JLG G6-42P Telehandler Service Manual (ANSI)

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This service manual PDF download for the G6-42P JLG Telescopic Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


JLG G6-42P
Starting Serial No. 0189001 thru 0189345
& 0160000230 thru Current




File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 9140-4002
Total Pages : 508

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9140-4002 G6-42P SERVICE MANUAL

Revision Log
Read This First
Table of Contents

Section 1 – General Safety Practices
1.1 Hazard Classification system
Safety Alert System and Safety Signal Words
1.2 General Precautions
1.3 Operation Safety
Electrical Hazards
Tip Over Hazard
Travel Hazard
Load Falling Hazard
Lifting Personnel
Driving Hazards on Slopes
Pinch Points and Crush Hazards
Fall Hazard
Chemical Hazards

Section 2 – Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection
2.2 Safety Decals
2.3 Walk-Around Inspection
2.4 Warm-Up and Operational Checks
Warm-Up Check
Operational Check
2.5 Operator Cab
2.6 Windows
Cab Door Window (if equipped)

Section 3 – Controls and Indicators
3.1 General
3.2 Controls
Transmission Control Lever
Ignition Switch
Boom Joystick
Attachment Tilt and Frame Sway Lever
Auxiliary Control Joystick (if equipped)
Dash Controls and Indicators
Park Brake Switch
Parking Procedure
3.3 Operator Seat
Seat Adjustments
Seat Belt
3.4 Boom Angle and Extension Indicators
3.5 Mirror

Section 4 – Operation
4.1 Engine
Starting the Engine
Cold Weather Starting Aids
Battery Boosted Starting
Normal Engine Operation
Shut-Down Procedure
4.2 Operating with a Load
Lift Load Safely
Picking Up a Load
Transporting the Load
Leveling Procedure
Placing the Load
Disengaging the Load
4.3 Operating with a Suspended Load
Lift Load Safely
Picking Up a Suspended Load
Transporting a Suspended Load
Leveling Procedure
Placing a Suspended Load
Disengaging a Suspended Load
4.4 Loading and Securing for Transport

Section 5 – Attachments
5.1 Approved Attachments
5.2 Unapproved Attachments
5.3 Telehandler/Attachment/Fork Capacity
5.4 Use of the Capacity Chart
Capacity Indicator Locations
Sample Capacity Chart
5.5 Attachment Installation
5.6 Adjusting/Moving Forks
5.7 Attachment Operation
Carriage w/Forks
Crane Hook
Truss Boom
Boom Head-Mounted Winch
6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m) Carriage
6 ft (1,8 m) – 100˚ Swing Mast W/Side Shift
Swing Carriage
Side Tilt Carriage
Personnel Work Platform

Section 6 – Emergency Procedures
6.1 Towing a Disabled Product
Moving Short Distances
Moving Longer Distances
6.2 Emergency Lower of Boom
6.3 Emergency Exit from Enclosed Cab

Section 7 – Lubrication and Maintenance
7.1 Introduction
Clothing and Safety Gear
7.2 General Maintenance Instructions
7.3 Service and Maintenance Schedules
10 & 1st 50 Hour Maintenance Schedule
50, 250 & 500 Hour Maintenance Schedule
1000 & 1500 Hour Maintenance Schedule
7.4 Lubrication Schedules
50 Hour Lubrication Schedule
250 Hour Lubrication Schedule
7.5 Operator Maintenance Instructions
Fuel System
Air Intake System
Engine Oil
Hydraulic Oil
Hydraulic Return Filter
Engine Cooling System

Section 8 – Additional Checks

Section 9 – Specifications
9.1 Product Specifications
Fluid and Lubrication Capacities
Inspection, Maintenance and Repair Log

20004 Liquid Coolant Test Manual
Engine Coolant Specifications
Testing Diesel Engine Coolant
Replenishing Supplemental Coolant Additives Between Coolant Changes
Operating in Warm Temperature Climates
Flush & Service Cooling System
Disposing of Coolant

Machine Start-Up Procedure
Hydraulic Schematic
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FMM9D Meritor PRA 352 Series Planetary Axles
Service Notes
Illustrations with parts list of Model:
PRA 352 – Trumpet Variation No. 1
PRA 352 – Trumpet Variation No. 2
PRA 353-383
PROA 352-382 (with Mechanical Drive Option
PROA 352/382
Section 1 Introduction
Section 2 Removal & Disassembly
Section 3 Prepare Parts for Assembly
Section 4 Assembly & Installation
Section 5 Adjustments
Section 6 Specifications
CA357248 Carraro 28.46M Axles
A.1 Utilizzo del manuale
A.2 Proprietà delle informazioni
A.3 Convenzioni e definizioni
A.4 Indicazioni generali
A.5 Indicazioni generali per le operazioni di riparazione
A General information
A.1 Manual use
A.2 Information property
A.3 Agreements and definitions
A.4 General description
A.5 Recommendations for repair operations
B.1 Indicazioni generali per la sicurezza
B.2 Simboli di sicurezza
B.3 Precauzioni generali
B Safety instructions
B.1 General safety recommendations
B.2 Safety symbols
B.3 General precautions
C.1 Usi previsti
C.2 Identificazione del prodotto
C.3 Descrizione generale
C.4 Caratteristiche Tecniche
C.5 Cambio olio e verifiche
C.6 Coppie di serraggio
C General specifications
C.1 Foreseen uses
C.2 Product identification
C.3 General description
C.4 Technical Features
C.5 Oil change and checks
C.6 Tightening torques
D.1 Gruppo flangia
D.2 Gruppo riduttore epicicloidale
D.3 Gruppo mozzo ruota
D.4 Gruppo trombe trave
D.5 Freno e supporto differenziale
D.6 Gruppo differenziale
D.7 Gruppo pignone
D.8 Sbloccaggio freno parcheggio
D.9 Riattivazione freno parcheggio
D.10 Prove dopo montaggio
D Disassembly and assembly operations
D.1 Flange group
D.2 Epicyclic reduction gear group
D.3 Wheel hub group
D.4 Axle beam trumpets group
D.5 Brake and differential support
D.6 Differential group
D.7 Pinion group
D.8 Parking brakes release
D.9 Re-activating parking brakes
D.10 Testing after assembly
E.1 Controllo ed esame dei guasti
E.2 Diagnosi per problemi all’assale
E Troubleshooting
E.1 Troubleshooting
E.2 Axle problems and diagnosis
F.1 Attrezzature speciali
F Special tools
F.1 Special tools

RA 92003-S Rexroth Application & Service
Name Tag Information
Type Code
Technical Data
Filtration Options
High Pressure Relief Valve
Pump Controls
Pump Installation
Start-Up Procedure
Troubleshooting Procedure
Charge Pressure Relief Adjustments
Mechanical Centering of Pump
Hydraulic Centering of Control Modules
Adjustments of Pressure Override Valve
Adjustments of High Pressure Relief Valves
Tow Option Engagement
Removal & Inspection of Charge Pump
Removal & Installation of Shaft Seal
Filter Replacement
Routine Maintenance
Replacement Subassemblies & Parts
Filter Configuration

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Electrical Schematic
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System Schematic
Representative Performance Data
Description & Operation of Power Brake Valve
External Dimensional Views
Installation of Power Brake Valve
Cross Sectional Views of Three Power Brake Valve Designs
Specification Chart
Primary Cup Design
Teflon Seal Design
Sliding Piston Design
Service Diagnosis


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JLG G6-42P Telehandler Service Manual (ANSI).pdf

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