JLG G6-42P Parts Manual

An Oshkosh Corporation Company

Illustrated Parts Manual

Model

G6-42P

S/N 0189001 thru 0189345

& 0160000230 & After

91404001

Revised

March 31, 2014

December 17, 2004 - A - Revised Manual

June 3, 2005 - B - Revised Manual

September 30, 2005 - C - Revised Manual

April 24, 2006 - D - Revised Manual

August 25, 2006 - E - Revised Manual

February 23, 2007 - F - Revised Manual

July 6, 2007 - G - Revised Manual

November 26, 2008 - H - Revised Manual

February 25, 2010 - I - Revised Manual

September 24, 2012 - J - Revised Manual

January 3, 2013 - K - Revised Manual

March 31, 2014 - L - Revised Manual

EFFECTIVITY PAGE

91404001 G6-42P i

EFFECTIVITY PAGE

G6-42P 91404001-ii

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

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

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

1-2 Rear Axle & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SECTION 2 –

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

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

2-2 Bearing Pads, Spacers & Shims, (First Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 Bearing Pads, Spacers & Shims, (Second Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-5 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-6 Bearing Pads, Spacers & Shims, (Third Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-7 Push/Beam Extend Chain & Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

SECTION 3 –

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

3-1 Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 48 Inch & 72 Inch Slope Piler Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-5 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-6 10 Foot & 15 Foot Truss Boom With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-7 12 Foot Truss Boom With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-8 100 Degree Swing Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-9 90 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-10 Sheet Material Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-11 Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-12 100 Degree Drywall Swing Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-13 Personnel Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-14 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-15 100 Degree Swing Carriage With Side Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-16 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-17 Fork Mounted Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-18 Grapple Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-19 Fork Pin Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3-20 6 Foot Mast With 48 Inch & 72 Inch Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-21 8 Foot Standard Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3-22 8 Foot Side Tilt Electric Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

91404001 G6-42P iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 4 –

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

4-1 Engine Assembly, LH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Engine Assembly, RH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-3 John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-4 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-5 Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-6 Air Cleaner & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

4-7 Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

SECTION 5 –

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

5-1 Front Axle Assembly - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Front Axle - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 Carrier Assembly - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 Brake Assembly - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-5 Left & Right Housing & Axle & Wheel Flange Assemblies - Rockwell . . . . . . . . . . . . . . . . . . . . . 5-12

5-6 Front Axle Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-7 Front Axle - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-8 Carrier Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-9 Brake Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-10 Axle Housing Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-11 Rear Axle Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-12 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SECTION 6 –

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

6-1 Open Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Cab Enclosure With Heater Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-4 Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-5 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-6 Dash Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-7 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

SECTION 7 –

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

7-1 Tilt & Sway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-4 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-5 Foot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-6 Boom Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-7 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

G6-42P 91404001iv

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

7-8 RH Horizontal Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

SECTION 8 –

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

8-1 Oil Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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

8-3 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-4 Rear Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-5 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-6 Service/Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-7 Boom Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-8 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-9 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-10 Tilt & Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8-11 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

SECTION 9 –

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

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

9-2 Crowd Cylinder - Iowa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9-3 Tilt Cylinder - Iowa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9-4 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9-5 Sway Cylinder - Iowa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

9-6 Steering Cylinder - Iowa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

9-7 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

9-8 Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

9-9 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44

9-10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46

9-11 Rear Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48

9-12 Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50

9-13 Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

9-14 Traction Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54

9-15 Inching Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56

9-16 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58

9-17 Priority Flow Divider Valve & Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62

9-18 Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

9-19 Sway Cylinder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66

9-20 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70

9-21 Grapple Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-72

9-22 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74

9-23 72 Inch 90 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-76

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SECTION 10 –

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

10-1 Battery & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10-3 Boom Work Lights Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

10-4 Cab Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10-5 Cab Work Light & Beacon Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

10-6 Frame Road Lights Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

10-7 Cab Road Lights Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

SECTION 11 –

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

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

11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

SECTION 12 –

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

12-1 Turbo Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12-2 Turbo Engine Assembly, LH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12-3 Turbo Engine Assembly, RH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

