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JLG G6-42P Parts Manual

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Illustrated Parts Manual
Model
G6-42P
S/N 0189001 thru 0189345
& 0160000230 & After
91404001
Revised
March 31, 2014
An Oshkosh Corporation Company

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Summary of Contents for JLG G6-42P

  • Page 1 Illustrated Parts Manual Model G6-42P S/N 0189001 thru 0189345 & 0160000230 & After 91404001 Revised March 31, 2014 An Oshkosh Corporation Company...
  • Page 3 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 91404001 G6-42P...
  • Page 4 EFFECTIVITY PAGE G6-42P 91404001...

  • Page 5: Table Of Contents

    8 Foot Side Tilt Electric Mast ........... . 3-62 91404001 G6-42P...
  • Page 6 Joystick Assembly ............7-20 G6-42P...
  • Page 7 72 Inch 90 Degree Swing Carriage Cylinder ........9-76 91404001 G6-42P...
  • Page 8 Swing Cylinder ............. . . 12-94 G6-42P...
  • Page 9 SECTION 14 – PART NUMBER INDEX ..........14-1 91404001 G6-42P...
  • Page 10 TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. viii G6-42P 91404001...

  • Page 11: Frame & Attaching Parts

    SECTION 1 FRAME & ATTACHING PARTS 91404001 G6-42P...

  • Page 12: Frame Shrouding & Trim

    FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim PAP23330 G6-42P 91404001...
  • Page 13 FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim (Continued) SHOWN WITH WORK LIGHT BEFORE S/N 0160032846 S/N 0160032846 & AFTER FRAME MOUNT WELDMENT WALL MOUNT WELDMENT FRAME MOUNT WELDMENT LOWER UPPER MOUNT MOUNT PAP23310 91404001 G6-42P...
  • Page 14 SEAT RISER ASSY, (includes items 36 thru 39) 91406115 RISER WELDMENT, (S/N 0189001 thru 0160015436) 91516044 RISER WELDMENT, (S/N 0160015465 & After) 91401415 ACCESS COVER, (S/N 0189001 thru 0160015436) 88261015 SOCKET BUTTON HD CAPSCREW, 1/4-20X5/8 88551009 LOCKWASHER, 1/4 88201035 HEX HD CAPSCREW, 3/8-16X1, GR5 G6-42P 91404001...
  • Page 15 BALL STUD, (13mm) 7023483 PROP CLIP 91404348 GAS PROP, 100# 91474427 LATCH PACKING PLATE 91401487 CAB FENDER 80973025 WHIZ-LOCK BOLT, 3/8-16X1 91403217 REBOUND WASHER 88501014 HEX NUT, 7/8-9 91403153 SHOCK MOUNT 91403325 HARDENED WASHER 77321274 HEX HD CAPSCREW, 7/8-9X5 91404001 G6-42P...
  • Page 16 LH MIRROR INSTALLATION, (includes items 301 thru 304) 0700610 HEX HD CAPSCREW, M6X20, GR8.8 3140007 RECTANGULAR MIRROR 8307024 LOCKWASHER, M6 1001114675 MIRROR ARM 1001116274 MOLDED RESISTOR MOUNTING BAR 86683480 BUTT CONNECTOR 2915184 BACK-UP ALARM SERVICE KIT, (includes items 1 thru 4, 402 & 403) G6-42P 91404001...
  • Page 17 FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P...

