JLG G6-42A Parts Manual

31200727

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

3

Machine Configuration

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387 A

1

OY2700

REAR VIEW OF CAB

Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1).

If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra Low Sulfur (ULS) from this point forward.

If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Low Sulfur (LS) from this point forward.

1

General Information

1.MACHINE IDENTIFICATION

Machines are identified by model & in some cases a combination of model, serial number (S/N) or regional standard (CE, AUS, ANSI). Components may also be identified by S/N or manufacturer. Common components that may be identified by these characteristics are attachments, engine, transmission & hydraulic components.

2.PARTS MANUAL ORGANIZATION

Product information in this manual is organized under section titles. Frame & Attaching Parts, Drive Train & Electrical are a few examples. Each section is organized by Figure & page number. The information within the Figure is then organized by item number, part number, description & corresponding illustration(s).

3.TABLE OF CONTENTS

A table of contents (TOC) is found toward the beginning of the manual. Figure number, description & page number are provided for quick reference to the page containing the related information.

4.RECOMMENDED SPARE PARTS

The Recommended Spare Parts, located near the end of the manual, references most frequently used maintenance parts.

5.PART NUMBER INDEX

A numerical index listing all part numbers & the corresponding page number(s) appears at the back of the manual.

6.NON-SERVICED PARTS

In some instances it is necessary to display non-serviced parts, assemblies or installations. In the case of assemblies & installations there will be a Ref in the Qty column & a note after the item description stating what is available for service within. In the case of parts that are not available for service within assemblies or components there will be a NSS (Not Sold Separately) listed in the part number column of the manual.

7.PARTS LIST ITEM NUMBERS

Numbers shown in the Item column correspond to numbers used in the associated illustration(s). Item numbers which are missing from sequence & are not shown in the illustration(s) are not used on that page.

8.INDENTED PART DESCRIPTION

An indented part description is included in the item under which it is indented.

9.ABBREVIATIONS & SYMBOLS

AC ....................................................................	Air Conditioning	LB ....................................................................................	Pound
ANSI .............................	American National Standards Institute	LH..............................................................................	Left Hand
AR..........................................................................	As Required	LS .............................................................................	Low Sulfur
ASME....................	American Society of Mechanical Engineers	MAX...........................................................................	Maximum
ASSY .........................................................................	Assembly	MM .............................................................................	Millimeter
AUS..............................................................................	Australia	N....................................................................................	Newton
AUX..............................................................................	Auxiliary	NA ......................................................................	Not Applicable
CE............................................................	European Conformity	NLA ...........................................................	No Longer Available
DIA..............................................................................	Diameter	NSS ...........................................................	Not Sold Separately
EURO.........................................................................	European	OD .................................................................	Outside Diameter
FT ......................................................................................	Foot	OZ ..................................................................................	Ounce
GA...................................................................................	Gauge	P/N ........................................................................	Part Number
GR ...................................................................................	Grade	QTY ..............................................................................	Quantity
HD.....................................................................................	Head	REF ...........................................................................	Reference
HYD ............................................................................	Hydraulic	REQ............................................................................	Required
ID .....................................................................	Inside Diameter	RH ...........................................................................	Right Hand
IN ........................................................................................	Inch	S/N .....................................................................	Serial Number
ISO.............................	International Organization for Standards	SAE .......................................	Society of Automotive Engineers
ITSDF .....	Industrial Truck Standards Development Foundation	STD ............................................................................	Standard
KG...............................................................................	Kilogram	ULS ..................................................................	Ultra Low Sulfur
kW.................................................................................	Kilowatt	V ..........................................................................................	Volt

10.ILLUSTRATION REFERENCE LETTERS

When necessary, illustrations may contain reference letters that are intended to track information from one point to another in the illustration such as harnesses & hoses or any other information that has been separated in the illustration.