12-4 John Deere Turbo Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

12-5 Turbo Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

12-6 Turbo Air Cleaner & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

12-7 Turbo Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32

12-8 Heater Option Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

12-9 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40

12-10 Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-42

12-11 Cold Start Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46

12-12 Block Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48

12-13 Stabilizer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50

12-14 Stabilizer Cylinder - Iowa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-52

12-15 Beacon Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-54

12-16 Tilt on Joystick With LH Sway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-56

12-17 Tilt on Joystick With RH Sway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-58

12-18 LH Sway Option Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-62

12-19 RH Tilt & Sway Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-64

12-20 Auxiliary Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-66

12-21 LH Auxiliary Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70

12-22 RH Auxiliary Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-72

12-23 Auxiliary Electrics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-74

12-24 Main Control Valve With Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-82

12-25 Boom Joystick With Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-90

12-26 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-92

12-27 Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-94

G6-42P 91404001vi

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

12-28 5 Inch & 8 Inch Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96

12-29 Winch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-100

12-30 Truss Boom Pressure Reducer Valve - 1200 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-102

12-31 Truss Boom Pressure Reducer Valve - 1360 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-104

12-32 Starter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-106

12-33 Fuel/Water Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-108

12-34 Standard Seat Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-110

12-35 Heavy Seat Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112

12-36 Work Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-114

12-37 Pintle Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-122

12-38 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-124

12-39 Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-126

12-40 Road Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-128

12-41 Beacon Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-132

12-42 Stabilizer Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-136

SECTION 13 –

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

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

91404001 G6-42P vii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

G6-42P 91404001viii

SECTION 1

FRAME & ATTACHING PARTS

91404001 G6-42P

FRAME & ATTACHING PARTS

PAP23330

11 12 44

31 33

7 218

73 93

9 48 63 64 65 66 67

68 69 70 78

94 95

1 401 403

402

25 26 27 28

Figure 1-1 Frame Shrouding & Trim

G6-42P 914040011-2

FRAME & ATTACHING PARTS

PAP23310

35 36

89 90 91 92

104

108 109

103

102

101

105 106 107 110 111

108 109

102

103

301

303

302

304

FRAME MOUNT

WELDMENT

CAB

WALL

UPPER

CAB

MOUNT

CAB

MOUNT

WELDMENT

FRAME

MOUNT

WELDMENT

LOWER

CAB

MOUNT

SHOWN WITH WORK LIGHT

BEFORE S/N 0160032846

S/N 0160032846 &

AFTER

Figure 1-1 Frame Shrouding & Trim (Continued)

91404001 G6-42P 1-3

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim

Item Part Number Qty. Description Rev.

14404646 AR T-9 METAL PROTECTANT, (1 gal.) 14404645 AR T-9 METAL PROTECTANT, (12 oz.)

1 91403574 Ref BACK-UP ALARM, (Before S/N 0160016458), (no longer available, use Kit K1

for replacement)

8270621 1 BACK-UP ALARM, (S/N 0160016458 & After) 2 0641406 2 HEX HD CAPSCREW, 1/4-20X3/4 3 8305624 2 HEX NUT, 1/4-20 4 4711400 2 FLAT WASHER, 1/4 5 91140001 1 COUNTERWEIGHT, (no pintle hook)

1001091458 1 COUNTERWEIGHT, (with pintle hook) 6 88561011 4 FLAT WASHER, 1 7 83201183 4 HEX HD CAPSCREW, 1-18X6, (torque to 545-595 lb-ft) 8NSS1FRAME WELDMENT 9 91404346 2 ROD CLIP

10 88201551 2 HEX HD CAPSCREW, 7/16-20X1-1/2, GR5, (S/N 0189001 thru 0160015436) 11 4761500 1 LOCKWASHER, 5/16 12 91143357 1 HORN 13 91403268 1 ENGINE COVER, (includes items 9, 24, 47, 48, 51, 60 thru 78 & 93) E