  • Page 18: Rear Axle & Attaching Parts

    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. INSTALL 5/8 LONG THREAD ON STUD INTO DRIVE HUB, (SHORTEST LENGTH THREADS ON STUD) UPPER LOWER ENLARGED VIEW UPPER LOWER PAP19290 G6-42P 91404001...
  • Page 19 KING PIN SHIM, (see note #1) STEERING CYLINDER, (see Figure 9-6 for details) 91406098 LH TUBE SUPPORT 91406099 RH TUBE SUPPORT 0641608 HEX HD CAPSCREW, 3/8-16X1, GR5 4761600 LOCKWASHER, 3/8 88212272 SOCKET HD CAPSCREW, 5/8-11X8, GR8 88521210 HEX LOCKNUT, 5/8, (nylok) 91404001 G6-42P...
  • Page 20 STEERING CYLINDER PIN KIT, (includes one each of items 1 thru 8, one kit needed for each side) 91555032 RH KNUCKLE KIT, (includes items 8, 30 & 102 thru 105) 91555031 LH KNUCKLE KIT, (includes items 8, 46 & 102 thru 105) 1-10 G6-42P 91404001...
  • Page 21 FRAME & ATTACHING PARTS Figure 1-2 Rear Axle & Attaching Parts (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 1-11...

  • Page 22: Front Axle Mounting

    S/N 0189001 thru 0189345 FRAME & ATTACHING PARTS Figure 1-3 Front Axle Mounting ROCKWELL 1-12 G6-42P 91404001...
  • Page 23 FRONT AXLE ASSY, (see Figure 5-1 for details) 91413004 FRONT AXLE PIVOT PIN 83201172 HEX HD CAPSCREW, 1-8X6, GR8 88521016 HEX LOCKNUT, 1-8 91403241 HARDENED WASHER 91403242 HARDENED WASHER 91403243 HARDENED WASHER 14404793 MYSTIK TETRIMOLY GREASE, (not shown) 91404001 G6-42P 1-13...
  • Page 24 S/N 0160000230 & After FRAME & ATTACHING PARTS Figure 1-3 Front Axle Mounting CARRARO 1-14 G6-42P 91404001...
  • Page 25 Part Number Qty. Description Rev. FRONT AXLE ASSY, (see Figure 5-6 for details) 91413004 FRONT AXLE PIVOT PIN 83201036 HEX HD CAPSCREW, 1-8X6, GR8 88521016 HEX LOCKNUT, 1-8 91403241 HARDENED WASHER 91403242 HARDENED WASHER 91403243 HARDENED WASHER 91404001 G6-42P 1-15...
  • Page 26 FRAME & ATTACHING PARTS This Page Intentionally Left Blank 1-16 G6-42P 91404001...

  • Page 27: Boom

    SECTION 2 BOOM 91404001 G6-42P...
  • Page 28 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. G6-42P 91404001...

  • Page 29: First Boom Section

    SECOND BOOM SECTION, (see Figure 2-3 for details) 88501310 HEX NUT, 5/8-18 91413138 SPRING WASHER, 5/8 91403114 BOOM PIVOT BUSHING 88671001 STRAIGHT LUBE FITTING, 1/8 PUSH BEAM, (see Figure 2-7 for details) 88581149 RETAINING RING 0682048 HEX HD CAPSCREW, 5/8-11X6, GR8 88521010 HEX NUT, 5/8-11 91404001 G6-42P...

  • Page 30: Bearing Pads, Spacers & Shims, (First Boom Section)

    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. G6-42P 91404001...
  • Page 31 HEX HD CAPSCREW, 3/8-24X1-1/4, GR5, (torque to 32-37 lb-ft) 91401450 SPACER 91401456 SHIM 91401457 SHIM 91403532 WEAR PAD 0651810 HEX HD CAPSCREW, 1/2-20X1-1/4, GR5, (S/N 0160037689 & After) 0651812 HEX HD CAPSCREW, 1/2-20X1-1/2, GR5, (S/N 0160037689 & After) 88671008 STRAIGHT GREASE FITTING, (S/N 0160037689 & After) 91404001 G6-42P...
  • Page 32 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. G6-42P 91404001...

  • Page 33: Second Boom Section

    CLEVIS, 866-634, (see Figure 2-7, item 102 for details) 4761600 LOCKWASHER, 3/8 0641632 HEX HD CAPSCREW, 3/8-16X4, GR5 91403126 THRUST WASHER 91403127 THRUST WASHER 91403053 SEAL 91403519 RETRACT ROLLER ASSY, (includes items 20 & 22) 91403052 BUSHING 3580347 HOSE SHEAVE 8522012 ANTI-SEIZE LUBE 91404001 G6-42P...

