Jlg G6-42A Operator Manual User Manual

Operation & SafetyManualOriginal InstructionsKeep this manual with machine at all times.An Oshkosh Corporation CompanyModelG6-42AS/N 0160003986 &a

Table of Contentsiv 31200149Section 7 - Lubrication and Maintenance7.1 Introduction...

Section 5 - Attachments5-24 31200149Dual Fork Positioning CarriageUse Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Teleh

Section 5 - Attachments5-2531200149Operation:• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Practices.Equipment D

Section 5 - Attachments5-26 31200149Mast CarriageUse Mast Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork

Section 5 - Attachments5-2731200149Operation:• Always lower forks fully in mast before engaging load.• To drive with a load, lower forks fully in mast

Section 5 - Attachments5-28 31200149Mast Carriage with Swing and Side Shift(Before S/N 0160037722)Use 6 ft Mast Carriage Capacity ChartTo determine ma

Section 5 - Attachments5-2931200149To Raise/Lower Mast:Press Forks Raise/Lower Switch (6) located on dash panel to activate Forks Raise/Lower function

Section 5 - Attachments5-30 31200149Mast Carriage with Side Tilt (S/N 0160037722 & After)Use Mast Carriage Capacity ChartTo determine maximum capa

Section 5 - Attachments5-3131200149To Side Tilt:Press Side Tilt Switch (5) located on dash panel (4) to activate Side Tilt function. The auxiliary hyd

Section 5 - Attachments5-32 31200149Fork Mounted HookUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Teleha

Section 5 - Attachments5-3331200149Operation:• Pallet or lumber forks of an appropriate load rating must be used. Do not use withcubing or block forks

Section 1 - General Safety Practices1-131200149SECTION 1 - GENERAL SAFETY PRACTICES1.1 HAZARD CLASSIFICATION SYSTEMSafety Alert System and Safety Sign

Section 5 - Attachments5-34 31200149Truss BoomUse Appropriate Truss Boom Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment

Section 5 - Attachments5-3531200149Operation:• Weight of rigging must be included as part of total load being lifted.WARNINGCRUSH HAZARD. Maintain a m

Section 5 - Attachments5-36 31200149BucketUse Appropriate Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork Ca

Section 5 - Attachments5-3731200149Equipment Damage Precautions• Except for lifting or dumping a load, the boom must be fully retracted for allbucket

Section 5 - Attachments5-38 31200149Grapple BucketUse Grapple Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/For

Section 5 - Attachments5-3931200149Operation:• Raise or lower boom to appropriate height and open grapple for loading materialfrom stockpile.• Align t

Section 5 - Attachments5-40 31200149Personnel Work Platform - Quick Switch Mounted(Before S/N 0160037722)Use Personnel Work Platform - Quick Switch Mo

Section 5 - Attachments5-4131200149Preparation and Setup:1. Ensure the telehandler is on a firm surface and is level.2. Engage the park brake. Blockin

Section 5 - Attachments5-42 31200149Personnel Work Platform - Fork Mounted Use Appropriate Carriage Attachment Capacity ChartTo determine maximum capa

Section 5 - Attachments5-4331200149Preparation and Setup:1. Ensure the telehandler is on a firm surface and is level.2. Engage the park brake. Blockin

Section 1 - General Safety Practices1-2 312001491.3 OPERATION SAFETYElectrical Hazards• This machine is not insulated and does not provide protection

Section 5 - Attachments5-44 31200149Boom Head-Mounted Winch (Before S/N 0160037722)Use Carriage Attachment Capacity ChartTo determine maximum capacity

Section 6 - Emergency Procedures6-131200149SECTION 6 - EMERGENCY PROCEDURES6.1 TOWING A DISABLED PRODUCTThe following information assumes the telehand

Section 6 - Emergency Procedures6-2 312001496.2 EMERGENCY LOWERING OF BOOMIn the event of total loss of engine power or hydraulic pump failure with an