Note: Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

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This Page Intentionally Left Blank

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	TABLE OF CONTENTS
SECTION 1 - FRAME AND ATTACHING PARTS................................................................................................................................		9
FIGURE 1-1. FRAME AND ATTACHING PARTS ..........................................................................................................................		10
FIGURE 1-2. COVERS G6-42A......................................................................................................................................................		12
FIGURE 1-3. COVERS G9-43A AND G10-43A..............................................................................................................................		16
FIGURE 1-4. OUTRIGGER INSTALLATION ..................................................................................................................................		20
FIGURE 1-5. PINTLE HOOK ..........................................................................................................................................................		22
SECTION 2 - BOOM ..........................................................................................................................................................................		25
FIGURE 2-1. BOOM INSTALLATION G9-43A & G10-43A.............................................................................................................		26
FIGURE 2-2. FIRST BOOM SECTION G6-42A .............................................................................................................................		28
FIGURE 2-3. FIRST BOOM SECTION G9-43A & G10-43A...........................................................................................................		30
FIGURE 2-4. SECOND BOOM SECTION G6-42A.........................................................................................................................		32
FIGURE 2-5. SECOND BOOM SECTION G9-43A & G10-43A......................................................................................................		36
FIGURE 2-6. THIRD BOOM SECTION G6-42A .............................................................................................................................		38
FIGURE 2-7. THIRD BOOM SECTION G9-43A & G10-43A ..........................................................................................................		40
FIGURE 2-8. PUSH BEAM/EXTEND CHAIN .................................................................................................................................		42
FIGURE 2-9. RETRACT CHAINS...................................................................................................................................................		46
FIGURE 2-10. MANUAL QUICK SWITCH......................................................................................................................................		48
FIGURE 2-11. HYDRAULIC QUICK ATTACH................................................................................................................................		50
SECTION 3 - ATTACHMENTS ..........................................................................................................................................................		53
FIGURE 3-1. TILT CARRIAGE (G6-42A Prior to SN 0160052010; G9-43A Prior to SN 0160051085; G10-43A Prior to SN
0160052011) ..................................................................................................................................................................................		54
FIGURE 3-2. TILT CARRIAGE (G6-42A SN 0160052010 to Present; G9-43A SN 0160051085 to Present; G10-43A SN
0160052011 to Present) .................................................................................................................................................................		56
FIGURE 3-3. SIDE TILT CARRIAGE..............................................................................................................................................		58
FIGURE 3-4. 50IN SIDE SHIFT CARRIAGE ..................................................................................................................................		60
FIGURE 3-5. 50IN DUAL FORK CARRIAGE .................................................................................................................................		62
FIGURE 3-6. 90, SWING CARRIAGE ............................................................................................................................................		64
FIGURE 3-7. SHEET MATERIAL HANDLER .................................................................................................................................		66
FIGURE 3-8. FORKS......................................................................................................................................................................		68
FIGURE 3-9. FORK MOUNTED PLATFORM.................................................................................................................................		70
FIGURE 3-10. LIFTING HOOK.......................................................................................................................................................		72
FIGURE 3-11. FORK PIN LOCK INSTALLATION ..........................................................................................................................		74
FIGURE 3-12. BUCKETS ...............................................................................................................................................................		76
FIGURE 3-13. GRAPPLE BUCKET................................................................................................................................................		78
FIGURE 3-14. TRUSS BOOM ........................................................................................................................................................		80
FIGURE 3-15. 12FT TRUSS BOOM WITH WINCH	.......................................................................................................................	82
FIGURE 3-16. 8FT STANDARD MAST ..........................................................................................................................................		84
FIGURE 3-17. 8FT SIDE TILT ELECTRIC MAST ..........................................................................................................................		88
SECTION 4 - ENGINE AND ATTACHING PARTS ............................................................................................................................		93
FIGURE 4-1. ENGINE INSTALLATION IF EQUIPPED FOR ULS..................................................................................................		94
FIGURE 4-2. ENGINE INSTALLATION IF EQUIPPED FOR LS ....................................................................................................		96
FIGURE 4-3. ENGINE IF EQUIPPED FOR ULS ............................................................................................................................		98
FIGURE 4-4. ENGINE IF EQUIPPED FOR LS.............................................................................................................................		100
FIGURE 4-5. FUEL TANK AND LINES IF EQUIPPED FOR ULS ................................................................................................		102
FIGURE 4-6. FUEL TANK AND LINES IF EQUIPPED FOR LS ...................................................................................................		104
FIGURE 4-7. RADIATOR AND COOLING INSTALLATION IF EQUPPED FOR ULS ..................................................................		106
FIGURE 4-8. RADIATOR AND COOLING INSTALLATION IF EQUIPPED FOR LS....................................................................		110
FIGURE 4-9. AIR CLEANER INSTALLATION IF EQUIPPED FOR ULS......................................................................................		114
FIGURE 4-10. AIR CLEANER INSTALLATION IF EQUIPPED FOR LS ......................................................................................		116
FIGURE 4-11. EXHAUST INSTALLATION IF EQUIPPED FOR ULS...........................................................................................		118
FIGURE 4-12. EXHAUST INSTALLATION IF EQUIPPED FOR LS .............................................................................................		120
SECTION 5 - DRIVE TRAIN ............................................................................................................................................................		123
FIGURE 5-1. DRIVE TRAIN COMPONENTS G6-42A .................................................................................................................		124
FIGURE 5-2. DRIVE TRAIN COMPONENTS G9-43A & G10-43A...............................................................................................		126
FIGURE 5-3. FRONT AXLE .........................................................................................................................................................		128
FIGURE 5-4. CENTRAL HOUSING AND STEERING G6-42A ....................................................................................................		130
FIGURE 5-5. CENTRAL HOUSING AND STEERING G9-43A & G10-43A..................................................................................		132
31200727	G10-43A,G9-43A,G6-42A	5