  • Page 34: Bearing Pads, Spacers & Shims, (Second Boom Section)

    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. G6-42P 91404001...
  • Page 35 HEX HD CAPSCREW, 1/2-20X7/8, (S/N 0160037689 & After), (torque to 76-86 lb-ft) 0651806 HEX HD CAPSCREW, 1/2-20X3/4, (S/N 0160037689 & After), (torque to 76-86 lb-ft) 1001117654 WEAR PAD 88201563 HEX HD CAPSCREW, 1/2-20X7/8, GR5, (Before S/N 0160037689 ), (torque to 76-86 lb-ft) 91404001 G6-42P...
  • Page 36 HEX HD CAPSCREW, 3/8-24X1/2, GR5, (S/N 0160037689 & After), (torque to 32-37 lb-ft) 0651606 HEX HD CAPSCREW, 3/8-24X3/4, GR5, (S/N 0160037689 & After), (torque to 32-37 lb-ft) 0651605 HEX HD CAPSCREW, 3/8-24X5/8, GR5, (S/N 0160037689 & After), (torque to 32-37 lb-ft) 2-10 G6-42P 91404001...
  • Page 37 BOOM Figure 2-4 Bearing Pads, Spacers & Shims, (Second Boom Section) (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 2-11...

  • Page 38: Third Boom Section

    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 2-12 G6-42P 91404001...
  • Page 39 HEX HD CAPSCREW, 3/8-24X1-3/4, GR5 PUSH BEAM ASSY, (see Figure 2-7 for details) LEAF CHAIN ASSY, (see Figure 2-7 for details) 91403425 ANCHOR PIN 0641606 HEX HD CAPSCREW, 3/8-16X3/4, GR5, (torque to 25-30 lb-ft) 4761600 LOCKWASHER, 3/8 91403377 BUSHING 91404001 G6-42P 2-13...

  • Page 40: Bearing Pads, Spacers & Shims, (Third Boom Section)

    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. 2-14 G6-42P 91404001...
  • Page 41 HARDENED WASHER, 1/2 91401226 SPACER 88671027 GREASE FITTING, (S/N 0160037689 & After) 88991005 HEX HD CAPSCREW, 1/2-20X1, GR5, (S/N 0160037689 & After), (torque to 45-50 lb-ft) 91161222 MODIFIED BOLT, GR5, (S/N 0160037689 & After), (torque to 45-50 lb-ft) 91404001 G6-42P 2-15...

  • Page 42: Push/Beam Extend Chain & Roller Assembly

    ATTACHES TO THE STRONG BACK, IN FIGURE 2-1 NOTE: THE CLEVIS ROD, SEATS IN THE REAR OF THE THIRD BOOM SECTION, SHOWN IN FIGURE 2-5 PAL1111 NOTE: SEE FIGURE 2-5 FOR PUSH BEAM, CHAIN RETAINER & WEAR PADS. 2-16 G6-42P 91404001...
  • Page 43 UHMW TAPE, 13 FT 91406015 PUSH BEAM WELDMENT 91413122 ANCHOR PIN 91403432 LEAF CHAIN, 866 1360298 CLEVIS, 866-634 91413123 ANCHOR PIN 88581112 SNAP RING, 3/8 8522012 ANTI-SEIZE LUBE 91403047 BUSHING 91403119 SEAL ANCHOR PIN, (see Figure 2-5 for details) 91404001 G6-42P 2-17...