Section 7 - Lubrication and Maintenance7-131200149SECTION 7 - LUBRICATION AND MAINTENANCE7.1 INTRODUCTIONService the product in accordance with the ma

Section 7 - Lubrication and Maintenance7-2 312001497.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the telehandl

Section 7 - Lubrication and Maintenance7-3312001497.3 SERVICE AND MAINTENANCE SCHEDULE10, 1st 50 & 50 Hour Maintenance ScheduleOY2240CheckTransmis

Section 7 - Lubrication and Maintenance7-4 312001491st 250, 250 & 500 Hour Maintenance ScheduleNote: Engine oil and filter service interval can b

Section 7 - Lubrication and Maintenance7-5312001491000, 1500 & 2000 Hour Maintenance ScheduleOY22602000EVERYChange EngineCoolant (S/N0160040678 &a

Section 7 - Lubrication and Maintenance7-6 312001497.4 LUBRICATION SCHEDULES50 Hour Lubrication ScheduleOY227050EVERY22B2B2B2B2B2B2B2B2B2

Section 7 - Lubrication and Maintenance7-731200149250 Hour Lubrication ScheduleOY2280B2B2B2B2B2B2B2B2A2A2A2A2EVERY250

Section 1 - General Safety Practices1-331200149Tip Over HazardGeneral• For additional load requirements, refer to the appropriate capacity chart.• Nev

Section 7 - Lubrication and Maintenance7-8 312001491000 Hour Lubrication ScheduleOY2290EVERY1000BB

Section 7 - Lubrication and Maintenance7-931200149This Page Intentionally Left Blank

Section 7 - Lubrication and Maintenance7-10 312001497.5 OPERATOR MAINTENANCE INSTRUCTIONSFuel SystemA. Fuel Level Check1. Check fuel gauge (1) located

Section 7 - Lubrication and Maintenance7-1131200149B. Drain Fuel/Water Separator1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine cover.

Section 7 - Lubrication and Maintenance7-12 31200149Air Intake SystemA. Air Filter Restriction Indicator Check1. Perform “Shut-Down Procedure” on page

Section 7 - Lubrication and Maintenance7-1331200149B. Element Change (as restriction indicator indicates)1. Perform “Shut-Down Procedure” on page 4-5.

Section 7 - Lubrication and Maintenance7-14 31200149Engine OilA. Engine Oil Level Check1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine

Section 7 - Lubrication and Maintenance7-1531200149Hydraulic OilA. Hydraulic Oil Level Check1. Be sure all cylinders are fully retracted and machine i

Section 7 - Lubrication and Maintenance7-16 31200149TiresA. Tire Air Pressure Check1. Perform “Shut-Down Procedure” on page 4-5.2. Remove valve stem c

Section 7 - Lubrication and Maintenance7-1731200149C. Tire and Wheel ReplacementIt is recommended that a replacement tire to be the same size, ply and

Section 1 - General Safety Practices1-4 31200149• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, this machine

Section 7 - Lubrication and Maintenance7-18 31200149E. Wheel InstallationTorque lug nuts after first 100 hours and after each wheel installation.Note:

Section 7 - Lubrication and Maintenance7-1931200149Transmission OilA. Transmission Oil Level Check1. Apply park brake, shift transmission to "Neu

Section 7 - Lubrication and Maintenance7-20 31200149Hydraulic Return Filter (Before S/N 0160040678)A. Hydraulic Return Filter Indicator Check1. Apply

Section 7 - Lubrication and Maintenance7-2131200149Engine Cooling SystemA. Engine Coolant Level CheckBefore S/N 01600406781. Perform “Shut-Down Proced

Section 7 - Lubrication and Maintenance7-22 31200149S/N 0160040678 & After1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine cover.3.