91404275 1 ENGINE COVER KEY 14 88261029 6 SOCKET BUTTON HD CAPSCREW, 3/8-16X1 15 80263053 1 MIRROR 16 91406094 1 MIRROR BRACKET 17 88201036 3 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 18 88501106 3 HEAVY HEX JAM NUT, 3/8-16 19 91401347 1 MIRROR MOUNT BRACKET PLATE 20 91406117 1 FRONT SHEET METAL COVER 21 77143006 21 WHIZ-LOCKNUT, 5/16-18, (S/N 0189001 thru 0160015436) 22 91403441 1 DUST SHIELD 23 91083533 14 FENDER WASHER 24 91404344 3 ALUMINUM WEAR PLATES 25 91403582 3 BEARING PAD 26 91401524 AR SHIM 27 88201534 4 HEX HD CAPSCREW, 3/8-24X1, GR5 28 88551011 14 LOCKWASHER, 3/8 29 88261030 4 SOCKET BUTTON HD CAPSCREW, 3/8-16X1-1/4 30 90027470 4 HARDENED WASHER, 3/8 31 88561004 6 FLAT WASHER, 3/8 32 91403600 1 U-BOLT 33 88501006 2 HEX NUT, 3/8-16 34 91401570 1 LATCH PLATE 35 91405051 1 SEAT RISER ASSY, (includes items 36 thru 39) 36 91406115 1 RISER WELDMENT, (S/N 0189001 thru 0160015436)

91516044 1 RISER WELDMENT, (S/N 0160015465 & After) 37 91401415 1 ACCESS COVER, (S/N 0189001 thru 0160015436) 38 88261015 6 SOCKET BUTTON HD CAPSCREW, 1/4-20X5/8 39 88551009 6 LOCKWASHER, 1/4 40 88201035 4 HEX HD CAPSCREW, 3/8-16X1, GR5

G6-42P 914040011-4

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

41 91033029 1 SEAT BELT, (not used with optional seat), (includes items 50 & two of

items 52 & 59) 42 91513099 1 TETHER, (S/N 0189001 thru 0160015436), (includes items 10, 52 & 59) 43 91403230 1 MANUAL CASE 44 88201016 1 HEX HD CAPSCREW, 5/16-18X1/2, GR5 45 90206202 45 in TRIM-LOCK 46 91143220 118 in TRIM-LOCK 47 91404343 1 REINFORCING PLATE 48 91404342 4 RIVET WASHERS 49 88501012 4 HEX LOCKNUT, 3/4-10 50 88201549 2 HEX HD CAPSCREW, 7/16-20X1, GR5 51 91404437 13 ft BULB SEAL 52 88551012 4 LOCKWASHER, 7/16, (S/N 0189001 thru 0160015436) 53 91403098 4 TAIL WASHER 54 Ref OPEN CAB ASSY, (see Figure 6-1 for details) 5 5 1 T R IM L I N E S E AT, ( n o l on g e r av a i la b l e, s e e F ig u r e 1 2 -3 4 f or d e t a il s ) ,

(S/N 0189001 thru 0160015436)

Ref SUSPENSION SEAT WITH 2 IN SEAT BELT, (see Figure 6-5 for details),

(S/N 0160015465 & After)