TABLE OF CONTENTS
	FIGURE 5-6. DIFFERENTIAL G6-42A..........................................................................................................................................	134
	FIGURE 5-7. DIFFERENTIAL G9-43A & G10-43A .......................................................................................................................	136
	FIGURE 5-8. HUB REDUCTION G6-42A .....................................................................................................................................	138
	FIGURE 5-9. HUB REDUCTION G9-43A & G10-43A...................................................................................................................	142
	FIGURE 5-10. BRAKES G6-42A...................................................................................................................................................	146
	FIGURE 5-11. BRAKES G9-43A & G10-43A ................................................................................................................................	148
	FIGURE 5-12. REAR AXLE ..........................................................................................................................................................	150
	FIGURE 5-13. CENTRAL HOUSING AND STEERING G6-42A ...................................................................................................	152
	FIGURE 5-14. CENTRAL HOUSING AND STEERING G9-43A & G10-43A ................................................................................	154
	FIGURE 5-15. DIFFERENTIAL G6-42A........................................................................................................................................	156
	FIGURE 5-16. DIFFERENTIAL G9-43A & G10-43A .....................................................................................................................	158
	FIGURE 5-17. HUB REDUCTION G6-42A ...................................................................................................................................	160
	FIGURE 5-18. HUB REDUCTION G9-43A & G10-43A.................................................................................................................	164
	FIGURE 5-19. BRAKES G6-42A...................................................................................................................................................	168
	FIGURE 5-20. BRAKES G9-43A & G10-43A ................................................................................................................................	170
	FIGURE 5-21. ZF TRANSMISSION ..............................................................................................................................................	172
	FIGURE 5-22. ZF TRANSMISSION - CONVERTER AND INPUT ................................................................................................	174
	FIGURE 5-23. ZF TRANSMISSION - GEARBOX HOUSING .......................................................................................................	176
	FIGURE 5-24. ZF TRANSMISSION - FORWARD GEAR GROUP ...............................................................................................	178
	FIGURE 5-25. ZF TRANSMISSION - REVERSE GEAR GROUP ................................................................................................	180
	FIGURE 5-26. ZF TRANSMISSION - 1ST SHAFT GROUP .........................................................................................................	182
	FIGURE 5-27. ZF TRANSMISSION - 2ND SHAFT GROUP.........................................................................................................	184
	FIGURE 5-28. ZF TRANSMISSION - 3RD SHAFT GROUP.........................................................................................................	186
	FIGURE 5-29. ZF TRANSMISSION - 4TH SHAFT GROUP .........................................................................................................	188
	FIGURE 5-30. ZF TRANSMISSION - POWER TAKE-OFF...........................................................................................................	190
	FIGURE 5-31. ZF TRANSMISSION - CONTROL UNIT AND PRESSURE REGULATOR............................................................	192
	FIGURE 5-32. ZF TRANSMISSION - GEARSHIFT SYSTEM.......................................................................................................	194
	FIGURE 5-33. ZF TRANSMISSION - OIL PUMP, FILTER AND DIPSTICK .................................................................................	196
	FIGURE 5-34. ZF TRANSMISSION - TRANSFER BOX ...............................................................................................................	198
	FIGURE 5-35. FENDER INSTALLATION .....................................................................................................................................	200
	FIGURE 5-36. WHEEL ASSEMBLY G6-42A & G9-43A................................................................................................................	202
	FIGURE 5-37. WHEEL ASSEMBLY G10-43A ..............................................................................................................................	204
SECTION 6 - CAB ............................................................................................................................................................................		207
	FIGURE 6-1. CAB INSTALLATION...............................................................................................................................................	208
	FIGURE 6-2. CAB ASSEMBLY.....................................................................................................................................................	212
	FIGURE 6-3. CAB DOOR .............................................................................................................................................................	216
	FIGURE 6-4. CAB INTERIOR .......................................................................................................................................................	218
	FIGURE 6-5. WIPER.....................................................................................................................................................................	220
	FIGURE 6-6. SEAT .......................................................................................................................................................................	222
	FIGURE 6-7. HEATER INSTALLATION........................................................................................................................................	224
	FIGURE 6-8. HEATER INSTALLATION........................................................................................................................................	226
	FIGURE 6-9. AIR CONDITIONING INSTALLATION.....................................................................................................................	228
SECTION 7 - CONTROLS................................................................................................................................................................		233
	FIGURE 7-1. BRAKE ....................................................................................................................................................................	234
	FIGURE 7-2. ACCELERATOR......................................................................................................................................................	236
	FIGURE 7-3. STEERING COLUMN..............................................................................................................................................	238
	FIGURE 7-4. BOOM JOYSTICK G6-42A......................................................................................................................................	240
	FIGURE 7-5. BOOM JOYSTICK G6-42A......................................................................................................................................	242
	FIGURE 7-6. BOOM JOYSTICK ...................................................................................................................................................	244
	FIGURE 7-7. TILT AND FRAME LEVEL JOYSTICK INSTALLATION ..........................................................................................	246
	FIGURE 7-8. TILT AND FRAME LEVEL JOYSTICK ASSEMBLY ................................................................................................	248
	FIGURE 7-9. FRAME LEVEL JOYSTICK INSTALLATION ...........................................................................................................	250
	FIGURE 7-10. AUXILIARY HYDRAULIC JOYSTICK INSTALLATION G6-42A ............................................................................	252
	FIGURE 7-11. AUXILIARY HYDRAULIC JOYSTICK INSTALLATION G9-43A ............................................................................	254
	FIGURE 7-12. ELECTRIC AUXILIARY HYDRAULIC JOYSTICK .................................................................................................	256
	FIGURE 7-13. OUTRIGGER CONTROLLER ...............................................................................................................................	258
SECTION 8 - HYDRAULIC CIRCUITS .............................................................................................................................................		261
	FIGURE 8-1. SUPPLY CIRCUIT G6-42A......................................................................................................................................	262
	FIGURE 8-2. SUPPLY CIRCUIT G9-43A & G10-43A...................................................................................................................	266
	FIGURE 8-3. DUMP CIRCUIT G6-42A .........................................................................................................................................	270
	FIGURE 8-4. DUMP CIRCUIT G9-43A & G10-43A.......................................................................................................................	274
6	G10-43A,G9-43A,G6-42A	31200727