Section 7 - Lubrication and Maintenance7-2331200149BatteryA. Battery Check1. Perform “Shut-Down Procedure” on page 4-5.2. Open the engine cover.3. Wea

Section 7 - Lubrication and Maintenance7-24 31200149Windshield Washer System (if equipped)A. Windshield Washer Fluid Level Check1. Perform “Shut-Down

Section 8 - Additional Checks8-131200149SECTION 8 - ADDITIONAL CHECKSThis Page Intentionally Left Blank

Section 8 - Additional Checks8-2 31200149This Page Intentionally Left Blank

Section 9 - Specifications9-131200149SECTION 9 - SPECIFICATIONS9.1 PRODUCT SPECIFICATIONSCapacitiesEngine Crankcase OilCapacity with Filter ChangeBefo

Section 1 - General Safety Practices1-531200149Non-Suspended Load• DO NOT drive with boom raised.Suspended Load• Tether suspended loads to restrict mo

Section 9 - Specifications9-2 31200149TransmissionCapacity with Filter Change...4.2 gal

Section 9 - Specifications9-331200149Tires13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 PlyPneumatic...

Section 9 - Specifications9-4 31200149PerformanceNote: Values shown are per machine as originally manufactured. Reference capacity charts in operator

Section 9 - Specifications9-531200149DimensionsOverall Height...95.4 in

Section 9 - Specifications9-6 31200149This Page Intentionally Left Blank

Index131200149AAccessory Control Lever... 3-16Additional Checks... 8-1Adjusting/Moving Forks...

Index2 31200149IIgnition... 3-6LLeveling Procedure...4-7, 4-10Lifting Personnel...

Index331200149TransportLifting ... 4-13Tiedown ... 4-12Transporting a Load...

Index4 31200149

Inspection, Maintenance and Repair LogSerial Number ______________________________Date CommentsInspection, Maintenance and Repair Log

Section 1 - General Safety Practices1-6 31200149Travel Hazard• Steering characteristics differ between steer modes. Identify the steer modesettings of

Inspection, Maintenance and Repair LogDate Comments

TRANSFER OF OWNERSHIPTo Product Owner:If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know w

Hand SignalsSpecial Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in adva

JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-485-5161Customer Support Toll Free: 1-877-554-5438Fax: +1-717-485-6417JLG

Section 1 - General Safety Practices1-731200149Load Falling Hazard• Never suspend load from forks or other parts of carriage.• DO NOT burn or drill ho

Section 1 - General Safety Practices1-8 31200149Lifting Personnel• When lifting personnel, USE ONLY a JLG approved personnel work platform,with proper

Section 1 - General Safety Practices1-931200149Driving Hazards on SlopesTo maintain sufficient traction and braking capabilities, travel on slopes as

CALIFORNIA PROPOSITION 65BATTERY WARNINGBattery posts,terminals and relatedaccessories containlead and lead compounds,chemical known to theState of Ca

Section 1 - General Safety Practices1-10 31200149Pinch Points and Crush HazardsStay clear of pinch points and rotating parts on the telehandler.• Stay

Section 1 - General Safety Practices1-1131200149• Keep clear of boom holes.• Keep arms and hands clear of attachment tilt cylinder.• Keep hands and fi

Section 1 - General Safety Practices1-12 31200149Fall Hazard• Enter using the proper hand holds and steps provided. Always maintain 3-pointcontact whe

Section 1 - General Safety Practices1-1331200149Chemical HazardsExhaust Fumes• DO NOT operate machine in an enclosed area without proper ventilation.•

Section 1 - General Safety Practices1-14 31200149This Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection2-131200149SECTION 2 - PRE-OPERATION AND INSPECTION2.1 PRE-OPERATION CHECK AND INSPECTIONNote: Complete all r

Section 2 - Pre-Operation and Inspection2-2 312001498. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operatio

Section 2 - Pre-Operation and Inspection2-3312001492.2 SAFETY DECALSEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity

Section 2 - Pre-Operation and Inspection2-4 31200149OY09619141306191413061806030268060-3026COOLING SYSTEMIS PRESSURIZED.REMOVE CAP SLOWLY.HOT FLUID CA

