Jlg G6-42A Service Manual manuels

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Jlg G6-42A Service Manual Manuel d'utilisateur (206 pages)

marque: Jlg | Catégorie: Machines spéciales | Taille: 18.23 MB |

Anglais

Table des matières

Service Manual

1

EFFECTIVITY PAGE

3

READ THIS FIRST

4

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

Safety Practices

9

1.1 INTRODUCTION

10

1.2 DISCLAIMER

10

1.4 DO NOT OPERATE TAGS

10

1.5 SAFETY INFORMATION

10

1.6 SAFETY INSTRUCTIONS

11

1.7 SAFETY DECALS

12

Section 2

13

2.1 REPLACEMENT PARTS AND

14

WARRANTY INFORMATION

14

2.2 THREAD LOCKING COMPOUND

14

2.3 TORQUE CHARTS

15

SOCKET HEAD CAP SCREWS

19

2.4 SPECIFICATIONS

26

2.4.4 Engine Specifications

28

2.4.5 Tires

29

2.5.3 Capacities

32

LB/FT (Nm)

33

2.7 LUBRICATION SCHEDULE

36

2.7.2 250 Hour

37

2.7.3 1000 Hour

38

Section 3

39

3.1 BOOM SYSTEM

41

3.2 BOOM SYSTEM—THREE SECTION

42

3.4 COMPLETE BOOM REMOVAL/

43

INSTALLATION

43

3.5 BOOM SECTION

44

REMOVAL/INSTALLATION

44

3.5.6 Second and Third Boom

51

Section Installation

51

3.6 EXTEND/RETRACT CHAIN

53

3.7 PUSH BEAM—EXTEND/RETRACT

54

CYLINDER REMOVAL/

54

Remove strong back

56

3.8 BOOM ADJUSTMENTS

58

G9-43A/G10-43A

61

3.9 QUICK SWITCH ASSEMBLY

63

3.10 BOOM WEAR PADS

64

Lubrication:

65

3.11 BOOM EXTEND AND

66

RETRACT CHAINS

66

3.11.3 Inspection Guidelines

67

3.11.4 Chain Lubrication

68

3.12 FORKS

69

3.13 EMERGENCY BOOM LOWERING

69

PROCEDURE

69

3.14 TROUBLESHOOTING

72

Section 4

77

Cab and Covers

77

4.1 OPERATOR CAB AND COVERS

78

4.2 OPERATOR CAB

80

4.3 CAB COMPONENTS

80

4.3.2 Service Brake Pedal

81

4.3.3 Accelerator Pedal

82

Accelerator Pedal Removal

82

4.3.4 Boom Joystick Assembly

83

Outrigger Joysticks

83

(if equipped)

