JLG G6-23A Parts Manual

An Oshkosh Corporation Company

Illustrated Parts Manual

Models G5-19A

G6-23A

31200194

Revised

April 4, 2014

EFFECTIVITY PAGE

March 10, 2006 - A - Original Issue Of Manual

February 23, 2007 - B - Revised Manual

July 6, 2007 - C - Revised Manual

May 15, 2008 - D - Revised Manual

May 29, 2009 - E - Revised Manual

April 3, 2014 - F - Revised Manual

31200194 G5-19A/G6-23A i

EFFECTIVITY PAGE

G5-19A/G6-23A 31200194-ii

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1 Frame Shrouding & Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Frame Shrouding & Trim, Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

SECTION 2 –

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-4 Hydraulic Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3 –

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 Four In One Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4 Fork Mounted Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-5 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-6 Manure Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-7 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-8 Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-9 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-10 Fork Position/Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-11 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

SECTION 4 –

ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4 Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-5 Air Cleaner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-6 Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION 5 –

DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Front Axle - Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 Front Axle - Housing and Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-4 Front Axle - Bevel Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-5 Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-6 Front Axle - Double U-Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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5-7 Front Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-8 Front Axle - Wheel Hub and Final Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-9 Front Axle - Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-10 Front Axle - Lower and Upper Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-11 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-12 Rear Axle - Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-13 Rear Axle - Swivel Housing and Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-14 Rear Axle - Bevel Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-15 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-16 Rear Axle - Double U-Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-17 Rear Axle - Wheel Hub and Final Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-18 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5-19 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

SECTION 6 –

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Cab Interior Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 Cab Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-5 Cab Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-6 Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-7 Air Circulation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-8 Tool Box Assembly (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-9 Fire Extinguisher Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

SECTION 7 –

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 Boom Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-4 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

SECTION 8 –

HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8-1 Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-3 Front Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-4 Steer Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8-5 Service/Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-6 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-7 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-8 Tilt & Tilt Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-9 Auxiliary Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

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8-10 Rear Hydraulic Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

SECTION 9 –

HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-2 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9-3 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9-4 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9-5 Fork Locking Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

9-6 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9-7 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9-8 Hydrostatic Transmission Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

9-9 Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

9-10 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

9-11 Auxiliary Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

SECTION 10 –

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10-3 Rear Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

10-4 Front Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

10-5 PWM Valve Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

10-6 Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

10-7 Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

10-8 Ground Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10-9 Bucket Shake Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

10-10 Oil Temperature Gauge Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

SECTION 11 –

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-1 Frame & Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-2 Cab Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

11-3 Machine Decals, G5-19A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

11-4 Machine Decals, G6-23A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

SECTION 12 –

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12-1 Cab Worklight Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12-2 Boom Worklight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12-3 Rotating Beacon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12-4 Air Conditioner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12-5 Draw Bar Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

12-6 Dual Boom Aux Hydraulic, Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

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12-7 Dual Boom Aux Hydraulic, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

12-8 Option Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

12-9 Upper Cab Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

12-10 Pintle Hitch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

12-11 Dump Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

12-12 Boom Auxiliary Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

SECTION 13 –

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

G5-19A/G6-23A 31200194vi

SECTION 1

FRAME & ATTACHING PARTS

31200194 G5-19A/G6-23A

FRAME & ATTACHING PARTS

PAH0010

Figure 1-1 Frame Shrouding & Trim

G5-19A/G6-23A 312001941-2

46 48

58 59

PAH0021

CAB MOUNTING

HARDWARE FOR

G5-19A

MIRROR

REAR VIEW MIRROR

FOR G5-19A

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

31200194 G5-19A/G6-23A 1-3

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim

Item Part Number Qty. Description Rev.

0275028 1 ENGINE HOOD INSTALLATION, (includes items 1 thru 17) A 1 1671260 1 HOOD ASSY, (includes items 22 thru 24) A 2 1671177 1 ENGINE PANEL HOOD 3 0903274 1 BRACKET 4 3575643 1 SUPPORT PLATE 5 8000382 1 HOOD LATCH 6 8000801 1 HOOD LOCK 7 4806433 2 HINGE 8 4160213 1 GAS SPRING 9 2014226 6.4 M RUBBER SEAL

10 0760810 11 HEX HD CAPSCREW, 8-1.25X20mm, GR 8.8 11 0761010 2 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8 12 3290605 3 HEX LOCK NUT, M6X1 13 3290805 2 HEX LOCK NUT, M8X1.25 14 4811700 3 FLAT WASHER, 6mm 15 4811900 11 FLAT WASHER, 8mm 16 4812000 2 FLAT WASHER, 10mm 17 5220800 1 RIPP NUT, 8mm 22 2520136 1 GRILL 23 4340868 1 HOOD SUPPORT 24 4806444 1 PLATE 30 0275255 1 REAR COVER PANEL, (includes item 33) A 33 3380687 1 REAR PANEL 35 2360729 1 FRAME, (G5-19A), (Before S/N 1160002168)

