Jlg G6-42A Operator Manual User Manual

Operation & SafetyManualOriginal InstructionsKeep this manual with machine at all times.An Oshkosh Corporation CompanyModelsG6-42A, G9-43A& G1

Table of Contentsiv 31200744Section 7 - Lubrication and Maintenance7.1 Introduction...

Section 5 - Attachments5-24 31200744Mast CarriageUse Mast Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork

Section 5 - Attachments5-2531200744Operation:• Always lower forks fully in mast before engaging load.• To drive with a load, lower forks fully in mast

Section 5 - Attachments5-26 31200744Mast Carriage w/Side TiltUse Mast Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Atta

Section 5 - Attachments5-2731200744To Raise/Lower Mast:Press Forks Raise/Lower Switch (6) located on dash panel to activate Forks Raise/Lower function

Section 5 - Attachments5-28 31200744Fork ExtensionUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandl

Section 5 - Attachments5-2931200744Installation Procedure:• Ensure carriage is properly installed. Refer to “Attachment Installation” onpage 5-9.• Ens

Section 5 - Attachments5-30 31200744Fork Mounted HookUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Teleha

Section 5 - Attachments5-3131200744Operation:• Pallet or lumber forks of an appropriate load rating must be used. Do not use withcubing or block forks

Section 5 - Attachments5-32 31200744BucketUse Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork Capacity” on p

Section 5 - Attachments5-3331200744Operation:• Raise or lower boom to appropriate height for loading material from stockpile.• Align telehandler with

Section 1 - General Safety Practices1-131200744SECTION 1 - GENERAL SAFETY PRACTICES1.1 HAZARD CLASSIFICATION SYSTEMSafety Alert System and Safety Sign

Section 5 - Attachments5-34 31200744Grapple BucketUse Grapple Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/For

Section 5 - Attachments5-3531200744Operation:• Raise or lower boom to appropriate height and open grapple for loading materialfrom stockpile.• Align t

Section 5 - Attachments5-36 31200744Truss BoomUse Appropriate Truss Boom Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment

Section 5 - Attachments5-3731200744Installation Procedure:• Refer to “Attachment Installation” on page 5-9.Operation:• Weight of rigging must be inclu

Section 5 - Attachments5-38 31200744Personnel Work Platform - Fork MountedUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capac

Section 5 - Attachments5-3931200744Preparation and Setup:1. Ensure the telehandler is on a firm surface and is level.2. Engage the park brake. Blockin

Section 5 - Attachments5-40 31200744This Page Intentionally Left Blank

Section 6 - Emergency Procedures6-131200744SECTION 6 - EMERGENCY PROCEDURES6.1 TOWING A DISABLED PRODUCTThe following information assumes the telehand

Section 6 - Emergency Procedures6-2 312007446.2 EMERGENCY LOWERING OF BOOMIn the event of total loss of engine power or hydraulic pump failure with an

Section 7 - Lubrication and Maintenance7-131200744SECTION 7 - LUBRICATION AND MAINTENANCE7.1 INTRODUCTIONService the product in accordance with the ma

Section 1 - General Safety Practices1-2 312007441.3 OPERATION SAFETYElectrical Hazards• This machine is not insulated and does not provide protection

Section 7 - Lubrication and Maintenance7-2 312007447.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the telehandl

Section 7 - Lubrication and Maintenance7-3312007447.3 SERVICE AND MAINTENANCE SCHEDULE10, 1st 50 & 50 Hour Maintenance ScheduleOAL2650CheckTransmi

Section 7 - Lubrication and Maintenance7-4 312007441st 250, 250 & 1st 500 Hour Maintenance ScheduleOY3430250EVERYChange EngineOil and FilterCheck

Section 7 - Lubrication and Maintenance7-531200744500, 1000 & 1500 Hour Maintenance ScheduleOY34401500EVERYChangeHydraulicFluid & FiltersChang

Section 7 - Lubrication and Maintenance7-6 312007447.4 LUBRICATION SCHEDULES50 Hour Lubrication ScheduleOY255050EVERYB2B2B2B222BB2B2B2G10-43A42222222G

Section 7 - Lubrication and Maintenance7-731200744250 Hour Lubrication ScheduleOY2560EVERY250B22BB2B2B2B2B2B2G10-43AAAAAA2AAA22AA2

Section 7 - Lubrication and Maintenance7-8 312007441000 Hour Lubrication ScheduleOY2570EVERY1000BBG10-43A

Section 7 - Lubrication and Maintenance7-931200744This Page Intentionally Left Blank

Section 7 - Lubrication and Maintenance7-10 312007447.5 OPERATOR MAINTENANCE INSTRUCTIONSFuel SystemA. Fuel Level Check1. Check fuel gauge (1) located

Section 7 - Lubrication and Maintenance7-1131200744B. Fuel/Water Separator Check1. Perform “Shut-Down Procedure” on page 4-4.2. Open the engine cover.