84

4.4 CAB REMOVAL

86

4.5 CAB INSTALLATION

87

Section 5

89

5.2 AXLE SERIAL NUMBER

92

5.3 AXLE SPECIFICATIONS AND

92

MAINTENANCE INFORMATION

92

5.4 AXLE REPLACEMENT

92

5.5 DRIVE SHAFTS

97

5.6 WHEELS AND TIRES

98

5.7 BRAKES

99

5.8 TOWING A DISABLED MACHINE

100

Section 6

101

Transmission

101

COMPONENT TERMINOLOGY

102

6.1 TRANSMISSION ASSEMBLY

102

AND MAINTENANCE INFORMATION

103

6.4 TRANSMISSION REPLACEMENT

103

Internal Repair

105

BY-PASS VALVE

107

6.6.2 Torque Convertor

108

Diaphragm Installation

108

6.7 TROUBLESHOOTING

109

Problem Cause Remedy

109

Section 7

113

7.1 INTRODUCTION—CUMMINS

114

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

115

7.2 ENGINE COOLING SYSTEM

117

7.3 ENGINE ELECTRICAL SYSTEM

120

7.4 FUEL SYSTEM

120

7.4.2 Fuel Tank

121

7.5 ENGINE EXHAUST SYSTEM

123

7.6 AIR CLEANER ASSEMBLY

125

7.7 ENGINE REPLACEMENT

127

7.7.2 Engine Installation

128

Section 8

129

Hydraulic System

129

8.1 HYDRAULIC COMPONENT

130

TERMINOLOGY

130

8.2 SAFETY INFORMATION

132

8.4 HYDRAULIC CIRCUITS

134

STABILIZER OPTION

139

AUXILIARY

139

HYDRAULICS OPTION

139

8.4.8 Anti-Stall System

142

8.5 HYDRAULIC RESERVOIR

143

8.6 IMPLEMENT PUMP

144

8.7 CONTROL VALVES

145

8.7.2 Service Brake Valve

148

8.7.3 Service Brake Bleeding

148

8.7.4 Steering Orbitrol Valve

149

8.7.5 Steer Select Valve

149

8.8 HYDRAULIC CYLINDERS

151

AFTER the head gland

153

8.8.3 Steering Cylinders

153

Section 9

157

Electrical System

157

9.1 ELECTRICAL COMPONENT

159

9.2 SPECIFICATIONS

161

9.3 SAFETY INFORMATION

161

9.4 FUSES AND RELAYS

161

SEE ACCESSORY MODULE

164

9.5.2 Options Schematic

165

9.5.4 Chassis Schematic

167

PUMP DISPLACEMENT MODULE

168

9.6 ENGINE START CIRCUIT

170

9.7 CHARGING CIRCUIT

171

9.7.2 Alternator—LS

172

9.8 WINDOW WIPER/WASHER

173

WINDSHIELD WIPER MOTOR

173

Reservoir

174

9.9 CAB HEATER AND FAN

175

9.10 SOLENOIDS, SENSORS

176

AND SENDERS

176

9.10.5 Fuel Level Sender

178

9.11 DISPLAY GAUGE AND

180

DASH SWITCHES

180

9.11.3 Dash Switches

181

9.12 HAND HELD ANALYZER

183

- G9-43A AND G10-43A

183

MAL0890B

184

DTC Event Comment Latched

187

FAULT CODES

194

JLG Worldwide Locations

206

Jlg G6-42A Service Manual Manuel d'utilisateur (246 pages)

marque: Jlg | Catégorie: Machines spéciales | Taille: 32.01 MB |

Anglais

Table des matières

Service Manual

1

EFFECTIVITY PAGE

3

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

Safety Practices

9

1.1 INTRODUCTION

10

1.2 DISCLAIMER

10

1.4 DO NOT OPERATE TAGS

10

1.5 SAFETY INFORMATION

10

1.6 SAFETY INSTRUCTIONS

11

1.7 SAFETY DECALS

12

Section 2

13

2.1 REPLACEMENT PARTS AND

14

WARRANTY INFORMATION

14

2.2 TORQUE CHARTS

15

(Continued)

16

SOCKET HEAD CAP SCREWS

17

CLASS 8.8 METRIC BOLTS

19

CLASS 8 METRIC NUTS

19

CLASS 10.9 METRIC BOLTS

20

CLASS 10 METRIC NUTS

20

M6 AND ABOVE*

21

2.3 SPECIFICATIONS

23

2.3.4 Electrical System

25

2.3.5 Tires

26

2.5 SERVICE AND MAINTENANCE

30

SCHEDULE

30

2.6 LUBRICATION SCHEDULE

33

2.6.2 G9-43A / G10-43A

36

Section 3

39

3.1 BOOM SYSTEM COMPONENT

41

3.2.1 Boom System Operation

42

3.4 COMPLETE BOOM REMOVAL/

43

INSTALLATION

43

3.5 BOOM SECTION REMOVAL/

44

Assembly

47

Installation

50

3.6 EXTEND/RETRACT CHAIN

52

REMOVAL/INSTALLATION

52

CYLINDER REMOVAL/

54

Remove the strong back

55

3.8 BOOM ADJUSTMENTS

58

G9-43A/G10-43A

60

3.9 QUICK SWITCH ASSEMBLY

63

3.11 BOOM WEAR PADS

64

3.12 BOOM EXTEND AND RETRACT

65

3.12.2 Inspection Guidelines

66

3.13 FORKS

68

3.14 EMERGENCY BOOM LOWERING

69

PROCEDURE

69

3.15 TROUBLESHOOTING

71

Section 4

75

Cab and Covers

75

4.1 OPERATOR CAB AND COVERS

76

4.1.2 General Overview

77

4.2 OPERATOR CAB

79

4.3 CAB COMPONENTS

79

4.3.2 Service Brake Pedal

80

4.3.3 Throttle Pedal

81

(If Equipped)