	TABLE OF CONTENTS
FIGURE 8-5. STEER SELECT CIRCUIT......................................................................................................................................		278
FIGURE 8-6. SERVICE BRAKE CIRCUIT G6-42A ......................................................................................................................		280
FIGURE 8-7. SERVICE BRAKE CIRCUIT G9-43A & G10-43A....................................................................................................		282
FIGURE 8-8. BOOM JOYSTICK CIRCUIT G6-42A......................................................................................................................		284
FIGURE 8-9. BOOM JOYSTICK CIRCUIT G9-43A & G10-43A ...................................................................................................		286
FIGURE 8-10. OUTRIGGER CONTROLLER ...............................................................................................................................		288
FIGURE 8-11. LIFT CYLINDER CIRCUIT ....................................................................................................................................		290
FIGURE 8-12. EXTEND/RETRACT CYLINDER CIRCUIT G6-42A..............................................................................................		292
FIGURE 8-13. EXTEND/RETRACT CYLINDER CIRCUIT G9-43A & G10-43A ...........................................................................		294
FIGURE 8-14. TILT CYLINDER AND COMPENSATING CYLINDER CIRCUIT G6-42A .............................................................		296
FIGURE 8-15. TILT CYLINDER AND COMPENSATING CYLINDER CIRCUIT G9-43A & G10-43A...........................................		298
FIGURE 8-16. AUXILIARY HYDRAULIC CIRCUIT G6-42A.........................................................................................................		300
FIGURE 8-17. AUXILIARY HYDRAULIC CIRCUIT G9-43A & G10-43A ......................................................................................		302
FIGURE 8-18. FRAME LEVEL CIRCUIT......................................................................................................................................		304
FIGURE 8-19. OUTRIGGER CIRCUIT.........................................................................................................................................		306
SECTION 9 - HYDRAULIC COMPONENTS ....................................................................................................................................		309
FIGURE 9-1. LIFT CYLINDER G6-42A (Prior to SN 0160052707) ..............................................................................................		310
FIGURE 9-2. LIFT CYLINDER G6-42A (SN 0160052707 to Present)..........................................................................................		312
FIGURE 9-3. LIFT CYLINDER G9-43A & G10-43A......................................................................................................................		314
FIGURE 9-4. EXTEND/RETRACT CYLINDER G6-42A (Prior to SN 0160057307) .....................................................................		316
FIGURE 9-5. EXTEND/RETRACT CYLINDER G6-42A (SN 0160057307 to Present).................................................................		318
FIGURE 9-6. EXTEND/RETRACT CYLINDER G9-43A & G10-43A.............................................................................................		320
FIGURE 9-7. TILT CYLINDER G6-42A (Prior to SN 0160057406) ..............................................................................................		322
FIGURE 9-8. TILT CYLINDER G6-42A (SN 0160057406 to Present)..........................................................................................		324
FIGURE 9-9. TILT CYLINDER G9-43A & G10-43A......................................................................................................................		326
FIGURE 9-10. COMPENSATION CYLINDER G6-42A (Prior to SN 0160057586).......................................................................		328
FIGURE 9-11. COMPENSATION CYLINDER G6-42A (SN 0160057586 to Present) ..................................................................		330
FIGURE 9-12. COMPENSATION CYLINDER G9-43A & G10-43A..............................................................................................		332
FIGURE 9-13. FRAME LEVEL CYLINDER G6-42A (Prior to SN 0160060495) ...........................................................................		334
FIGURE 9-14. FRAME LEVEL CYLINDER G6-42A .....................................................................................................................		336
FIGURE 9-15. FRAME LEVEL CYLINDER G9-43A & G10-43A ..................................................................................................		338
FIGURE 9-16. OUTRIGGER CYLINDER .....................................................................................................................................		340
FIGURE 9-17. SIDE TILT CARRIAGE CYLINDER.......................................................................................................................		342
FIGURE 9-18. 50IN SIDE SHIFT CARRIAGE CYLINDER ...........................................................................................................		344
FIGURE 9-19. 72IN, 90, SWING CARRIAGE CYLINDER............................................................................................................		346
FIGURE 9-20. GRAPPLE BUCKET CYLINDER...........................................................................................................................		348
FIGURE 9-21. MAIN CONTROL VALVE G6-42A.........................................................................................................................		350
FIGURE 9-22. MAIN CONTROL VALVE G6-42A.........................................................................................................................		354
FIGURE 9-23. MAIN CONTROL VALVE G9-43A.........................................................................................................................		358
FIGURE 9-24. MAIN CONTROL VALVE G9-43A & G10-43A ......................................................................................................		360
FIGURE 9-25. HYDRAULIC PUMP G6-42A.................................................................................................................................		362
FIGURE 9-26. HYDRAULIC PUMP G9-43A & G10-43A ..............................................................................................................		364
FIGURE 9-27. HYDRAULIC TANK G6-42A .................................................................................................................................		368
FIGURE 9-28. HYDRAULIC TANK G9-43A & G10-43A...............................................................................................................		370
FIGURE 9-29. STEER SELECT VALVE.......................................................................................................................................		372
FIGURE 9-30. BRAKE VALVE .....................................................................................................................................................		374
FIGURE 9-31. PRIORITY VALVE.................................................................................................................................................		378
FIGURE 9-32. SOLENOID VALVE ...............................................................................................................................................		380
FIGURE 9-33. HYDRAULIC VALVE.............................................................................................................................................		382
FIGURE 9-34. OUTRIGGER CONTROL VALVE .........................................................................................................................		384
SECTION 10 - ELECTRICAL ...........................................................................................................................................................		387
FIGURE 10-1. ENGINE COMPARTMENT ELECTRICAL INSTALLATION ..................................................................................		388
FIGURE 10-2. ARCTIC PACKAGE INSTALLATION ....................................................................................................................		392
FIGURE 10-3. BOOM AND FRAME ELECTRICAL INSTALLATION G6-42A ..............................................................................		396
FIGURE 10-4. BOOM AND FRAME ELECTRICAL INSTALLATION G9-43A & G10-43A............................................................		398
FIGURE 10-5. CAB ELECTRICAL INSTALLATION	.....................................................................................................................	400
FIGURE 10-6. CAB SWITCHES...................................................................................................................................................		402
FIGURE 10-7. WORK LIGHTS INSTALLATION...........................................................................................................................		404
FIGURE 10-8. ROAD LIGHTS INSTALLATION ...........................................................................................................................		408
FIGURE 10-9. ENGINE HARNESS IF EQUIPPED FOR ULS ......................................................................................................		410
FIGURE 10-10. ENGINE HARNESS IF EQUIPPED FOR LS ......................................................................................................		412
FIGURE 10-11. TRANSMISSION HARNESS ..............................................................................................................................		414
FIGURE 10-12. FRAME HARNESS .............................................................................................................................................		416
31200727	G10-43A,G9-43A,G6-42A	7

