JLG G6-42A Guida

31200680

1.1 GENERAL GUIDELINES

•This repair procedure provides repair information for

a specific discrepancy. It is the responsibility of the

entity performing the repairs to determine if the

discrepancy can be corrected by this procedure. This

repair is only for the replacement of the rear axle

weldment.

•After inspection, if only weld cracks and NO plate

deflection is found, refer to instructions 31212011.

•After inspection, if weld cracks AND plate deflection

is found, complete the Rear Axle Block Weldment

Replacement Instructions.

1.2 WELD REPAIR GUIDELINES

•All welding must be in accordance with ANSI/AWS

D1.1 Standard.

•Disconnect the battery of the machine being repaired

prior to welding.

•Ground only to the component being welded. Do not

ground to any adjacent component or allow pins,

wear pads, wire ropes, bearings, gears, seals,

valves, electrical wiring, or hoses to be between the

grounding position and the area to be welded.

1.3 TOOLS & EQUIPMENT REQUIRED

1. Stands and lifting equipment capable of lifting/

supporting the affected components

2. Hand-held power grinder

3. Air carbon-arc equipment

4. Electric welding equipment

5. AWS 70 grade, low hydrogen rod or wire

6. Standard welder tools

7. Standard mechanic tools

8. Paint

1.4 PERSONNEL REQUIRED

1. Qualified JLG Equipment Mechanic

2. Certified Welder

1.5 PARTS LIST

1.6 REAR AXLE BLOCK WELDMENT

REPLACEMENT

1. Remove any attachment from the machine.

2. Park the machine on a firm, level surface with the

machine level, retract and level the boom. Place the

transmission control lever in the (N)

NEUTRAL position and engage the

parking brake. Shut the engine OFF.

3. Place a Do Not Operate Tag on both the

ignition key switch and the steering

wheel, stating that the machine should

not be operated.

4. Open the engine cover. Allow system

fluids to cool.

5. Properly disconnect the battery.

6. Properly support the frame to alleviate

pressure or stress at the affected repair

area.

7. Remove components as required to

facilitate repair. Refer to the machine

Service Manual for proper disassembly

procedures.

NOTICE

Reference the Service Manual for safe and proper

disassembly/assembly procedures.

NOTICE

Failure to comply with the above weld repair guidelines

may result in component damage.

P/N Qty Description

91476013 1 Rear Axle Weldment Block

G6-42A

Rear Axle Block Weldment

Replacement Instructions

For Kit 1001126991

7/14

31200680

An Oshkosh Corporation Company

2 31200680

G6-42A Rear Axle Block Weldment Replacement Instructions For Kit 1001126991

8. Protect any hoses, wires and hydraulic cylinder rods

before preparing or welding in the axle mount area.

9. Use air carbon-arc equipment or a portable power

grinder to remove the damaged rear axle mount

weldments (4) from the frame weldment.

10. Inspect the affected areas for cracks. If any

discrepancies are evident, notify a certified welder for

further evaluation.

11. Prepare the repair area (5) for the installation of the

new rear axle weldment.

12. Locate the Axle Weldment (6) P/N 91476013 using

1.6.1 “Rear Axle Weldment Welding Locations” on

page 3. Tack weld into position.

13. Weld the rear axle weldment into place using the

recommended weld material.

14. Inspect welds using the magnetic particle or dye-

penetrant inspection methods to assure there are no

cracks or deformities. If any cracks or deformities

exist, grind to remove affected area(s) and repeat the

weld and inspection procedures.

15. Remove the weld bars (7) from the rear axle

weldment.

16. Clean, prime and paint the affected areas.

17. Install previously removed components. Refer to the

machine Service Manual for proper assembly

procedures.

18. Remove all protective coverings from any hoses,

wires and hydraulic cylinder rods.

19. Properly connect the battery.

20. Close and secure the engine cover.

21. Cycle the drive, steer and frame level functions a

minimum of five times.

22. Verify proper clearance between the frame, rear axle,

hydraulic hoses and electrical wires.

23. Install the previously removed attachment.

24. Remove the Do Not Operate Tag from the ignition

key switch and the steering wheel.

25. Return machine to service.

NOTICE

Do not damage the parent metal during this procedure.

MY5230

MY5250

NOTICE

Do not damage the rear axle weldment during this

procedure.

MY4420

31200680

G6-42A Rear Axle Block Weldment Replacement Instructions For Kit 1001126991

1.6.1 Rear Axle Weldment Welding Locations

A. 1.0 in (25,4 mm)

5/16

WELD ALL AROUND EXCEPT AGAINST REAR PLATE

3/8

MY5260

4 31200680

G6-42A Rear Axle Block Weldment Replacement Instructions For Kit 1001126991

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