56 88201005 4 HEX HD CAPSCREW, 1/4-20X1, GR5 57 88561002 10 FLAT WASHER, 1/4 58 88561003 4 FLAT WASHER, 5/16, (S/N 0189001 thru 0160015436) 59 88501307 4 HEX NUT, 7/16-20, (S/N 0189001 thru 0160015436) 60 91404450 1 HINGE, 36 IN 61 91514246 2 PROP BRACKET, (13mm) 62 91474411 23 HEX HD SCREW, 8X3/4 63 91474412 2 LOCKWASHER, 5/16 64 91474413 2 NUT, 5/16 65 91474414 2 BOLT, 5/16X1-1/4 66 91404345 1 LINKAGE ROD 67 91474416 4 RIVETS, 3/16 68 91474417 1 PADDLE HANDLE GASKET 69 91404442 1 ROTARY LATCH 70 91404441 1 PADDLE HANDLE 71 80384162 6 BOLT, 3/8X1-1/2 72 80384164 6 NUT, 3/8 73 91404347 2 EXPANDED SCREEN 74 91474423 1 GAS PROP, 225# 75 8340035 2 BALL STUD, (13mm) 76 7023483 4 PROP CLIP 77 91404348 1 GAS PROP, 100# 78 91474427 1 LATCH PACKING PLATE 79 91401487 1 CAB FENDER 80 80973025 4 WHIZ-LOCK BOLT, 3/8-16X1 81 91403217 2 REBOUND WASHER 82 88501014 2 HEX NUT, 7/8-9 83 91403153 4 SHOCK MOUNT 84 91403325 2 HARDENED WASHER 85 77321274 2 HEX HD CAPSCREW, 7/8-9X5

91404001 G6-42P 1-5

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

86 83201058 4 HEX HD CAPSCREW, 3/4-10X3-3/4 87 86681572 4 HARD WASHER, 13/16 88 91403097 4 CAB ISOLATOR MOUNT 89 91033320 Ref TILT GAUGE, (Before S/N 0160005745), (no longer available, use 8466306 for

replacement)

8466306 1 TILT GAUGE, (with adhesive), (S/N 0160005745 & After) 90 88204912 1 HEX HD CAPSCREW, 1/4-20X1, GR5, (Before S/N 0160005745) 91 88561107 1 FLAT WASHER, 1/4, (Before S/N 0160005745) 92 88521204 1 HEX LOCKNUT, 1/4-20, (Before S/N 0160005745) 93 7027772 1 ADHESIVE KIT, (includes 3 tubes & applicator) 94 91411071 1 COVER SUPPORT 95 91513197 AR BULB SEAL 97 88201532 2 HEX HD CAPSCREW, 3/8-24X3/4, GR5

1001096344 1 LH MIRROR INSTALLATION, (Before S/N 0160032846),

(includes items 101 thru 111)

1001097149 Ref LH MIRROR INSTALLATION, (S/N 0160032846 & After), (no longer available,

order 1001115153 or items 102, 103, 108 & 109 for service) 101 1001096327 1 MIRROR BRACKET 102 8866530 1 MIRROR MOUNT ARM ASSY 103 8866514 1 MIRROR HEAD 104 4420060 AR DOUBLE SIDED TAPE 105 1001096728 1 BOLT, 1/2-13 106 4751800 1 WASHER, 1/2 107 4761800 1 LOCKWASHER, 1/2 108 8303799 2 HEX HD CAPSCREW, M6X1X14mm, GR8.8 109 8307024 2 LOCKWASHER, M6 110 88501008 1 HEX NUT, 1/2-13 111 91403503 1 SPACER

218 0100019 AR

LOCTITE

271

1001115153 1 LH MIRROR INSTALLATION, (includes items 301 thru 304) A 301 0700610 2 HEX HD CAPSCREW, M6X20, GR8.8 302 3140007 1 RECTANGULAR MIRROR 303 8307024 2 LOCKWASHER, M6 304 1001114675 1 MIRROR ARM 401 1001116274 1 MOLDED RESISTOR 402 NSS 1 MOUNTING BAR 403 86683480 2 BUTT CONNECTOR

K1 2915184 1 BACK-UP ALARM SERVICE KIT, (includes items 1 thru 4, 402 & 403) A

G6-42P 914040011-6

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

91404001 G6-42P 1-7

FRAME & ATTACHING PARTS

PAP19290

ENLARGED VIEW

37 38

102

104 105

103

K1 K2

34 67 68

36 66

LOWER

UPPER

LOWER

42 64

K3 K4

NOTES:

1. CYLINDER BASE END MUST BE FREE TO ROTATE. SHIM

STEERING CYLINDER BASE END AS REQUIRED TO MAINTAIN A TOTAL MAXIMUM GAP OF 1/16 IN

2. SHIM BOTTOM KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/32 IN MOVEMENT. SHIM TOP KNUCKLES TO MAINTAIN NO MORE THAN 1/16 IN GAP. MUST HAVE A MINIMUM OF ONE SHIM. 3

. INSTALL 5/8 LONG THREAD ON STUD INTO DRIVE HUB,

(SHORTEST LENGTH THREADS ON STUD)

Figure 1-2 Rear Axle & Attaching Parts

G6-42P 914040011-8

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts

Item Part Number Qty. Description Rev.

1 88521312 2 LOCKNUT, 3/4-10, (torque to 160-175 lb-ft) 2 91081415 2 DIRT SHIELD 3 91041732 2 SPACER 4 88591019 2 O-RING 5 3790226 2 O-RING 6 91343052 2 ROD END STEER CYLINDER PIN 8 1001099173 2 FLANGE NUT

9 91403082 2 TIE ROD PIN 10 88551011 4 LOCKWASHER, 3/8 11 83201021 2 HEX HD CAPSCREW, 3/8-16X3 12 88521306 2 HEX LOCKNUT, 3/8-16, (nylok) 13 91403145 8 WIPER SEAL 14 91403034 2 LOWER BUSHING 15 91403146 2 O-RING 16 3790230 2 O-RING 17 91401081 2 THRUST BUSHING 18 91406017 1 REAR AXLE WELDMENT, (includes items 14, 23, 56 & 69) 19 91403163 AR KING PIN SHIM, (see note #2)

91403164 AR KING PIN SHIM, (see note #2) 91403165 AR KING PIN SHIM, (see note #2)

91403166 AR KING PIN SHIM, (see note #2) 20 91403078 2 LOWER KING PIN 21 91403067 2 RETAINING WASHER 22 88211068 2 SOCKET HD CAPSCREW, 3/8-16X5/8, GR8 23 91403031 2 UPPER BUSHING 24 91403079 2 UPPER KING PIN 25 88581325 2 SNAP RING 26 91123092 8 STUD, (see note #3) 27 85401340 8 HARD WASHER 28 91083449 8 HEX NUT, 1/2-13 29 Ref DRIVE HUB, (see Figure 5-11 for details) 30 Use Kit K3 1 RH KNUCKLE 31 88501110 2 HEX NUT, 5/8-11 32 88212321 2 SOCKET HD CAPSCREW, 5/8-11X3-3/4, GR8 33 90028740 2 FEMALE GREASE FITTING 34 88701021 2 NIPPLE, 1/8X2 35 88501006 2 HEX NUT, 3/8-16 36 83201144 2 HEX HD CAPSCREW, 3/8-16X5-3/4 37 91403372 2 BASE END STEER CYLINDER PIN 38 88711280 2 HEX SOCKET PIPE PLUG, 1/8 39 91403065 AR KING PIN SHIM, (see note #1)

91403066 AR KING PIN SHIM, (see note #1) 40 Ref STEERING CYLINDER, (see Figure 9-6 for details) 41 91406098 1 LH TUBE SUPPORT

91406099 1 RH TUBE SUPPORT 42 0641608 4 HEX HD CAPSCREW, 3/8-16X1, GR5 43 4761600 4 LOCKWASHER, 3/8 44 88212272 2 SOCKET HD CAPSCREW, 5/8-11X8, GR8 45 88521210 2 HEX LOCKNUT, 5/8, (nylok)

91404001 G6-42P 1-9

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts (Continued)

Item Part Number Qty. Description Rev.