TABLE OF CONTENTS
FIGURE 10-13. VEC OPTIONS HARNESS..................................................................................................................................	418
FIGURE 10-14. TRANSMISSION RELAY HARNESS ..................................................................................................................	420
FIGURE 10-15. ENCLOSED CAB OPTION HARNESS................................................................................................................	422
FIGURE 10-16. DASH HARNESS ................................................................................................................................................	424
FIGURE 10-17. INSTRUMENT PANEL HARNESS ......................................................................................................................	426
FIGURE 10-18. FRAME ROAD LIGHTS HARNESS.....................................................................................................................	428
FIGURE 10-19. BOOM WORK LIGHTS HARNESS .....................................................................................................................	430
FIGURE 10-20. CAB ROAD LIGHTS HARNESS..........................................................................................................................	432
FIGURE 10-21. CAB WORK LIGHT HARNESS ...........................................................................................................................	434
FIGURE 10-22. A/C HARNESS ....................................................................................................................................................	436
FIGURE 10-23. VEC HARNESS ...................................................................................................................................................	438
FIGURE 10-24. TILT AND AUX CONTROL MODULE..................................................................................................................	440
FIGURE 10-25. ACCESSORY MODULE HARNESS....................................................................................................................	442
SECTION 11 - DECALS ...................................................................................................................................................................	445
FIGURE 11-1. CAB AND FRAME DECALS..................................................................................................................................	446
FIGURE 11-2. BOOM DECALS ....................................................................................................................................................	452
SECTION 12 - RECOMMENDED SPARE PARTS ...........................................................................................................................	455
FIGURE 12-1. RECOMMENDED SPARE PARTS........................................................................................................................	456
PART NUMBER INDEX....................................................................................................................................................................	459