Section 1 - General Safety Practices1-331200744Tip Over HazardGeneral• For additional load requirements, refer to the appropriate capacity chart.• Nev

Section 7 - Lubrication and Maintenance7-12 31200744Air Intake SystemIf Equipped for ULSA. Air Filter Restriction Indicator Check1. Perform “Shut-Down

Section 7 - Lubrication and Maintenance7-1331200744B. Element Change (as restriction indicator indicates)1. Perform “Shut-Down Procedure” on page 4-4.

Section 7 - Lubrication and Maintenance7-14 31200744If Equipped for LSA. Air Filter Restriction Indicator Check1. Perform “Shut-Down Procedure” on pag

Section 7 - Lubrication and Maintenance7-1531200744B. Element Change (as restriction indicator indicates)1. Perform “Shut-Down Procedure” on page 4-4.

Section 7 - Lubrication and Maintenance7-16 31200744Engine OilA. Engine Oil Level Check1. Perform “Shut-Down Procedure” on page 4-4.2. Open the engine

Section 7 - Lubrication and Maintenance7-1731200744Hydraulic OilA. Hydraulic Oil Level Check1. Be sure all cylinders are fully retracted and machine i

Section 7 - Lubrication and Maintenance7-18 31200744TiresA. Tire Air Pressure Check1. Perform “Shut-Down Procedure” on page 4-4.2. Remove valve stem c

Section 7 - Lubrication and Maintenance7-1931200744C. Tire and Wheel ReplacementIt is recommended that a replacement tire to be the same size, ply and

Section 7 - Lubrication and Maintenance7-20 31200744E. Wheel InstallationTorque lug nuts after first 50 hours and after each wheel installation.Note:

Section 7 - Lubrication and Maintenance7-2131200744Transmission OilA. Transmission Oil Level Check1. Check transmission oil level with engine at idle

Section 1 - General Safety Practices1-4 31200744• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, this machine

Section 7 - Lubrication and Maintenance7-22 31200744Engine Cooling SystemA. Engine Coolant Level Check1. Perform “Shut-Down Procedure” on page 4-4.2.

Section 7 - Lubrication and Maintenance7-2331200744BatteryA. Battery Check1. Perform “Shut-Down Procedure” on page 4-4.2. Open the engine cover.3. Wea

Section 7 - Lubrication and Maintenance7-24 31200744Windshield Washer System (if equipped)A. Windshield Washer Fluid Level Check1. Perform “Shut-Down

Section 8 - Additional Checks8-131200744SECTION 8 - ADDITIONAL CHECKS8.1 GENERALIf any of the following test results cannot be achieved, the system is

Section 8 - Additional Checks8-2 312007444. Verify operation with no objects in detection zone. No audible alarm.5. Verify operation when object is in

Section 9 - Specifications9-131200744SECTION 9 - SPECIFICATIONS9.1 PRODUCT SPECIFICATIONSFluidsIf Equipped for ULSCompartment or SystemType and Classi

Section 9 - Specifications9-2 31200744Note: Friction Modifier may be added to front axle differential.Fuel#2 DieselUltra Low Sulfur(S ≤ 15 mg/kg)Stan

Section 9 - Specifications9-331200744If Equipped for LSNote: Friction Modifier may be added to front axle differential.Compartment or SystemType and

Section 9 - Specifications9-4 31200744CapacitiesEngine Crankcase OilCapacity with Filter Change...

Section 9 - Specifications9-531200744TiresG6-42A13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 PlyPneumatic...

Section 1 - General Safety Practices1-531200744Non-Suspended Load• DO NOT drive with boom raised.Suspended Load• Tether suspended loads to restrict mo

Section 9 - Specifications9-6 31200744PerformanceNote: Values shown are per machine as originally manufactured. Reference capacity charts in operator

Section 9 - Specifications9-731200744DimensionsOverall HeightG6-42A ...