Section 2 - Pre-Operation and Inspection2-531200149OY1251806030378060-3037-APINCH POINTKEEP OUTREACHING INTO BOOMHOLES AND OTHER PINCHPOINTS CAN CAUSE

Revision Loga31200149Revision LogREVISION LOGApril 28, 2006 - A - Original Issue of ManualJanuary 14, 2009 - B - Revised manual.January 5, 2010 - C -

Section 2 - Pre-Operation and Inspection2-6 31200149S/N 0160040169 & After, If EquippedOY209117058811706768(ENCLOSED CAB)DO NOT use Ether orother

Section 2 - Pre-Operation and Inspection2-731200149OY21001706850ACRUSHING HAZARDKeep othersaway whileoperating.Lowering boom or falling load couldcaus

Section 2 - Pre-Operation and Inspection2-8 31200149OY21101706302-10°0°10°20°30°40°50°60°70°80°1706302-100102030405060708041052621706298A1706298170630

Section 2 - Pre-Operation and Inspection2-931200149ISO (S/N 0160040169 & After, If Equipped)OY21219116302891163028 REV.BFNR10011308021001130920AB1

Section 2 - Pre-Operation and Inspection2-10 31200149OY213041098014109801410980141098011706281915632209156-3220 REV A410018141001811706285915632209156

Section 2 - Pre-Operation and Inspection2-1131200149OY21401706282170629217062921706292915530721706292-10°0°10°20°30°40°50°60°70°80°-100102030405060708

Section 2 - Pre-Operation and Inspection2-12 312001492.3 WALK-AROUND INSPECTIONBegin your walk-around inspection at item 1, as noted below. Continue t

Section 2 - Pre-Operation and Inspection2-13312001495. Cab and Electrical - • General appearance; no visible damage.• Frame level indicator and window

Section 2 - Pre-Operation and Inspection2-14 312001492.4 WARM-UP AND OPERATIONAL CHECKSWarm-Up CheckDuring warm-up period, check:1. Heater, defroster

Section 2 - Pre-Operation and Inspection2-15312001492.5 OPERATOR CABThe telehandler is equipped with an open or enclosed ROPS/FOPS cab.WARNINGNever op

Read This Firstb 31200149Read This FirstThis manual is a very important tool! Keep it with the machine at all times.The purpose of this manual is to p

Section 2 - Pre-Operation and Inspection2-16 312001492.6 WINDOWSKeep all windows and mirrors clean and unobstructed.Cab Door Window (if equipped)• Cab

Section 3 - Controls and Indicators3-131200149SECTION 3 - CONTROLS AND INDICATORS3.1 GENERALThis section provides the necessary information needed to

Section 3 - Controls and Indicators3-2 312001493.2 CONTROLSBefore S/N 01600406781. Transmission Control Lever: See page 3-8.2. Instrument Panel: See p

Section 3 - Controls and Indicators3-331200149S/N 0160040678 & After1. Transmission Control Lever: See page 3-8.2. Instrument Panel: See page 3-4.

Section 3 - Controls and Indicators3-4 31200149Dash Controls and IndicatorsBefore S/N 01600406781. Hourmeter: Indicates total time of engine operation

Section 3 - Controls and Indicators3-531200149S/N 0160040678 & After1. Transmission Temperature Light: Illuminates when transmission temperature i

Section 3 - Controls and Indicators3-6 31200149Ignition• In "ACC" or "RUN" position, voltage is available for all electrical funct

Section 3 - Controls and Indicators3-731200149Park BrakePark brake switch controls the application and release of the park brake. Indicatorlight on sw

Section 3 - Controls and Indicators3-8 31200149Transmission Control LeverDirection of Travel SelectionTransmission control lever (1) engages forward o

Section 3 - Controls and Indicators3-931200149Gear SelectionGear selection is located on the twist grip handle (2) of transmission control lever.• Twi

