliary Temperature Sensor Input #1 Circuit -
Voltage Above Normal, or Shorted to High
Source

294 441 4 Amber OEM Temperature Auxiliary Temperature Sensor Input #1 Circuit -
Voltage Below Normal, or Shorted to Low
Source

295 108 2 Amber Barometric Pressure Barometric Pressure Sensor Circuit - Data
Erratic, Intermittent, or Incorrect

296 1388 14 Red Auxiliary Pressure Auxiliary Pressure Sensor Input 1 - Special
Instructions

297 1388 3 Amber Auxiliary Pressure Auxiliary Pressure Sensor Input #2 Circuit -
Voltage Above Normal, or Shorted to High
Source

298 1388 4 Amber Auxiliary Pressure Auxiliary Pressure Sensor Input #2 Circuit -
Voltage Below Normal, or Shorted to Low
Source

319 251 2 Maint Real Time Clock Real Time Clock Power Interrupt - Data Erratic,
Power Intermittent, or Incorrect

322 651 5 Amber Injector Cylinder #01 Injector Solenoid Cylinder #1 Circuit - Current
Below Normal, or Open Circuit

323 655 5 Amber Injector Cylinder #05 Injector Solenoid Cylinder #5 Circuit - Current
Below Normal, or Open Circuit

324 653 5 Amber Injector Cylinder #03 Injector Solenoid Cylinder #3 Circuit - Current
Below Normal, or Open Circuit

325 656 5 Amber Injector Cylinder #06 Injector Solenoid Cylinder #6 Circuit - Current
Below Normal, or Open Circuit

331 652 5 Amber Injector Cylinder #02 Injector Solenoid Cylinder #2 Circuit - Current
Below Normal, or Open Circuit

332 654 5 Amber Injector Cylinder #04 Injector Solenoid Cylinder #4 Circuit - Current
Below Normal, or Open Circuit

334 110 2 Amber Engine Coolant Coolant Temperature Sensor Circuit - Data
Temperature Erratic, Intermittent, or Incorrect

338 1267 3 Amber Vehicle Accessories Idle Shutdown Vehicle Accessories Relay Driver
Relay Driver Circuit - Voltage Above Normal, or Shorted to
High Source

339 1267 4 Amber Vehicle Accessories Idle Shutdown Vehicle Accessories Relay Driver
Relay Driver Circuit - Voltage Below Normal, or Shorted to
Low Source

9-72 G6-42A, G9-43A, G10-43A

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

341 630 2 Amber Calibration Memory Engine Control Module data lost - Data Erratic,
Intermittent, or Incorrect

342 630 13 Red Calibration Memory Electronic Calibration Code Incompatibility - Out
of Calibration

343 629 12 Amber Controller #1 Engine Control Module Warning internal

hardware failure - Bad Intelligent Device or
Component

349 191 16 Amber Transmission Output Transmission Output Shaft Speed - Data Valid
Shaft Speed but Above Normal Operational Range -
Moderately Severe Level

351 627 12 Amber Controller #1 Injector Power Supply - Bad Intelligent Device
or Component

352 3509 4 Amber 5 Volts DC Supply Sensor Supply Voltage #1 Circuit - Voltage
Below Normal, or Shorted to Low Source

386 3509 3 Amber 5 Volts DC Supply Sensor Supply Voltage #1 Circuit - Voltage
Above Normal, or Shorted to High Source

415 100 1 Red Engine Oil Pressure Oil Pressure Low - Data Valid but Below Normal
Operational Range - Most Severe Level

418 97 15 Maint. Water in Fuel Water in Fuel Indicator High - Data Valid but
Indicator Above Normal Operational Range - Least
Severe Level

422 111 2 Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or
Incorrect

425 175 2 Amber Oil Temperature Engine Oil Temperature - Data Erratic,
Intermittent, or Incorrect

428 97 3 Amber Water in Fuel Water in Fuel Sensor Circuit - Voltage Above
Indicator Normal, or Shorted to High Source

429 97 4 Amber Water in Fuel Water in Fuel Sensor Circuit - Voltage Below
Indicator Normal, or Shorted to Low Source

431 558 2 Amber Accelerator Pedal Accelerator Pedal or Lever Idle Validation
Low Idle Switch Circuit - Data Erratic, Intermittent, or Incorrect