2360778 1 FRAME, (G5-19A), (S/N 1160002168 & after)

2360663 1 FRAME, (G6-23A)

36 3575641 1 PANEL SUPPORT 37 Ref HEADLIGHT ASSY, (see Figure 10-1 for details) 38 3140007 2 MIRROR, (G5-19A)

3140007 1 MIRROR, (G6-23A)

39 1781813 8 CAB MOUNT 40 4806626 4 BUSHING 41 8000565 4 WASHER 42 8000567 4 RUBBER MOUNT 43 0712029 4 HEX HD CAPSCREW, GR 10.9, (torque to 111 ft-lb [150 Nm]) 44 3292001 4 HEX NUT, M20X2.5 46 0761012 2 HEX HD CAPSCREW, 10-1.50X25mm 47 8003392 1 CABLE SET, GROUND CONNECTION 48 4812000 2 FLAT WASHER, 10mm 49 Ref CAB, (see Figure 6-1 for details) 54 80363195 1 MIRROR 55 3841634 1 MIRROR ATTACH BAR 56 3291601 2 HEX NUT, M16X2 57 4812300 2 FLAT WASHER, 16mm 58 3292001 2 HEX NUT, M20X2.5 59 4812500 2 WASHER, 20mm 60 0100011 AR LOCTITE, #242

G5-19A/G6-23A 312001941-4

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

31200194 G5-19A/G6-23A 1-5

FRAME & ATTACHING PARTS

103

101

102

PAH0030

Figure 1-2 Frame Shrouding & Trim, Fender Installation

G5-19A/G6-23A 312001941-6

FRAME & ATTACHING PARTS

Figure 1-2 Frame Shrouding & Trim, Fender Installation

Item Part Number Qty. Description Rev.

0274812 1 FENDER INSTALLATION, (G5-19A), (optional), (includes items 1 thru 11) B

0273812 1 FENDER INSTALLATION, (G6-23A), (optional), (includes items 1 thru 11) F 1 328027 4 BOLT, MUSHROOM HEAD 8-1.25X20mm 2 0701018 16 HEX HD CAPSCREW, 10-1.50X50mm, GR 8.8 3 0761617 16 HEX HD CAPSCREW, 16X45, GR 8.8 4 1001096569 4 FENDER, (G5-19A)

1001096345 4 FENDER, (G6-23A)

5 1001098263 4 SUPPORT PLATE, (G5-19A)

3575386 4 SUPPORT PLATE, (G6-23A) 6 4340882 4 FENDER SUPPORT, (G5-19A)

4340883 4 FENDER SUPPORT, (G6-23A) 7 4812000 16 WASHER, 10mm 8 4812300 16 WASHER, 16mm 9 5220800 8 RIPP NUT, (G5-19A)

5220800 4 RIPP NUT, (G6-23A)

10 5221000 16 RIPP NUT 11 8006580 8 PLUG

0275259 1 CAB FENDER INSTALLATION, (includes items 101 thru 103) A

101 0761010 3 HEX HD CAPSCREW, 10-1.50X20mm 102 2090061 1 CAB FENDER 103 4812000 3 FLAT WASHER, 10mm

31200194 G5-19A/G6-23A 1-7

FRAME & ATTACHING PARTS

2 6

62 63

31 53

2 5

PAH0041

G5-19A

Figure 1-3 Axle Installation

G5-19A/G6-23A 312001941-8

FRAME & ATTACHING PARTS

Figure 1-3 Axle Installation

Item Part Number Qty. Description Rev.

2 0100019 AR LOCTITE, #271 3 Ref FRONT AXLE ASSY, (see Figure 5-1 for details) 4 Ref REAR AXLE ASSY, (see Figure 5-11 for details) 5 0630599 6 HEX HD CAPSCREW, 20-1.50X140mm 6 0712040 8 HEX HD CAPSCREW, 20X230, GR10.9

10 3300478 6 HEX NUT, M20X1.5 11 3332001 8 HEX NUT, M20X2.5 12 3574829 2 AXLE PLATE 20 7028416 32 LUG NUT, (torque to 221 ft-lb [300 Nm]) 21 7028415 32 SPRING WASHER 31 0761005 11 HEX HD CAPSCREW, 10X10 43 1671334 1 HOSE COVER 53 4812000 11 FLAT WASHER, 10mm 60 Ref TIRE & RIM ASSY, (see Figure 5-19 for details) 61 1001097241 1 COVER 62 4191707 6 SCREW, M16X6mm 63 4811700 6 FLAT WASHER, 6mm 64 1001099383 1 MOTOR ACCESS COVER

31200194 G5-19A/G6-23A 1-9

FRAME & ATTACHING PARTS

2 6

2 5

31 53

62 63

PAH0051

G6-23A

Figure 1-3 Axle Installation

G5-19A/G6-23A 312001941-10

FRAME & ATTACHING PARTS

Figure 1-3 Axle Installation

Item Part Number Qty. Description Rev.