  • Page 44: Quick Switch Assembly

    Before S/N 0160037689 BOOM Figure 2-8 Quick Switch Assembly NOTE: USE LOCTITE, 14403364, ON ALL BOLT THREADS. 2-18 G6-42P 91404001...
  • Page 45 88561105 FLAT WASHER, #10 88521012 HEX LOCKNUT, 3/4-10 91403412 HEX HD CAPSCREW, 1/2-13X6 91403060 QUICK SWITCH CASTING 8310308 HARDENED WASHER, 1/2 88201067 HEX HD CAPSCREW, 1/2-13X1-1/2, GR5 91403405 PIN WELDMENT 88221276 SOCKET SET SCREW, (flat point), 1/2-13X1/2 91404001 G6-42P 2-19...
  • Page 46 S/N 0160037689 & After BOOM Figure 2-8 Quick Switch Assembly PY2050 2-20 G6-42P 91404001...
  • Page 47 HEX HD CAPSCREW, 3/4-10X5-1/2, GR8 4740003 WASHER, 1/2 0641808 HEX HD CAPSCREW, 1/2-13X1, GR5 8307916 WASHER, SHIM, (not shown) 8307917 WASHER, SHIM, (not shown) 1001098174 QUICK SWITCH COUPLER 1001098176 POPPIN PIN ASSY 1001105441 QUICK SWITCH LOCK PIN 91404001 G6-42P 2-21...
  • Page 48 BOOM This Page Intentionally Left Blank 2-22 G6-42P 91404001...

  • Page 49: Attachments

    SECTION 3 ATTACHMENTS 91404001 G6-42P...
  • Page 50 Before S/N 0160023812 ATTACHMENTS Figure 3-1 Tilt Carriage PY1950 G6-42P 91404001...
  • Page 51 48 IN CARRIAGE WELDMENT 72 IN CARRIAGE WELDMENT S/N PLATE 90200003 COLLAR 88201105 HEX HD CAPSCREW, 5/8-11X4, GR5 88521310 HEX LOCKNUT, 5/8-11, (nylok) 91401303 FORK PIN, (48 IN carriage) 91401324 FORK PIN, (72 IN carriage) FORK, (see Figure 3-16 for details) 91404001 G6-42P...
  • Page 52 S/N 0160023812 & After ATTACHMENTS Figure 3-1 Tilt Carriage PY0430 G6-42P 91404001...

  • Page 53: Tilt Carriage

    72 IN TILT CARRIAGE, (S/N 0160037689 & After), (includes all items) 0642032 HEX HD CAPSCREW, 5/8-11X4, GR5 TILT CARRIAGE 3300240 LOCKNUT, 5/8-11 3423275 50 IN FORK PIN 3423242 60 IN FORK PIN 3423276 72 IN FORK PIN 90200003 COLLAR S/N PLATE 91404001 G6-42P...

  • Page 54: Buckets

    ATTACHMENTS Figure 3-2 Buckets G6-42P 91404001...
  • Page 55 74 IN BUCKET, 1-1/4 ³ YARD, (Before S/N 0160037689) 1001100823 96 IN BUCKET, 1-1/2 ³ YARD, (S/N 0160037689 & After) 91405071 102 IN BUCKET, 1-1/4 ³ YARD, (Before S/N 0160037689) 1001100824 102 IN BUCKET, 2.0 ³ YARD, (S/N 0160037689 & After) 91404001 G6-42P...

  • Page 56: Inch & 72 Inch Slope Piler Carriage

    Before S/N 0160037689 ATTACHMENTS Figure 3-3 48 Inch & 72 Inch Slope Piler Carriage PY1760 G6-42P 91404001...
  • Page 57 SPACER 91033186 BEARING PAD 88561109 FLAT WASHER, 3/8 88201534 HEX HD CAPSCREW, 3/8-24X1, GR5 88201535 HEX HD CAPSCREW, 3/8-24X1-1/4, GR5 90204007 TUBE 88521016 HEX LOCKNUT, 1-8 05101441 WASHER, 1-1/16 88501016 HEX NUT, 1-8 88591205 O-RING 91041387 ORIFICE PLUG 91404001 G6-42P...
  • Page 58 S/N 0160037689 & After ATTACHMENTS Figure 3-4 Side Tilt Carriage PAP2971 3-10 G6-42P 91404001...