432 558 13 Red Accelerator Pedal Accelerator Pedal or Lever Idle Validation
Low Idle Switch Circuit - Out of Calibration

435 100 2 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Data Erratic,
Intermittent, or Incorrect

441 168 18 Amber Electrical Potential Battery #1 Voltage Low - Data Valid but Below
(Voltage) Normal Operational Range - Moderately Severe
Level

G6-42A, G9-43A, G10-43A 9-73

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

442 168 16 Amber Electrical Potential Battery #1 Voltage High - Data Valid but Above
(Voltage) Normal Operational Range - Moderately Severe
Level

449 157 0 Red Injector Metering Fuel Pressure High - Data Valid but Above
Rail 1 Pressure Normal Operational Range - Moderately Severe
Level

451 157 3 Amber Injector Metering Injector Metering Rail #1 Pressure Sensor
Rail 1 Pressure Circuit - Voltage Above Normal, or Shorted to
High Source

452 157 4 Amber Injector Metering Injector Metering Rail #1 Pressure Sensor
Rail 1 Pressure Circuit - Voltage Below Normal, or Shorted to
Low Source

488 105 16 Amber Intake Manifold Intake Manifold 1 Temperature - Data Valid but
Above Normal Operational Range - Moderately
Severe Level

489 191 18 Amber Transmission Output Transmission Output Shaft Speed - Data Valid
Shaft Speed but Below Normal Operational Range -
Moderately Severe Level

497 1377 2 Amber Switch Circuit AEB15.60 Page 151 of 157 Multiple Unit
Synchronization Switch Circuit - Data Erratic,
Intermittent, or Incorrect

523 611 2 Amber System Diagnostic OEM Intermediate (PTO) Speed switch
code #1 Validation - Data Erratic, Intermittent, or
Incorrect

527 702 3 Amber Circuit - Voltage Auxiliary Input/Output 2 Circuit - Voltage Above
Normal, or Shorted to High Source

528 93 2 Amber Switch - Data Auxiliary Alternate Torque Validation Switch -

Data Erratic, Intermittent, or Incorrect

529 703 3 Amber Circuit - Voltage Auxiliary Input/Output 3 Circuit - Voltage Above
Normal, or Shorted to High Source

546 94 3 Amber Fuel Delivery Fuel Delivery Pressure Sensor Circuit - Voltage
Pressure Above Normal, or Shorted to High Source

547 94 4 Amber Fuel Delivery Fuel Delivery Pressure Sensor Circuit - Voltage
Pressure Below Normal, or Shorted to Low Source

551 558 4 Amber Accelerator Pedal Accelerator Pedal or Lever Idle Validation
Low Idle Switch Circuit - Voltage Below Normal, or Shorted to
Low Source

553 157 16 Amber Injector Metering Injector Metering Rail #1 Pressure High - Data
Rail 1 Pressure Valid but Above Normal Operational Range -
Moderately Severe Level

9-74 G6-42A, G9-43A, G10-43A

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

554 157 2 Amber Injector Metering Fuel Pressure Sensor Error - Data Erratic,
Rail 1 Pressure Intermittent, or Incorrect

559 157 18 Amber Injector Metering Injector Metering Rail #1 Pressure Low - Data
Rail 1 Pressure Valid but Below Normal Operational Range -
Moderately Severe Level

584 677 3 Amber Starter Solenoid Starter Relay Circuit - Voltage Above Normal, or
Lockout Relay Driver Shorted to High Source
Circuit

585 677 4 Amber Starter Solenoid Starter Relay Circuit - Voltage Below Normal, or
Lockout Relay Driver Shorted to Low Source
Circuit

595 103 16 Amber Turbocharger 1 Turbocharger #1 Speed High - Data Valid but
Speed Above Normal Operational Range - Moderately
Severe Level

596 167 16 Amber Alternate Potential Electrical Charging System Voltage High - Data
(voltage) Valid but Above Normal Operational Range -
Moderately Severe Level

597 167 18 Amber Alternate Potential Electrical Charging System Voltage Low - Data
(voltage) Valid but Below Normal Operational Range -
Moderately Severe Level

598 167 1 Red Alternate Potential Electrical Charging System Voltage Low - Data
(voltage) Valid but Below Normal Operational Range -
Most Severe Level

599 640 14 Red Engine External Auxiliary Commanded Dual Output Shutdown -
Protection Input Special Instructions