82

(G10-43A) Joysticks

83

(if equipped)

84

4.4 CAB REMOVAL

85

4.5 CAB INSTALLATION

86

Section 5

89

5.2 GENERAL INFORMATION

91

5.3 AXLE ASSEMBLIES

91

5.3.5 Axle Removal

92

5.3.6 Axle Installation

93

TRANSMISSION

98

5.5 WHEELS AND TIRES

99

5.6 BRAKES

100

5.7 TOWING A DISABLED MACHINE

100

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

101

Section 6

103

Transmission

103

6.1 TRANSMISSION ASSEMBLY

104

COMPONENT TERMINOLOGY

104

DANA TRANSMISSION

106

ZF TRANSMISSION

106

Replacement

108

6.5 ENGINE DRIVE PLATE

109

6.7 TROUBLESHOOTING

112

Problem Cause Remedy

112

Section 7

117

7.1 INTRODUCTION - JOHN DEERE

118

7.1.4 Component Terminology

119

7.2 INTRODUCTION - PERKINS

120

7.2.4 Component Terminology

121

7.3 INTRODUCTION - CUMMINS

122

7.3.4 Component Terminology

123

TYPICAL

124

THERMOSTAT

124

CUMMINS RADIATOR ASSSEMBLY

125

7.5 ENGINE ELECTRICAL SYSTEM

126

7.6 FUEL SYSTEM

126

7.6.2 Fuel Tank

127

7.7 ENGINE EXHAUST SYSTEM

128

7.8 AIR CLEANER ASSEMBLY

129

7.9 ENGINE REPLACEMENT

130

7.9.2 Engine Installation

131

7.10 TROUBLESHOOTING

133

Section 8

135

Hydraulic System

135

8.1 HYDRAULIC COMPONENT

136

TERMINOLOGY

136

8.2 SAFETY INFORMATION

137

8.4 HYDRAULIC CIRCUITS

139

8.5 HYDRAULIC RESERVOIR

151

8.6 IMPLEMENT PUMP

152

8.7 CONTROL VALVES

153

G9-43A & G10-43A

154

8.7.2 Service Brake Valve

156

8.7.3 Brake Test

156

8.7.4 Steering Orbitrol Valve

157

8.7.5 Steer Select Valve

157

8.8 HYDRAULIC CYLINDERS

159

AXLE CENTER SECTION

161

STEERING CYLINDER

161

Section 9

165

Electrical System

165

TILT SPEED

167

9.4.3 Power Control Board

170

9.5.1 Before S/N 0160011059

174

JOHN DEERE ENGINE

187

PERKINS ENGINE

188

DANA SHIFTER

189

AIR CONDITIONING OPTION

195

(JOHN DEERE ONLY)

195

CUMMINS ENGINE

200

9.6 CIRCUIT BREAKDOWNS

202

MY6360 B

203

JOHN DEERE

204

9.6.3 Charging Circuit

207

9.7 ENGINE START CIRCUIT

209

9.8 CHARGING CIRCUIT

210

9.9 WINDOW WIPER/WASHER

211

WINDSHIELD WIPER MOTOR

211

9.10 CAB HEATER AND FAN

212

9.11.7 Fuel Level Sender

218

9.12.1 Analog Gauges

219

9.13 DASH SWITCHES

220

9.13.2 Dash Switches

221

9.14.2 Diagnostics Menu

223

9.15 HAND HELD ANALYZER

224

MAL0890A

225

9.16 JOYSTICK FAULT CODES

226

DTC Event Comment Latched

226

JLG Worldwide Locations

246

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