  • Page 59: Side Tilt Carriage

    HYDRAULIC CYLINDER, (see Figure 9-22 for details) 1001090140 BEARING 1001099113 1001099115 SLEEVE 1001102378 HOSE ASSY, 3/8X39 0100011 ® LOCTITE 0741610 FLAT HD SOCKET SCREW, 3/8-16X1-1/4 1001120914 BEARING RETAINER SHIM 1001120915 BEARING RETAINER PLATE 2890228 SIDE TILT CARRIAGE KIT, (includes items 30 & 31) 91404001 G6-42P 3-11...
  • Page 60 Before S/N 0160037689 ATTACHMENTS Figure 3-5 Truss Boom ENLARGED VIEW PY1920 3-12 G6-42P 91404001...
  • Page 61 10 FT TRUSS BOOM WELDMENT 15 FT TRUSS BOOM WELDMENT 88671001 STRAIGHT LUBE FITTING, 1/8 90402948 88501008 HEX NUT, 1/2-13 88201073 HEX HD CAPSCREW, 1/2-13X3, GR5 90451053 HANGER 90453041 SHACKLE 90453040 SWIVEL HOOK 91164440 SAFETY LATCH KIT ATTACHMENT S/N PLATE 91404001 G6-42P 3-13...
  • Page 62 S/N 0160037689 & After ATTACHMENTS Figure 3-5 Truss Boom PY1540 3-14 G6-42P 91404001...

  • Page 63: Truss Boom

    S/N 0160037689 & After ATTACHMENTS Figure 3-5 Truss Boom Item Part Number Qty. Description Rev. 1001099902 12 FT TRUSS BOOM, (includes all items) 1001099901 15 FT TRUSS BOOM, (includes all items) 4110422 WARNING SWINGING LOADS DECAL S/N PLATE TRUSS BOOM 91404001 G6-42P 3-15...

  • Page 64: Foot & 15 Foot Truss Boom With Winch

    Before S/N 0160037689 ATTACHMENTS Figure 3-6 10 Foot & 15 Foot Truss Boom With Winch 24 25 35 21 ENLARGED VIEW PAP2390 3-16 G6-42P 91404001...
  • Page 65 2220596 ELBOW, 90 DEGREE, (includes two of item 34) 2220726 ELBOW, 90 DEGREE 2220499 ELBOW, 45 DEGREE, (includes item 33) 88591206 O-RING 88591205 O-RING 2220373 CONNECTOR, (includes two of item 34) 91043125 DUST PLUG 91043126 DUST CAP 91404001 G6-42P 3-17...

  • Page 66: Foot Truss Boom With Winch

    S/N 0160037689 & After ATTACHMENTS Figure 3-7 12 Foot Truss Boom With Winch PAP3440 3-18 G6-42P 91404001...
  • Page 67 70021342 FEMALE QUICK COUPLER 90554076 DUST COVER 70021978 BALL SWIVEL WITH SAFETY HOOK 70021979 SOCKET ASSY, (includes items 17 & 18) COTTER PIN CLAMP 70021935 PULLEY 70022028 CABLE 4110422 WARNING SWINGING LOADS DECAL FLAT WASHER SNAP RING 91404001 G6-42P 3-19...

  • Page 68: Degree Swing Fork Assembly

    Before S/N 0160037689 ATTACHMENTS Figure 3-8 100 Degree Swing Fork Assembly RIGHT LEFT PY1940 3-20 G6-42P 91404001...
  • Page 69 91403414 MALE QUICK DISCONNECT 91043126 DUST CAP 91041356 SPACER 91413099 RELIEF VALVE 88201029 HEX HD CAPSCREW, 5/16-18X3-1/4, GR5 88551010 LOCKWASHER, 5/16 SWING CYLINDER, (see Figure 12-27 for details) 88501005 HEX NUT, 5/16-18 2220373 CONNECTOR, (includes item 38) 91404001 G6-42P 3-21...
  • Page 70 8765204 ELBOW, 90 DEGREE, (swivel nut) 91041361 MODIFIED FITTING 91411050 ORIFICE 88561002 FLAT WASHER, 1/4 91043186 DBL PILOT CHECK VALVE 84718208 HOSE ASSY 2220657 ELBOW, 45 DEGREE, (swivel nut) 71492142 24 in FLEX LOOM 86683122 TIE WRAP 3-22 G6-42P 91404001...
  • Page 71 Before S/N 0160037689 ATTACHMENTS Figure 3-8 100 Degree Swing Fork Assembly (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 3-23...