46 Use Kit K4 1 LH KNUCKLE 47 8050001 2 SELF-ALIGNING BUSHING, (tie rod) 48 88671001 4 STRAIGHT LUBE FITTING, 1/8 49 91406021 1 TIE ROD WELDMENT, (includes item 47) 50 86681572 12 HARDENED WASHER, 3/4 51 83201006 12 HEX HD CAPSCREW, 3/4-10X2 52 91043222 4 12 POINT SCREW, 3/4-10X2 53 88551154 2 LOCKWASHER, 3/4, (hi-collar) 54 88212285 2 SOCKET HD CAPSCREW, 3/4-10X5, GR8 55 91403145 2 WIPER SEAL 56 91403033 2 PIVOT TUBE BUSHING 58 91081177 1 REAR AXLE PIN 59 90020247 1 HEX HD CAPSCREW, 1-1/4-7X6 60 88521020 1 LOCKNUT, 1-1/4-7 61 91403174 AR SHIM, (.125 thick) 62 91403173 AR SHIM, (.109 thick) 63 91403172 AR SHIM, (.062 thick) 64 14404793 AR UNION 76 MEGAPLEX GREASE 65 4711600 4 FLAT WASHER, 3/8 67 14403303 AR LOCTITE PIPE SEALANT

277

641

68 14404102 AR

LOCTITE

69 91163019 2 BUSHING, (not shown) 102 91403354 2 BUSHING 103 91403355 1 BUSHING 104 91551039 1 BUSHING 105 14404978 AR

LOCTITE

201 14404067 AR SILICON SEALANT

K1 91415039 1 STEERING KNUCKLE KIT, (includes items 2 thru 5, 13 thru 17, 19 thru 25, 44,

45, 53 & 54)

K2 91415040 1 STEERING CYLINDER PIN KIT, (includes one each of items 1 thru 8, one kit

needed for each side) K3 91555032 AR RH KNUCKLE KIT, (includes items 8, 30 & 102 thru 105) K4 91555031 AR LH KNUCKLE KIT, (includes items 8, 46 & 102 thru 105)

G6-42P 914040011-10

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts (Continued)

Item Part Number Qty. Description Rev.

91404001 G6-42P 1-11

FRAME & ATTACHING PARTS

ROCKWELL

Figure 1-3 Front Axle Mounting

S/N 0189001 thru 0189345

G6-42P 914040011-12

S/N 0189001 thru 0189345

FRAME & ATTACHING PARTS

Figure 1-3 Front Axle Mounting

Item Part Number Qty. Description Rev.

1 Ref FRONT AXLE ASSY, (see Figure 5-1 for details) 2 91413004 1 FRONT AXLE PIVOT PIN 3 83201172 1 HEX HD CAPSCREW, 1-8X6, GR8 4 88521016 1 HEX LOCKNUT, 1-8 5 91403241 AR HARDENED WASHER

91403242 AR HARDENED WASHER 91403243 AR HARDENED WASHER

6 14404793 AR MYSTIK TETRIMOLY GREASE, (not shown)

91404001 G6-42P 1-13

FRAME & ATTACHING PARTS

CARRARO

Figure 1-3 Front Axle Mounting

S/N 0160000230 & After

G6-42P 914040011-14

S/N 0160000230 & After

FRAME & ATTACHING PARTS

Figure 1-3 Front Axle Mounting

Item Part Number Qty. Description Rev.

1 Ref FRONT AXLE ASSY, (see Figure 5-6 for details) 2 91413004 1 FRONT AXLE PIVOT PIN 3 83201036 1 HEX HD CAPSCREW, 1-8X6, GR8 4 88521016 1 HEX LOCKNUT, 1-8 5 91403241 AR HARDENED WASHER

91403242 AR HARDENED WASHER 91403243 AR HARDENED WASHER

91404001 G6-42P 1-15

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

G6-42P 914040011-16

SECTION 2

BOOM

91404001 G6-42P

BOOM

NOTE:

1. USE LOCTITE

242

(0100011) ON ALL BOLT THREADS & JAM NUTS.