Section 9 - Specifications9-8 31200744Maximum Ground Bearing PressureG6-42A13.00 x 24Air Filled ...

Index131200744AAccessory Control Lever ... 3-18Additional Checks... 8-1Adjusting/Moving Forks ...

Index2 31200744HHazard Classification System... 1-1Headlights... 3-18Heater Controls ...

Index331200744TTip Over Hazard... 1-3Tires ... 7-18, 9-5Air Pressure ...

Index4 31200744

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

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

Section 1 - General Safety Practices1-6 31200744Travel Hazard• Steering characteristics differ between steer modes. Identify the steer modesettings of

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 Practices1-731200744Load Falling Hazard• Never suspend load from forks or other parts of carriage weldment. Use onlyJLG app

Section 1 - General Safety Practices1-8 31200744Lifting Personnel• When lifting personnel, USE ONLY an approved personnel work platform, withproper ca

Section 1 - General Safety Practices1-931200744Driving 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 31200744Pinch Points and Crush HazardsStay clear of pinch points and rotating parts on the telehandler.• Stay

Section 1 - General Safety Practices1-1131200744• Keep clear of boom holes.• Keep arms and hands clear of attachment tilt cylinder.• Keep hands and fi

Section 1 - General Safety Practices1-12 31200744Fall Hazard• Enter using the proper hand holds and steps provided. Always maintain 3-pointcontact whe

Section 1 - General Safety Practices1-1331200744Chemical HazardsExhaust Fumes• DO NOT operate machine in an enclosed area without proper ventilation.•

Section 1 - General Safety Practices1-14 312007441.4 CLEARSKY (IF EQUIPPED)Federal Communications Commission (FCC) Information for UsersFCC Statement

Section 1 - General Safety Practices1-1531200744Antenna InstallationA minimum separation distance of eight inches (20 centimeters) must be maintainedb

Section 1 - General Safety Practices1-16 31200744This Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection2-131200744SECTION 2 - PRE-OPERATION AND INSPECTION2.1 PRE-OPERATION CHECK AND INSPECTIONNote: Complete all r

Section 2 - Pre-Operation and Inspection2-2 312007448. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operatio

Section 2 - Pre-Operation and Inspection2-3312007442.2 SAFETY DECALSEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity

Revision Loga31200744Revision LogREVISION LOGSeptember 28, 2012 - A - Original Issue of ManualNovember 16, 2012 - B - Revised pages 3-6, 9-6 & 9-7

Section 2 - Pre-Operation and Inspection2-4 312007441706296-ENGLISH1001163174-ENGLISH/FRENCH41001814100181915632209156-3220 REVA1706301A1706301-ENGLIS

Section 2 - Pre-Operation and Inspection2-531200744OY2111-10°0°10°20°30°40°50°60°70°80°1706302-ENGLISH1001163223-ENGLISH/FRENCH-1001020304050607080410

Section 2 - Pre-Operation and Inspection2-6 31200744ISOOY315117062881706284100109287717023001702300170230017023001702300170230091503112(G9-43A IFEQUIP

Section 2 - Pre-Operation and Inspection2-731200744170628141001814100181915632209156-3220 REVA17062851001139942(UNDERSIDE OFENGINE COVER)1001139069100

Section 2 - Pre-Operation and Inspection2-8 31200744OY21401706282170629217062921706292915530721706292-10°0°10°20°30°40°50°60°70°80°-100102030405060708

Section 2 - Pre-Operation and Inspection2-931200744This Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection2-10 312007442.3 WALK-AROUND INSPECTIONBegin your walk-around inspection at item 1, as noted below. Continue t

Section 2 - Pre-Operation and Inspection2-11312007445. Mirror - Clean and undamaged.6. Cab and Electrical - • General appearance; no visible damage. •

Section 2 - Pre-Operation and Inspection2-12 312007442.4 WARM-UP AND OPERATIONAL CHECKSWarm-Up CheckDuring warm-up period, check:1. Heater, defroster

Section 2 - Pre-Operation and Inspection2-13312007442.5 OPERATOR CABThe telehandler is equipped with an open or enclosed ROPS/FOPS cab.WARNINGNever op

Read This Firstb 31200744Read 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 Inspection2-14 312007442.6 WINDOWSKeep all windows and mirrors clean and unobstructed.Cab Door Window (if equipped)• Cab