2 0100019 AR LOCTITE, #271 3 Ref FRONT AXLE ASSY, (see Figure 5-1 for details) 4 Ref REAR AXLE ASSY, (see Figure 5-11 for details) 5 0630599 6 HEX HD CAPSCREW, 20-1.50X140mm 6 0712445 8 HEX HD CAPSCREW, 20X230, GR10.9

10 3300478 6 HEX NUT, M20X1.5 11 3332401 8 HEX NUT, M20X2.5 12 3575706 2 AXLE PLATE 20 7028416 32 LUG NUT, (torque to 221 ft-lb [300 Nm]) 21 7028415 32 SPRING WASHER 31 0761005 9 HEX HD CAPSCREW, 10X10 43 1671206 1 HOSE COVER 53 4812000 9 FLAT WASHER, 10mm 60 Ref TIRE & RIM ASSY, (see Figure 5-19 for details) 61 1001097241 1 COVER 62 4191707 6 SCREW, M16X6mm 63 4811700 6 FLAT WASHER, 6mm 64 1001099383 1 MOTOR ACCESS COVER

31200194 G5-19A/G6-23A 1-11

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

G5-19A/G6-23A 312001941-12

SECTION 2

BOOM

31200194 G5-19A/G6-23A

BOOM

PAH0060

G5-19A

Figure 2-1 First Boom Section

G5-19A/G6-23A 312001942-2

BOOM

Figure 2-1 First Boom Section

Item Part Number Qty. Description Rev.

1 0801412 1 FIRST BOOM SECTION, (G5-19A) 2 0701016 4 HEX HD CAPSCREW, 10-1.50X40mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0701017 4 HEX HD CAPSCREW, 10-1.50X45mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0701018 4 HEX HD CAPSCREW, 10-1.50X50mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

3 4812000 16 FLAT WASHER, 10mm 4 3574821 2 SPACER 5 8002901 6 SPACER 6 8002200 4 BEARING PAD 7 8008640 AR SHIM, 50X200X0.5

8008641 AR SHIM, 50X200X1.0

8008642 AR SHIM, 50X200X1.5

8008070 AR SHIM, 50X200X2.0 8 0761008 8 HEX HD CAPSCREW, 10-1.50X16mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761010 8 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761012 8 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

9 4700027 4 BEARING PAD

10 0761010 4 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8, (torque to 37 ft-lb [50 Nm]) 11 4100076 2 BUSHING 12 2160016 2 LUBE FITTING, STRAIGHT 13 3423218 1 PIN 14 0761215 1 HEX HD CAPSCREW, GR 8.8, 12-1.75X35mm 15 4812100 1 FLAT WASHER, 12mm

31200194 G5-19A/G6-23A 2-3

BOOM

PAH0070

G6-23A

Figure 2-1 First Boom Section

G5-19A/G6-23A 312001942-4

BOOM

Figure 2-1 First Boom Section

Item Part Number Qty. Description Rev.

1 0801413 1 FIRST BOOM SECTION, (G6-23A) 2 0701016 4 HEX HD CAPSCREW, 10-1.50X40mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0701017 4 HEX HD CAPSCREW, 10-1.50X45mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0701018 4 HEX HD CAPSCREW, 10-1.50X50mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm]) 3 4812000 16 FLAT WASHER, 10mm 4 3574821 2 SPACER 5 8002901 6 SPACER 6 8002200 8 BEARING PAD 7 8008640 SHIM, 50X200X0.5

8008641 SHIM,50X200X1.0 8008642 SHIM,50X200X1.5 8008070 SHIM,50X200X2.0

8 0761010 8 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761012 8 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761014 8 HEX HD CAPSCREW, 10-1.50X30mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm]) 9 4100076 2 BUSHING

10 2160016 2 LUBE FITTING, STRAIGHT 11 0761010 4 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8 (torque to 37 ft-lb [50 Nm]) 12 3423220 1 PIN 13 0761215 1 HEX HD CAPSCREW, 12-1.75X35mm, GR 8.8 14 4812100 1 FLAT WASHER, 12mm

31200194 G5-19A/G6-23A 2-5

BOOM

PAH0080

G5-19A

Figure 2-2 Second Boom Section

G5-19A/G6-23A 312001942-6

BOOM

Figure 2-2 Second Boom Section

Item Part Number Qty. Description Rev.