  • Page 72: Degree Swing Carriage

    S/N 0160037689 & After ATTACHMENTS Figure 3-9 90 Degree Swing Carriage PAP3360 3-24 G6-42P 91404001...
  • Page 73 8420055 DUST PLUG 8580315 PLUG 8584001 TIE WRAP 8642207 RETAINING RING 8769132 CLAMP 8770016 ADAPTER 90200003 COLLAR 91403413 FEMALE QUICK DISCONNECT 91403414 MALE QUICK DISCONNECT CARRIAGE FRAME S/N PLATE 1001110704 WARNING CRUSH HAZARD DECAL 1001111190 WARNING DECAL 91404001 G6-42P 3-25...

  • Page 74: Sheet Material Handler

    Before S/N 0160037689 ATTACHMENTS Figure 3-10 Sheet Material Handler PY1960 3-26 G6-42P 91404001...
  • Page 75 SIDE DRYWALL GUARD 88201105 HEX HD CAPSCREW, 5/8-11X4, GR5 90200003 COLLAR 88521310 HEX LOCKNUT, 5/8-11, (nylok) 91401340 FORK PIN 88241053 SOCKET FLAT HD CAPSCREW, 3/8-16X1-1/2 88551011 LOCKWASHER, 3/8 88501006 HEX NUT, 3/8-16 90553013 BOTTOM DRYWALL GUARD 91403366 DRYWALL FORK 91404001 G6-42P 3-27...
  • Page 76 S/N 0160037689 & After ATTACHMENTS Figure 3-10 Sheet Material Handler LEFT SIDE SHOWN, PY1510 RIGHT SIDE OPPOSITE 3-28 G6-42P 91404001...
  • Page 77 LH FORK SUPPORT ASSY, (includes items 101 thru 107) 7114941 LOCK BAR 8303626 HEX HD CAPSCREW, 1/2-13X1-1/2, GR5 8305644 HEX LOCKNUT, 1/2-13 8307007 LOCK WASHER, 1/2 8307112 WASHER, 1/2 1001100228 RH FORK SUPPORT, (not shown) 1001100229 LH FORK SUPPORT, (shown) S/N PLATE 91404001 G6-42P 3-29...

  • Page 78: Winch Installation

    ATTACHMENTS Figure 3-11 Winch Installation HOOK STORAGE ONLY. DO NOT USE AS LIFTING EYE. MACHINE DAMAGE OR INJURY COULD OCCUR. 9108-3535 VIEW A-A 3-30 G6-42P 91404001...
  • Page 79 HOSE ASSY 2220596 ELBOW, 90 DEGREE, (includes item 25) 91411044 WINCH HOOK STOWAGE 2753902 HOSE ASSY 2220671 ELBOW, 90 DEGREE, (includes item 26) 88591205 O-RING 88591206 O-RING 2220726 ELBOW, 90 DEGREE 2220385 SWIVEL NUT RUN TEE, 1/2, TUBE 91404001 G6-42P 3-31...

  • Page 80: Degree Drywall Swing Carriage Assembly

    Before S/N 0160037689 ATTACHMENTS Figure 3-12 100 Degree Drywall Swing Carriage Assembly RIGHT LEFT 25 17 PY0441 3-32 G6-42P 91404001...
  • Page 81 MALE QUICK DISCONNECT 91043126 DUST CAP 91041356 SPACER 91413099 RELIEF VALVE 88201029 HEX HD CAPSCREW, 5/16-18X3-1/4, GR5 88501005 HEX NUT, 5/16-18 SWING CYLINDER, (see Figure 12-27 for details) 88241053 SOCKET FLAT HD CAPSCREW, 3/8-16X1-1/2 90553013 BOTTOM DRYWALL GUARD 91404001 G6-42P 3-33...
  • Page 82 ELBOW, 90 DEGREE, (swivel nut) 91041361 MODIFIED FITTING 91411050 ORIFICE 84719760 HOSE ASSY 91043186 DBL PILOT CHECK VALVE 88561002 FLAT WASHER, 1/4 IN 84718208 HOSE ASSY 2220657 ELBOW, 45 DEGREE, (swivel nut) 71492142 24 in FLEX LOOM 86683122 TIE WRAP 3-34 G6-42P 91404001...
  • Page 83 Before S/N 0160037689 ATTACHMENTS Figure 3-12 100 Degree Drywall Swing Carriage Assembly (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 3-35...