649 1378 31 Maint Engine Oil Change Change Lubricating Oil and Filter - Condition
Interval Exists

687 103 18 Amber Turbocharger 1 Turbocharger #1 Speed Low - Data Valid but
Speed Below Normal Operational Range - Moderately
Severe Level

689 190 2 Amber Engine Speed Primary Engine Speed Sensor Error - Data
Erratic, Intermittent, or Incorrect

691 1172 3 Amber Turbocharger #1 Turbocharger #1 Compressor Inlet Temperature

Compressor Inlet Sensor Circuit - Voltage Above Normal, or
Temperature Shorted to High Source

692 1172 4 Amber Turbocharger #1 Turbocharger #1 Compressor Inlet Temperature

Compressor Inlet Sensor Circuit - Voltage Below Normal, or
Temperature Shorted to Low Source

697 1136 3 Amber Sensor Circuit - ECM Internal Temperature Sensor Circuit -
Voltage Voltage Above Normal, or Shorted to High
Source

G6-42A, G9-43A, G10-43A 9-75

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

698 1136 4 Amber Sensor Circuit - ECM Internal Temperature Sensor Circuit -
Voltage Voltage Below Normal, or Shorted to Low
Source

719 22 3 Amber Crankcase Pressure AEB15.60 Page 152 of 157 Extended

Crankcase Blow-by Pressure Circuit - Voltage
Above Normal, or Shorted to High Source

729 22 4 Amber Crankcase Pressure Extended Crankcase Blow-by Pressure Circuit -

Voltage Below Normal, or Shorted to Low
Source

731 723 7 Amber Engine Speed Engine Speed/Position #2 mechanical

Sensor #2 misalignment between camshaft and crankshaft
sensors - Mechanical System Not Responding
Properly or Out of Adjustment

757 2802 31 Amber Electronic Control Electronic Control Module data lost - Condition
Module Exists

778 723 2 Amber Engine Speed Engine Speed Sensor (Camshaft) Error - Data
Sensor #2 Erratic, Intermittent, or Incorrect

779 703 11 Amber Auxiliary Equipment Warning Auxiliary Equipment Sensor Input #3
Sensor Input (OEM Switch) - Root Cause Not Known

951 166 2 None Cylinder Power Cylinder Power Imbalance Between Cylinders -
Data Erratic, Intermittent, or Incorrect

1117 627 2 None Power Supply Power Lost With Ignition On - Data Erratic,
Intermittent, or Incorrect

1139 651 7 Amber Injector Cylinder Injector Cylinder #1 - Mechanical System Not
#01 Responding Properly or Out of Adjustment

1141 652 7 Amber Injector Cylinder Injector Cylinder #2 - Mechanical System Not
#02 Responding Properly or Out of Adjustment

1142 653 7 Amber Injector Cylinder Injector Cylinder #3 - Mechanical System Not
#03 Responding Properly or Out of Adjustment

1143 654 7 Amber Injector Cylinder Injector Cylinder #4 - Mechanical System Not
#04 Responding Properly or Out of Adjustment

1144 655 7 Amber Injector Cylinder Injector Cylinder #5 - Mechanical System Not
#05 Responding Properly or Out of Adjustment

1145 656 7 Amber Injector Cylinder Injector Cylinder #6 - Mechanical System Not
#06 Responding Properly or Out of Adjustment

1239 2623 3 Amber Accelerator Pedal Accelerator Pedal or Lever Position Sensor 2
Position Circuit - Voltage Above Normal, or Shorted to
High Source

9-76 G6-42A, G9-43A, G10-43A

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

1241 2623 4 Amber Accelerator Pedal Accelerator Pedal or Lever Position Sensor 2
Position Circuit - Voltage Below Normal, or Shorted to
Low Source

1242 91 2 Red Accelerator Pedal Accelerator Pedal or Lever Position Sensor 1

Position and 2 - Data Erratic, Intermittent, or Incorrect

1256 1563 2 Amber Control Module Control Module Identification Input State Error -
Identification Input Data Erratic, Intermittent, or Incorrect
State

1257 1563 2 Red Control Module Control Module Identification Input State Error -
Identification Input Data Erratic, Intermittent, or Incorrect
State

1852 97 16 Amber Water in Fuel Water in Fuel Indicator - Data Valid but Above
Indicator Normal Operational Range - Moderately Severe
Level