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

31200727

SECTION 1 - FRAME AND ATTACHING PARTS

SECTION 1 - FRAME AND ATTACHING PARTS

31200727

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

9

SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. FRAME AND ATTACHING PARTS

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

31200727

SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. FRAME AND ATTACHING PARTS

ITEM	PART NUMBER	QTY	DESCRIPTION	REV
	1001131905	Ref	ENGINE POD INSTALLATION, (G6-42A), (if equipped for ULS),	F
			(not available to order, see items 1 thru 18)
	1001139428	Ref	ENGINE POD INSTALLATION, (G6-42A), (if equipped for LS), (not	E
			available to order, see items 1 thru 18)
	1001131899	Ref	ENGINE POD INSTALLATION, (G9-43A & G10-43A), (if equipped	F
			for ULS), (not available to order, see items 1 thru 18)
	1001139427	Ref	ENGINE POD INSTALLATION, (G9-43A & G10-43A), (if equipped	E
			for LS), (not available to order, see items 1 thru 18)
1	0682018	4	HEX HD CAPSCREW, 5/8-11X2-1/4
2	0811608	7	SCREW, 3/8-16X1
3	0811610	2	SCREW, 3/8-16X1-1/4
4	4892000	4	HARDENED WASHER, 5/8
5	1001121031	1	POD WELDMENT SUPPORT
6	1001121047	1	BOTTOM COVER PLATE
7	1001125491	1	FOAM GASKET SEAL
8	1001128248	1	COOLER ACCESS COVER PLATE
13	1001132796	1	HOSE GUIDE BRACKET
15	0641640	2	HEX HD CAPSCREW, 3/8-16X5
16	1001143653	2	SPACER TUBE
17	1001143654	1	HOSE GUIDE PLATE
18	1001150299	1	HOSE, 3/4
101	N.S.S.	1	FRAME WELDMENT
202	80241137	4	SPECIAL WASHER
203	83201030	4	HEX HD CAPSCREW, 1-8X3-1/2, (G6-42A)
203	80241147	4	HEX HD CAPSCREW, 1-8X9-1/2, (G9-43A & G10-43A)
251	91140001	1	COUNTERWEIGHT, (if equipped)
251	1001097095	1	COUNTERWEIGHT W/PINTLE HITCH ASSY, (if equipped),	B
			(includes items 304 & 305)
304		Ref	PINTLE HOOK, (not shown), (See PINTLE HOOK for Breakdown)
305	1001091458	1	COUNTERWEIGHT
401		Ref	HYDRAULIC TANK, (See HYDRAULIC COMPONENTS SECTION
			for Breakdown)
402		Ref	CAB WELDMENT, (See CAB SECTION for Breakdown)