  • Page 84: Personnel Platform

    BEFORE OCCUPYING PERSONNEL WORK PLATFORM. FAILURE TO COMPLY COULD RESULT IN FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH. SERIOUS INJURY OR DEATH. 9055-3026 REV. A 9055-3031 REV. A ATTACH LANYARD HERE 9055-3032 VIEW A-A PAP18600 3-36 G6-42P 91404001...
  • Page 85 CHAIN 0682012 HEX HD CAPSCREW, 5/8-11X1-1/2 4762000 LOCKWASHER, 5/8 91403230 MANUAL HOLDER 8310382 WHIZ-LOCKNUT, 1/4-20 31200160 PERSONNEL WORK PLATFORM MANUAL 1702773 JLG DECAL 1706893 WARNING DECAL 1706892 WARNING DECAL 1704277 LANYARD DECAL 1701509 MANUAL DECAL S/N PLATE 4846265 GATE 3539685...

  • Page 86: Fork Mounted Platform

    ATTACHMENTS Figure 3-14 Fork Mounted Platform BEFORE S/N 2009005-1 S/N 2009005-1 & AFTER PY6770 3-38 G6-42P 91404001...
  • Page 87 (no longer available, order 1001103736 for replacement or items 1 thru 8 for service) 1001103736 FORK MOUNTED PLATFORM, (S/N 2009005-1 & After), (ASME - FRENCH), (includes items 1 thru 8) 1702773 JLG DECAL 1704885 WEBSITE DECAL 1706892 PLATFORM WARNING DECAL, (ASME) 1001096025...
  • Page 88 LYNCH PIN 3/16 WITH LANYARD 1701509 MANUAL DECAL 1704277 LANYARD ATTACH DECAL 0641405 HEX HD CAPSCREW, 1/4-20X5/8 1060379 6 IN LANYARD CABLE 2080040 FASTENER 3311405 HEX NUT, 1/4-20 3421453 3760170 RING 4711400 WASHER, 1/4 1001102813 HITCH PIN 3-40 G6-42P 91404001...
  • Page 89 ATTACHMENTS Figure 3-14 Fork Mounted Platform (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 3-41...

  • Page 90: Degree Swing Carriage With Side Tilt

    Before S/N 0160037689 ATTACHMENTS Figure 3-15 100 Degree Swing Carriage With Side Tilt VIEW C-C VIEW F-F VIEW B-B PAP18810 3-42 G6-42P 91404001...
  • Page 91 Before S/N 0160037689 ATTACHMENTS Figure 3-15 100 Degree Swing Carriage With Side Tilt (Continued) SOLENOID VALVE BANK .094 HYD. LINES SIDE SHIFT CYLINDER RELIEF VALVE .060 .060 DUAL COUNTER- BALANCE VALVE VIEW A-A HYDRAULIC SCHEMATIC VIEW E-E 91404001 G6-42P 3-43...
  • Page 92 HEX HD CAPSCREW, 5/16-18X3-1/4, GR5 88501005 HEX NUT, 5/16-18 88551010 LOCKWASHER, 5/16 91406072 MAST WELDMENT 91416018 SWING FORK PIVOT WELDMENT 91406069 LH PIN SUPPORT WELDMENT 91406070 RH PIN SUPPORT WELDMENT 91401266 SWING CYLINDER, (see Figure 12-39 for details) 91041322 LOCKING PLATE 3-44 G6-42P 91404001...
  • Page 93 MODIFIED FITTING 90204097 HOSE ASSY 77133053 CLAMP SET 91041362 ORIFICE FITTING 8765204 ELBOW, 90 DEGREE, SWIVEL NUT 91411050 ORIFICE 86521144 SUPPORT CLAMP 77143006 WHIZ-LOCKNUT, 5/16-18 3780140 O-RING 3780177 O-RING 91403415 ELBOW, 90 DEGREE, SWIVEL NUT 91034377 SCREW 91404001 G6-42P 3-45...