1 0801419 1 SECOND BOOM SECTION, (G5-19A) 2 2160018 1 LUBE FITTING, 90 DEGREES 3 4100078 2 BUSHING 4 3574798 1 FRONT COVER PLATE 5 0760808 6 HEX HD CAPSCREW, 8-1.25X16mm 6 4831900 6 LOCKWASHER, 8mm 7 3423152 1 EXTEND/RETRACT CYLINDER PIN 8 3760492 2 RETAINING RING 9 4340827 1 BRACKET

10 4340826 1 BRACKET 11 0761012 6 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8, (torque to 37 ft-lb [50 Nm]) 12 4812000 18 FLAT WASHER, 10mm 13 Ref EXTEND/RETRACT CYLINDER, (see Figure 9-2 for details) 14 3423075 1 EXTEND/RETRACT BARREL PIN 15 3760491 2 RETAINING RING 16 8002199 2 BEARING PAD 17 8003242 2 SPACER 18 8008069 AR SHIM, OFFSET, 70X200X2.0

8008634 AR SHIM, OFFSET, 70X200X0.5 8008644 AR SHIM, OFFSET, 70X200X1.0 8008645 AR SHIM, OFFSET, 70X200X1.5

19 0761010 4 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761012 4 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

20 4812100 4 FLAT WASHER, 12mm 21 4700027 4 BEARING PAD 22 0761008 8 HEX HD CAPSCREW, 10-1.50X16mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761010 8 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761012 8 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

23 8002901 4 SPACER 24 4700026 1 SLIDER PAD 25 8008640 AR SHIM, 50X200X0.5

8008641 AR SHIM, 50X200X1.0 8008642 AR SHIM, 50X200X1.5 8008070 AR SHIM, 50X200X2.0

26 0761010 4 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8

31200194 G5-19A/G6-23A 2-7

BOOM

PAH0090

G6-23A

Figure 2-2 Second Boom Section

G5-19A/G6-23A 312001942-8

BOOM

Figure 2-2 Second Boom Section

Item Part Number Qty. Description Rev.

1 0801415 1 SECOND BOOM SECTION, (G6-23A) 2 2160018 1 LUBE FITTING, 90 DEGREES 3 4100078 2 BUSHING 4 3574798 1 FRONT COVER PLATE 5 0760808 6 HEX HD CAPSCREW, 8-1.25X16mm, GR8.8 6 4811900 6 LOCKWASHER, 8mm 7 3423149 1 EXTEND/RETRACT CYLINDER PIN 8 3760492 2 RETAINING RING 9 4340829 1 BRACKET

10 4340828 1 BRACKET 11 0761012 10 HEX HD CAPSCREW, 10-1.50X25mm, (torque to 37 ft-lb [50 Nm]) 12 4812000 18 FLAT WASHER, 10mm 13 Ref EXTEND/RETRACT CYLINDER, (see Figure 9-2 for details) 14 3423075 1 EXTEND/RETRACT BARREL PIN 15 3760491 2 RETAINING RING 16 8002199 2 BEARING PAD 17 8003242 2 SPACER 18 8008069 AR SHIM, OFFSET, 70X200X2.0

8008634 AR SHIM, OFFSET, 70X200X0.5 8008644 AR SHIM, OFFSET, 70X200X1.0 8008645 AR SHIM, OFFSET, 70X200X1.5

19 0761210 4 HEX HD CAPSCREW, 12-1.75X20mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761212 4 HEX HD CAPSCREW, 12-1.75X25mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761214 4 HEX HD CAPSCREW, 12-1.75X30mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

20 4812100 4 FLAT WASHER, 12mm 21 8002200 4 BEARING PAD 22 0761010 8 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761012 8 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

0761014 8 HEX HD CAPSCREW, 10-1.50X30mm, GR 8.8, (as required), (torque to 37 ft-lb

[50 Nm])

23 8002901 4 SPACER 24 4700026 1 SLIDER PAD 25 8008640 AR SHIM, 50X200X0.5

8008641 AR SHIM, 50X200X1.0 8008642 AR SHIM, 50X200X1.5 8008070 AR SHIM, 50X200X2.0

31200194 G5-19A/G6-23A 2-9

BOOM

102

101

103

104

105

104

101

104

PAH0100

Figure 2-3 Quick Switch Assembly

G5-19A/G6-23A 312001942-10

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