2. COAT STATIC, NON ROTATING, PIN BORES WITH MOLY-PASTE (3020040). DO NOT COAT THE PIN OR ANY ROTATING PARTS.

3. COAT ALL BUSHINGS, SHEAVES & ROTATING PIN BORES WITH MYSTIK TETRIMOLY GREASE (14404793) PRIOR TO INSTALLATION OF THE PIN.

Figure 2-1 First Boom Section

G6-42P 914040012-2

BOOM

Figure 2-1 First Boom Section

Item Part Number Qty. Description Rev.

1 91406012 1 FIRST BOOM SECTION 2 Ref CHAIN CLEVIS ROD, (see Figure 2-7, item 4 for details) 3 91403061 1 STRONG BACK 4 91413139 8 SPRING WASHER, 7/8 5 91403493 2 HEAVY HEX NUT, 7/8-14, (torque to 100-110 lb-ft) 6 80973025 4 WHIZ-LOCK SCREW, 3/8-16X1 7 1001128273 1 REAR COVER 8 Ref EXTEND/RETRACT CYLINDER PIN, (see Figure 9-2 for details)

9 4712000 8 FLAT WASHER, 5/8 10 0642012 8 HEX HD CAPSCREW, 5/8-11X1-1/2, GR5, (torque to 125-155 lb-ft) 11 91403025 1 BOOM PIVOT PIN 12 Ref CHAIN CLEVIS, (see Figure 2-3, item 12 for details) 13 91401193 1 ANCHOR PLATE 14 0641810 4 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5 15 4711800 4 WASHER, 1/2 16 88501410 1 HEX JAM NUT, 5/8-18, (torque to 100-110 lb-ft) 17 Ref SECOND BOOM SECTION, (see Figure 2-3 for details) 18 88501310 1 HEX NUT, 5/8-18 19 91413138 8 SPRING WASHER, 5/8 20 91403114 2 BOOM PIVOT BUSHING 21 88671001 2 STRAIGHT LUBE FITTING, 1/8 22 Ref PUSH BEAM, (see Figure 2-7 for details) 23 88581149 2 RETAINING RING 24 0682048 1 HEX HD CAPSCREW, 5/8-11X6, GR8 25 88521010 1 HEX NUT, 5/8-11

91404001 G6-42P 2-3

BOOM

PY5310

186

112

NOTE:

1. WEAR PAD SHIMMING: A. WHENEVER A SHIM IS USED WITH A PAD, A SPACER WITH HOLES MUST BE INSERTED BETWEEN PAD & SHIM. B. THE WEAR PAD OR WEAR PAD INSERT MUST NOT SIT DIRECTLY ON THE SLOTTED SURFACE OF SHIMS. C. ADD WEAR PAD SHIMS & SPACERS AS REQUIRED TO SHIM BOOM TO MAINTAIN A TOTAL MINIMUM GAP OF

0.070 TO 0.130 IN (1.8MM TO 3.3MM) IN BOTH HORIZONTAL & VERTICAL DIRECTIONS. D. WEAR PAD BOLTS REQUIRE ONE HARDENED WASHER. HOWEVER, UPTO (2) HARDENED WASHERS MAY BE USED EXCEPT WHERE NOTED OTHERWISE. UNDER NO CIRCUMSTANCES SHOULD MORE THAN (2) HARDENED WASHERS EVER BE USED. E. THE LENGTH OF PAD BOLTS DEPENDS ON THE NUMBER OF THE SHIMS USED. THE BOLT CANNOT EXTEND PAST CHAMFER ON WEAR PAD.

2. ADD MYSTIK TETRIMOLY GREASE (14404793) TO ALL BEARING PADS & ALL BEARING PAD SLIDE PATHWAYS. IF APPLICABLE, THIS INCLUDES ALL PAD GREASE FITTINGS AT THE REAR OF BOOM.

Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section)

G6-42P 914040012-4

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