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

11

SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-2. COVERS G6-42A

12

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

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SECTION 1 - FRAME AND ATTACHING PARTS

31200727

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

13

SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-2. COVERS G6-42A

ITEM	PART NUMBER	QTY	DESCRIPTION	REV
	1001133442	Ref	HOOD INSTALLATION, (G6-42A), (not available to order, see items	C
			1 thru 27 for service)
1	0641406	10	HEX HD CAPSCREW, 1/4-20X3/4
2	0641610	10	HEX HD CAPSCREW, 3/8-16X1-1/4
3	0641624	3	HEX HD CAPSCREW, 3/8-16X3
4	0791410	2	SCREW, 1/4-20X1-1/4
5	0791608	6	SCREW, 3/8-16X1
6	3900316	5	BUTTON HD SCREW, 3/8-16X1
7	0811608	6	SCREW, 3/8-16X1
8	3311405	2	HEX LOCKNUT, 1/4-20, GR2
9	3520176	2	PLUG, 1-1/4
10	4751400	12	WASHER, 1/4
11	4751600	15	WASHER, 3/8
12	4761600	13	LOCKWASHER, 3/8
13	8866348	1	MIRROR ASSY
14	88501006	2	HEX NUT, 3/8-16
15	88662523	10	TINNERMAN NUT
16	1001121332	1	LATCH MOUNT BRACKET
17	1001121337	1	LATCH CATCH BRACKET
18	1001128847	1	FRONT COVER
19	1001129637	1	HINGE COVER
20	1001129639	1	MIRROR BRACKET
21	1001144114	1	HINGE MOUNT SUPPORT
22	1001131147	1	ENGINE COVER ASSY, (includes items 101 thru 111)	F
23	1001131247	2	GAS SPRING
24	1001132508	1	VALVE COVER PANEL
25	91473085	1	MAIN VALVE COVER
26	4711500	2	WASHER, 5/16
27	4711600	5	WASHER, 3/8
101	3290605	4	HEX LOCKNUT, M6X1
103	4811700	4	WASHER, 6mm
104	1001122219	1	COMPRESSION LATCH
104	91404275	1	ENGINE COVER KEY
107	1001129358	1	ENGINE COVER HINGE
108	1001129638	1	ENGINE COVER
110	3300492	5	NYLON INSERT LOCKNUT
111	4751600	5	WASHER, 3/8

14

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

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SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-3. COVERS G9-43A AND G10-43A

16

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

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SECTION 1 - FRAME AND ATTACHING PARTS

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17

SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-3. COVERS G9-43A AND G10-43A