1911 157 0 Amber Injector Metering Injector Metering Rail 1 Pressure - Data Valid
Rail but Above Normal Operational Range - Most
Severe Level

2111 52 3 Amber Coolant Temperature Coolant Temperature 2 Sensor Circuit - Voltage

Above Normal, or Shorted to High Source

2112 52 4 Amber Coolant Temperature Coolant Temperature 2 Sensor Circuit - Voltage

Below Normal, or Shorted to Low Source

2113 52 16 Amber Coolant Temperature Coolant Temperature 2 - Data Valid but Above
Normal Operational Range - Moderately Severe
Level

2114 52 0 Red Coolant Temperature Coolant Temperature 2 - Data Valid but Above
Normal Operational Range - Most Severe Level

2115 2981 3 Amber Coolant Pressure Coolant Pressure 2 Circuit - Voltage Above
Normal, or Shorted to High Source

2116 2981 4 Amber Coolant Pressure AEB15.60 Page 153 of 157 Coolant Pressure 2
Circuit - Voltage Below Normal, or Shorted to
Low Source

2117 2981 18 Amber Coolant Pressure Coolant Pressure 2 - Data Valid but Below
Normal Operational Range - Moderately Severe
Level

2182 1072 3 Amber Engine Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage
#1 Above Normal, or Shorted to High Source

2183 1072 4 Amber Engine Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage
#1 Below Normal, or Shorted to Low Source

2185 3512 3 Amber System Diagnostic Sensor Supply Voltage #4 Circuit - Voltage
code #1 Above Normal, or Shorted to High Source

G6-42A, G9-43A, G10-43A 9-77

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

2186 3512 4 Amber System Diagnostic Sensor Supply Voltage #4 Circuit - Voltage
code #1 Below Normal, or Shorted to Low Source

2195 703 14 Red Auxiliary Equipment Auxiliary Equipment Sensor Input 3 Engine
Sensor Protection Critical - Special Instructions

2215 94 18 Amber Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Below Normal Operational Range - Moderately
Severe Level

2216 94 1 Amber Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Above Normal Operational Range - Moderately
Severe Level

2217 630 31 Amber Calibration Memory ECM Program Memory (RAM) Corruption -
Condition Exists

2249 157 1 Amber Injector Metering Injector Metering Rail 1 Pressure - Data Valid
Rail 1 Pressure but Below Normal Operational Range - Most
Severe Level

2261 94 15 Maint Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Above Normal Operational Range - Least
Severe Level

2262 94 17 Maint Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Below Normal Operational Range - Least
Severe Level

2263 1800 16 Amber Battery Temperature Battery Temperature - Data Valid but Above
Normal Operational Range - Moderately Severe
Level

2264 1800 18 Amber Battery Temperature Battery Temperature - Data Valid but Below
Normal Operational Range - Moderately Severe
Level

2265 1075 3 Amber Electric Lift Pump for Fuel Priming Pump Control Signal Circuit -
Engine Fuel Voltage Above Normal, or Shorted to High
Source

2266 1075 4 Amber Electric Lift Pump for Fuel Priming Pump Control Signal Circuit -
Engine Fuel Voltage Below Normal, or Shorted to Low
Source

2292 611 16 Amber Fuel Inlet Meter Fuel Inlet Meter Device - Data Valid but Above
Device Normal Operational Range - Moderately Severe
Level

2293 611 18 Amber Fuel Inlet Meter Fuel Inlet Meter Device flow demand lower than
Device expected - Data Valid but Below Normal
Operational Range - Moderately Severe Level

2311 633 31 Amber Fuel Control Valve Fueling Actuator #1 Circuit Error - Condition
#1 Exists

9-78 G6-42A, G9-43A, G10-43A

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

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
Sensor #2 Erratic, Intermittent, or Incorrect

2345 103 10 Amber Turbocharger 1 Turbocharger speed invalid rate of change

Speed detected - Abnormal Rate of Change

2346 2789 15 None System Diagnostic Turbocharger Turbine Inlet Temperature

Code #1 (Calculated) - Data Valid but Above Normal
Operational Range - Least Severe Level

2347 2790 15 None System Diagnostic Turbocharger Compressor Outlet Temperature

Code #1 (Calculated) - Data Valid but Above Normal
Operational Range - Least Severe Level