Read This Firstc31200149This product must comply with all safety related bulletins. Contact JLG Industries,Inc. or the local authorized JLG representa

Section 3 - Controls and Indicators3-10 31200149Boom JoystickThe boom joystick (1) controls the boom and attachment tilt (if equipped) functions.Boom

Section 3 - Controls and Indicators3-1131200149Frame Level and Attachment Tilt (if equipped) JoystickThe rear joystick (4) controls the left to right

Section 3 - Controls and Indicators3-12 31200149Auxiliary Hydraulic Joystick (if equipped)• Auxiliary hydraulic joystick (1) controls function of atta

Section 3 - Controls and Indicators3-1331200149This Page Intentionally Left Blank

Section 3 - Controls and Indicators3-14 31200149Right Hand Panel (S/N 0160040678 & After)Heater and Air Conditioning Controls (if equipped)1. Air

Section 3 - Controls and Indicators3-1531200149Heater and Air Conditioning Controls (Before S/N 0160040678, if equipped)1. Air Vent: Two individually

Section 3 - Controls and Indicators3-16 31200149Accessory Control Lever (if equipped)Before S/N 0160031634The accessory control lever (1) operates the

Section 3 - Controls and Indicators3-1731200149S/N 0160031634 & AfterThe accessory control lever (5) operates the turn signals, parking lights and

Section 3 - Controls and Indicators3-18 312001493.3 STEER MODESThree steer modes are available for operator use.Note: 2-Wheel Front Steer mode is req

Section 3 - Controls and Indicators3-19312001493.4 OPERATOR SEATAdjustmentsPrior to starting engine adjust seat for position and comfort.Before S/N 01

Read This Firstd 31200149Other Publications AvailableService Manual...

Section 3 - Controls and Indicators3-20 31200149S/N 0160015458 & AfterPrior to starting engine adjust seat for position and comfort as follows:1.

Section 3 - Controls and Indicators3-2131200149Seat BeltFasten seat belt as follows:1. Grasp both free ends of the belt making certain that belt webbi

Section 3 - Controls and Indicators3-22 312001493.5 BOOM ANGLE AND EXTENSION INDICATORS• The boom angle indicator (1) is located on the left side of t

Section 4 - Operation4-131200149SECTION 4 - OPERATION4.1 ENGINEStarting the EngineThis machine can be operated under normal conditions in temperatures

Section 4 - Operation4-2 31200149Cold Weather Starting AidsJohn Deere EngineJLG approved starting aids employ ether. If your telehandler is equipped w

Section 4 - Operation4-331200149Extreme Cold Weather Starting (if equipped)If equipped with extreme cold weather components, machine can be operated i

Section 4 - Operation4-4 31200149Battery Boosted StartingIf battery-boost starting (jump-start) is necessary, proceed as follows:• Never allow vehicle

Section 4 - Operation4-531200149Normal Engine Operation• Observe instrument panel frequently to be sure all systems are functioningproperly.• Be alert

Section 4 - Operation4-6 312001494.2 OPERATING WITH A NON-SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you l

Section 4 - Operation4-731200149Transporting a LoadAfter engaging the load and resting it against the backrest, tilt the load back toposition it for t

Table of Contentsi31200149TABLE OF CONTENTSRevision LogRead This FirstOperator Qualifications ...bM

Section 4 - Operation4-8 31200149Placing a LoadBefore placing any load be sure that:• The landing point can safely support the weight of the load.• Th

Section 4 - Operation4-9312001494.3 OPERATING WITH A SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you lift.