Section 3 - Controls and Indicators3-131200744SECTION 3 - CONTROLS AND INDICATORS3.1 GENERALThis section provides the necessary information needed to

Section 3 - Controls and Indicators3-2 312007443.2 CONTROLSG6-42A & G9-43AOY31708591423671112131410

Section 3 - Controls and Indicators3-3312007441. Transmission Control Lever: See page 3-10.2. Instrument Panel: See page 3-6.3. Steering Wheel: Turnin

Section 3 - Controls and Indicators3-4 31200744G10-43AOY31808591423671112131410

Section 3 - Controls and Indicators3-5312007441. Transmission Control Lever: See page 3-10.2. Instrument Panel: See page 3-6.3. Steering Wheel: Turnin

Section 3 - Controls and Indicators3-6 31200744Dash Controls and Indicators1. Transmission Temperature Indicator: Illuminates red when transmission te

Section 3 - Controls and Indicators3-731200744Ignition• In "ACC" or "RUN" position, voltage is available for all electrical functi

Section 3 - Controls and Indicators3-8 31200744Park BrakePark brake switch controls the application and release of the park brake. Indicatorlight on s

Section 3 - Controls and Indicators3-931200744This Page Intentionally Left Blank

Read This Firstc31200744This product must comply with all safety related bulletins. Contact JLG Industries,Inc. or the local authorized JLG representa

Section 3 - Controls and Indicators3-10 31200744Transmission Control LeverDirection of Travel SelectionTransmission control lever (1) engages forward

Section 3 - Controls and Indicators3-1131200744Gear SelectionGear selection is located on the twist grip handle (2) of transmission control lever.• Tw

Section 3 - Controls and Indicators3-12 31200744Boom JoystickG6-42A, G9-43A If EquippedThe boom joystick (1) controls the boom and attachment tilt (if

Section 3 - Controls and Indicators3-1331200744G9-43A If Equipped, G10-43AThe boom joystick (1) controls the boom, attachment tilt and clutch lock fun

Section 3 - Controls and Indicators3-14 31200744Frame Level and Attachment Tilt (if equipped) JoystickThe middle joystick (1) controls the left to rig

Section 3 - Controls and Indicators3-1531200744Auxiliary Hydraulic JoystickThe auxiliary hydraulic joystick (1) controls function of attachments that

Section 3 - Controls and Indicators3-16 31200744Outrigger Joysticks (G10-43A)The rear joysticks (1) control the outriggers.• The left joystick control

Section 3 - Controls and Indicators3-1731200744Right Hand PanelHeater and Air Conditioning Controls (if equipped)1. Air Vent: Two individually adjusta

Section 3 - Controls and Indicators3-18 31200744Accessory Control Lever (if equipped)The accessory control lever (1) operates the turn signals, parkin

Section 3 - Controls and Indicators3-19312007443.3 STEER MODESThree steer modes are available for operator use.Note: 2-Wheel Front Steer mode is requ

Read This Firstd 31200744Other Publications AvailableService Manual...

Section 3 - Controls and Indicators3-20 312007443.4 OPERATOR SEATAdjustmentsPrior to starting engine adjust seat for position and comfort.1. Suspensio

Section 3 - Controls and Indicators3-2131200744Seat BeltFasten seat belt as follows:1. Grasp both free ends of the belt making certain that belt webbi

Section 3 - Controls and Indicators3-22 312007443.5 REVERSE SENSOR SYSTEM (IF EQUIPPED)Reverse Sensor System provides audible indication of objects to

Section 3 - Controls and Indicators3-23312007443.6 BOOM ANGLE AND EXTENSION INDICATORS• The boom angle indicator (1) is located on the left side of th

Section 3 - Controls and Indicators3-24 31200744This Page Intentionally Left Blank

Section 4 - Operation4-131200744SECTION 4 - OPERATION4.1 ENGINEStarting the EngineThis machine can be operated under normal conditions in temperatures

Section 4 - Operation4-2 31200744Extreme Cold Weather Starting (if equipped)If equipped with extreme cold weather components, machine can be operated

Section 4 - Operation4-331200744Battery Boosted StartingIf battery-boost starting (jump-start) is necessary, proceed as follows:• Never allow vehicles

Section 4 - Operation4-4 31200744Normal Engine Operation• Observe instrument panel frequently to be sure all systems are functioning properly.• Be ale

Section 4 - Operation4-5312007444.2 OPERATING WITH A NON-SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you li

Table of Contentsi31200744TABLE OF CONTENTSRevision LogRead This FirstOperator Qualifications ... b

Section 4 - Operation4-6 31200744Transporting a LoadAfter engaging the load and resting it against the backrest, tilt the load back toposition it for

Section 4 - Operation4-731200744Placing a LoadBefore placing any load be sure that:• The landing point can safely support the weight of the load.• The

Section 4 - Operation4-8 312007444.3 OPERATING WITH A SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you lift.