2363 1073 4 Amber Engine Compression Engine Brake Actuator Circuit #2 - Voltage
Brake Output #2 Below Normal, or Shorted to Low Source

2365 1112 4 Amber Engine Brake Output Engine Brake Actuator Driver Output 3 Circuit -
#3 Voltage Below Normal, or Shorted to Low
Source

2367 1073 3 Amber Engine Compression Engine Brake Actuator Circuit #2 - Voltage
Brake Output #2 Above Normal, or Shorted to High Source

2368 1112 3 Amber Engine Brake Output Engine Brake Actuator Driver 3 Circuit - Voltage
#3 Above Normal, or Shorted to High Source

2372 95 16 Amber Engine Fuel Filter Fuel Filter Differential Pressure - Data Valid but
Differential Pressure Above Normal Operational Range - Moderately
Severe Level

2373 1209 3 Amber Exhaust Gas Exhaust Gas Pressure Sensor Circuit - Voltage
Pressure Above Normal, or Shorted to High Source

2374 1209 4 Amber Exhaust Gas Exhaust Gas Pressure Sensor Circuit - Voltage
Pressure Below Normal, or Shorted to Low Source

2375 412 3 Amber Exhaust Gas Exhaust Gas Recirculation Temperature Sensor
Recirculation Circuit - Voltage Above Normal, or Shorted to
Temperature High Source

2376 412 4 Amber Exhaust Gas Exhaust Gas Recirculation Temperature Sensor
Recirculation Circuit - Voltage Below Normal, or Shorted to
Temperature Low Source

2377 647 3 Amber Fan Clutch Output Fan Control Circuit - Voltage Above Normal, or
Device Driver Shorted to High Source

2425 730 4 Intake Air Heater #2 Intake Air Heater 2 Circuit - Voltage Below
Normal, or Shorted to Low Source

2426 730 3 Intake Air Heater #2 Intake Air Heater 2 Circuit - Voltage Above
Normal, or Shorted to High Source

G6-42A, G9-43A, G10-43A 9-79

 Electrical System

Fault SPN FMI Lamp

SPN Description Cummins Description
Codes Codes Codes Color

2555 729 3 Amber Inlet Air Heater Intake Air Heater #1 Circuit - Voltage Above
Driver #1 Normal, or Shorted to High Source

2556 729 4 Amber Inlet Air Heater Intake Air Heater #1 Circuit - Voltage Below
Driver #1 Normal, or Shorted to Low Source

2557 697 3 Amber Auxiliary PWM Auxiliary PWM Driver #1 - Voltage Above
Driver #1 Normal, or Shorted to High Source

2558 697 4 Amber Auxiliary PWM Auxiliary PWM Driver #1 - Voltage Below
Driver #1 Normal, or Shorted to Low Source

2963 110 15 None Engine Coolant Engine Coolant Temperature High - Data Valid
Temperature but Above Normal Operational Range - Least
Severe Level

2973 102 2 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit - Data
Erratic, Intermittent, or Incorrect

9-80 G6-42A, G9-43A, G10-43A


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-lhlpohl
Germany
Phone: +49 (0)421 69 350 20
Fax: +49 (0)421 69 350 45
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UI. Krolewska
00-060 Warsawa
Poland
Phone: +48 (0)914 320 245
Fax: +48 (0)914 358 200
31200151
An Oshkosh Corporation Company
JLG Industries, Inc.
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McConnellsburg PA. 17233-9533
USA
Phone: +1-717-485-5161
Customer Support Toll Free: 1-877-554-5438
Fax: +1-717-485-6417
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Rua Antonia Martins Luiz, 580 Bentley House Z.I. de Baulieu
Distrito Industrial João Narezzi Bentley Avenue 47400 Fauillet
13347-404 Indaiatuba - SP Middleton France
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Phone: +55 19 3936 8870 M24 2GP Fax: +33 (0)5 53 88 31 79
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Phone: +44 (0)161 654 1000
Fax: +44 (0)161 654 1001
JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Sheung Shui N.T. Italy The Netherlands
Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
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Plataformas Elevadoras JLG Sverige AB
JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755Castellbisbal, Barcelona Sweden
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Phone: +34 93 772 4 700 Fax: +46 (0)850 659 534
Fax: +34 93 771 1762
www.jlg.com