Section 4 - Operation4-10 31200149Transporting a Suspended Load• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Pra

Section 4 - Operation4-1131200149Placing a Suspended LoadBefore placing any load be sure that:• The landing point can safely support the weight of the

Section 4 - Operation4-12 312001494.4 LOADING AND SECURING FOR TRANSPORTTiedown1. Level the telehandler prior to loading.2. Using a spotter, load the

Section 4 - Operation4-1331200149Lifting• When lifting machine, it is very important that the lifting device and equipment isattached only to designat

Section 4 - Operation4-14 31200149This Page Intentionally Left Blank

Section 5 - Attachments5-131200149SECTION 5 - ATTACHMENTS5.1 APPROVED ATTACHMENTSTo determine if an attachment is approved for use on the specific tel

Section 5 - Attachments5-2 312001495.2 UNAPPROVED ATTACHMENTSDo not use unapproved attachments for the following reasons:• Range and capacity limitati

Section 5 - Attachments5-3312001495.3 JLG SUPPLIED ATTACHMENTSBefore S/N 0160037722Attachment Part NumberApplicable ModelG6-42ACarriage, 48 in (1220 m

Table of Contentsii 31200149Transmission Control Lever... 3-8Boom Joystick ...

Section 5 - Attachments5-4 31200149Bucket, 102 in -1.25 yd391405071 XGrapple Bucket, 96 in -1.75 yd30930021 XHook, Fork Mounted 90553036 XHook, Fork M

Section 5 - Attachments5-531200149S/N 0160037722 & AfterAttachment Part NumberApplicable ModelG6-42ACarriage, 50 in (1270 mm) 1170021 XCarriage, 6

Section 5 - Attachments5-6 312001495.4 TELEHANDLER/ATTACHMENT/FORK CAPACITYPrior to installing the attachment verify it is approved and the telehandle

Section 5 - Attachments5-7312001495.5 USE OF THE CAPACITY CHARTTo properly use the capacity chart (see page 5-8), the operator must first determineand

Section 5 - Attachments5-8 31200149Sample Capacity ChartBefore S/N 0160037722Note: This is a sample capacity chart only! DO NOT use this chart, use t

Section 5 - Attachments5-931200149To identify the proper capacity chart on telehandlers equipped with outriggers, referto the following icons which ma

Section 5 - Attachments5-10 31200149S/N 0160037722 & AfterNote: This is a sample capacity chart only! DO NOT use this chart, use the one located

Section 5 - Attachments5-1131200149To identify the proper load chart on telehandlers equipped with outriggers, refer tothe following icons which may b

Section 5 - Attachments5-12 31200149ExampleA contractor owns a model xxxxx telehandler with a fork carriage. He knows thisattachment may be used with

Section 5 - Attachments5-13312001495.6 ATTACHMENT INSTALLATION1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retaining Pin 6.

Table of Contentsiii31200149Section 5 - Attachments5.1 Approved Attachments ...5-15.2 Unapproved

Section 5 - Attachments5-14 31200149Before S/N 0160037722This installation procedure is designed for one-person operation. Prior to exiting cab,perfor

Section 5 - Attachments5-1531200149S/N 0160037722 & AfterThis installation procedure is designed for one-person operation. Prior to exiting cab,pe

Section 5 - Attachments5-16 31200149Hydraulic Operated Attachment1. Install attachment (see page 5-13).2. Lower attachment to ground and perform “Shut

Section 5 - Attachments5-17312001495.7 ADJUSTING/MOVING FORKSCarriages may have different locations where forks can be positioned. Two differentmethod

Section 5 - Attachments5-18 312001495.8 ATTACHMENT OPERATION• Capacities and range limits for the telehandler change depending on theattachment in use

Section 5 - Attachments5-1931200149Carriage with ForksUse Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attac

Section 5 - Attachments5-20 31200149Side Tilt CarriageUse Side Tilt Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attach

Section 5 - Attachments5-2131200149Operation:• Approach load with forks centered on load and stop telehandler.• Level telehandler before side tilting

Section 5 - Attachments5-22 31200149Swing CarriageUse Swing Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/For

Section 5 - Attachments5-2331200149Operation:• To drive with a load, keep forks pointed forward and travel in accordance with therequirements set fort