Section 4 - Operation4-931200744Transporting a Suspended Load• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Pract

Section 4 - Operation4-10 31200744Placing a Suspended LoadBefore placing any load be sure that:• The landing point can safely support the weight of th

Section 4 - Operation4-11312007444.4 LOADING AND SECURING FOR TRANSPORTTiedown1. Level the telehandler prior to loading.2. Using a spotter, load the t

Section 4 - Operation4-12 31200744Lifting• When lifting machine, it is very important that the lifting device and equipment isattached only to designa

Section 5 - Attachments5-131200744SECTION 5 - ATTACHMENTS5.1 APPROVED ATTACHMENTSTo determine if an attachment is approved for use on the specific tel

Section 5 - Attachments5-2 312007445.3 JLG SUPPLIED ATTACHMENTSAttachment Part NumberApplicable ModelG6-42A G9-43A G10-43ACarriage, 50 in (1270 mm)117

Section 5 - Attachments5-331200744This Page Intentionally Left Blank

Table of Contentsii 31200744G10-43A ... 3-4Dash Controls and Indicators ...

Section 5 - Attachments5-4 312007445.4 TELEHANDLER/ATTACHMENT/FORK CAPACITYPrior to installing the attachment verify it is approved and the telehandle

Section 5 - Attachments5-5312007445.5 USE OF THE CAPACITY CHARTTo properly use the capacity chart (see page 5-6), the operator must first determineand

Section 5 - Attachments5-6 31200744Sample Capacity ChartNote: This is a sample capacity chart only! DO NOT use this chart, use the one located in you

Section 5 - Attachments5-731200744To identify the proper capacity chart on telehandlers equipped with outriggers, referto the following icons which ma

Section 5 - Attachments5-8 31200744ExampleA contractor owns a model xxxxx telehandler with a fork carriage. He knows thisattachment may be used with h

Section 5 - Attachments5-9312007445.6 ATTACHMENT INSTALLATION1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retaining Pin (me

Section 5 - Attachments5-10 31200744Mechanical Quick SwitchThis installation procedure is designed for one-person operation. Prior to exiting cab,perf

Section 5 - Attachments5-1131200744Hydraulic Quick SwitchThis installation procedure is designed for one-person operation.1. Tilt quick switch back to

Section 5 - Attachments5-12 312007445. Raise boom to eye level and visually check that the lock pins protrude through the holes on both sides of the q

Section 5 - Attachments5-13312007445.8 ADJUSTING/MOVING FORKSCarriages may have different locations where forks can be positioned. Two differentmethod

Table of Contentsiii31200744Section 5 - Attachments5.1 Approved Attachments ...5-15.2 Unapproved

Section 5 - Attachments5-14 312007445.9 ATTACHMENT OPERATION• Capacities and range limits for the telehandler change depending on theattachment in use

Section 5 - Attachments5-1531200744Carriage with ForksUse Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attac

Section 5 - Attachments5-16 31200744Side Shift CarriageUse Side Shift Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Atta

Section 5 - Attachments5-1731200744Equipment Damage Precautions:• Do not use forks as a lever to pry material. Excessive prying forces coulddamage for

Section 5 - Attachments5-18 31200744Side Tilt CarriageUse Rotate/Side Tilt Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler

Section 5 - Attachments5-1931200744Equipment Damage Precautions:• Do not use forks as a lever to pry material. Excessive prying forces coulddamage for

Section 5 - Attachments5-20 31200744Swing CarriageUse Swing Carriage Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/For

Section 5 - Attachments5-2131200744Operation:• To drive with a load, keep forks pointed forward and travel in accordance with therequirements set fort

Section 5 - Attachments5-22 31200744Dual Fork Positioning CarriageUse Dual Fork Positioning Carriage Capacity ChartTo determine maximum capacity, refe

Section 5 - Attachments5-2331200744Operation:• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Practices.Equipment D