ITEM	PART NUMBER	QTY	DESCRIPTION	REV
	1001131775	Ref	HOOD INSTALLATION, (G9-43A), (not available to order, see items	D
			1 thru 31 for service)
	1001132536	Ref	HOOD INSTALLATION, (G10-43A), (not available to order, see	G
			items 1 thru 31 for service)
1	0641405	5	HEX HD CAPSCREW, 1/4-20X5/8
2	0641508	3	HEX HD CAPSCREW, 5/16-18X1
3	0641610	9	HEX HD CAPSCREW, 3/8-16X1-1/4
4	0791410	2	SCREW, 1/4-20X1-1/4
5	0791608	6	SCREW, 3/8-16X1
6	0811606	5	BUTTON HD SCREW, 3/8-16X3/4, (G9-43A)
6	3900316	5	BUTTON HD SCREW, 3/8-16X1, (G10-43A)
7	0811608	6	SCREW, 3/8-16X1
8	3311405	2	HEX LOCKNUT, 1/4-20, GR2
9	3520176	2	PLUG, 1-1/4
10	4751400	12	WASHER, 1/4
11	4751500	3	WASHER, 5/16
12	4751600	11	WASHER, 3/8
13	4761600	9	LOCKWASHER, 3/8
14	8866348	1	MIRROR ASSY
15	88501005	3	HEX NUT, 5/16-18
16	88501006	2	HEX NUT, 3/8-16
17	88662523	9	TINNERMAN NUT
18	1001132441	1	VALVE COVER PANEL
19	1001121332	1	LATCH MOUNT BRACKET
20	1001121337	1	LATCH CATCH BRACKET
21	1001128847	1	FRONT COVER, (G9-43A)
21	1001128846	1	FRONT COVER, (G10-43A)
22	1001129637	1	HINGE COVER
23	1001129639	1	MIRROR BRACKET
24	1001144114	1	HINGE MOUNT SUPPORT
25	1001131147	1	ENGINE COVER ASSY, (includes items 101 thru 111)	F
26	1001131247	2	GAS SPRING
27	91513122	1	MAIN VALVE COVER
28	4711500	2	WASHER, 5/16
29	4711600	5	WASHER, 3/8, (G10-43A)
30	90206198	5 in	TRIM-LOK
31	0641406	5	HEX HD CAPSCREW, 1/4-20X3/4
101	3290605	4	HEX LOCKNUT, M6X1
103	4811700	4	WASHER, 6mm
104	1001122219	1	COMPRESSION LATCH
104	91404275	1	ENGINE COVER KEY
107	1001129358	1	ENGINE COVER HINGE
108	1001129638	1	ENGINE COVER
110	3300492	5	NYLON INSERT LOCKNUT
111	4751600	5	WASHER, 3/8

18

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

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SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-4. OUTRIGGER INSTALLATION

20

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

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SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-4. OUTRIGGER INSTALLATION

ITEM	PART NUMBER	QTY	DESCRIPTION	REV
	1001148233	Ref	OUTRIGGER INSTALLATION, (G10-43A), (not available to order,	A
			see items 1 thru 15 for service)
1	0100011	AR	LOCTITE 242
2	0641634	2	HEX HD CAPSCREW, 3/8-16X4-1/4, GR5
3	0641808	4	HEX HD CAPSCREW, 1/2-13X1, GR5
4	3300143	4	HEX LOCKNUT, 3/8-16
5	3931672	2	SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8
6	4761800	4	LOCKWASHER, 1/2
7	88671001	4	LUBE FITTING, STRAIGHT, 1/8
8	91081313	2	KEEPER
9	91563197	2	OUTRIGGER CYLINDER PIN
10	91563198	2	ARM PIN
11	91563199	2	SHOE PIN
12	1001141892	2	PAD WELD STABILIZER
13	1001142258	2	OUTRIGGER ARM WELDMENT
14	1001001211	2	OUTRIGGER CYLINDER ASSY, (includes items 101 & 105)	B
15		Ref	HOSE ASSY, (not shown), (See HYDRAULIC CIRCUITS
			SECTION for Breakdown)
101		Ref	OUTRIGGER CYLINDER AND MOUNTING HARDWARE, (See
			HYDRAULIC COMPONENTS SECTION for Breakdown)
105		Ref	STRAIGHT FITTING, (See HYDRAULIC CIRCUITS SECTION for
			Breakdown)

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21

SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-5. PINTLE HOOK

22

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

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SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-5. PINTLE HOOK

ITEM	PART NUMBER	QTY	DESCRIPTION	REV
301	0100011	AR	LOCTITE 242
302	0681814	4	HEX HD CAPSCREW, 1/2-13X1-3/4, GR8, (torque to 105 lb-ft/145
			Nm)
303	88551013	4	LOCKWASHER, 1/2
304	90200602	1	PINTLE HOOK
305		Ref	COUNTERWEIGHT, (See FRAME AND ATTACHING PARTS for
			Breakdown)

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

23

SECTION 2 - BOOM

SECTION 2 - BOOM

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

25

SECTION 2 - BOOM

FIGURE 2-1. BOOM INSTALLATION G9-43A & G10-43A

26

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

31200727