  • Page 94: Forks

    ATTACHMENTS Figure 3-16 Forks 3-46 G6-42P 91404001...
  • Page 95 DECREASES CAPACITY OF THE ATTACHMENT OR MACHINE TO THAT OF THE FORKS. FORKS RATED MORE THAN THE ATTACHMENT OR MACHINE’S CAPACITY DO NOT INCREASE ATTACHMENT OR MACHINE’S CAPACITY. Note PLEASE CONSULT JLG PARTS DEPARTMENT TO DETERMINE THE CORRECT FORKS APPLICABLE TO YOUR SPECIFIC CARRIAGE ASSEMBLY & APPLICATION. 91404001 G6-42P...

  • Page 96: Fork Mounted Lifting Hook

    Before S/N 2005134-01 ATTACHMENTS Figure 3-17 Fork Mounted Lifting Hook NOTE: PALLET/LUMBER FORKS OF AN APPROPRIATE LOAD RATING MUST BE USED 3-48 G6-42P 91404001...
  • Page 97 90553036 FORK MOUNTED LIFTING HOOK ASSY, (no longer available, use 91565094 for replacement or use items 1 thru 6 for service) S/N ATTACHMENT PLATE 88341022 DRIVE SCREW, 3/8 90554078 HAIRPIN CLIP 90554079 CLEVIS CONNECTOR 90554080 HOOK 90554081 91404001 G6-42P 3-49...
  • Page 98 S/N 2005134-01 & After ATTACHMENTS Figure 3-17 Fork Mounted Lifting Hook NOTE: PAP23210 PALLET/LUMBER FORKS OF AN APPROPRIATE LOAD RATING MUST BE USED. 3-50 G6-42P 91404001...
  • Page 99 Figure 3-17 Fork Mounted Lifting Hook Item Part Number Qty. Description Rev. 91565094 FORK MOUNTED LIFTING HOOK, (includes all items) 7029520 HAIRPIN CLIP 1001093171 70020555 SPRING BUSHING 90554080 SLING HOOK 7029521 CHAIN SHACKLE, 12,000LB LIFTING HOOK S/N PLATE 91404001 G6-42P 3-51...

  • Page 100: Grapple Bucket

    S/N 0160037689 & After ATTACHMENTS Figure 3-18 Grapple Bucket PAP18660 3-52 G6-42P 91404001...
  • Page 101 ELBOW, 90 DEGREE 7029692 MALE QUICK COUPLER 90554062 DUST COVER 70021342 FEMALE QUICK COUPLER 90554076 DUST COVER 90554016 MADE IN USA DECAL S/N PLATE 90554017 DANGER PINCH POINT DECAL 90554018 WARNING HIGH PRESSURE DECAL 70021387 HOSE CLAMP 91404001 G6-42P 3-53...

  • Page 102: Fork Pin Lock Installation

    ATTACHMENTS Figure 3-19 Fork Pin Lock Installation PY1650 3-54 G6-42P 91404001...
  • Page 103 Figure 3-19 Fork Pin Lock Installation Item Part Number Qty. Description Rev. 1001093465 FORK PIN LOCK INSTALLATION, (includes all items) 0240156 LH FORK PIN LOCK 1001093273 RH FORK PIN LOCK 1001093377 HITCH PIN 1001094830 CLAMP 1001094330 LANYARD 91404001 G6-42P 3-55...

  • Page 104: Foot Mast With 48 Inch & 72 Inch Carriage

    Before S/N 0160037689 ATTACHMENTS Figure 3-20 6 Foot Mast With 48 Inch & 72 Inch Carriage PAP3780 VIEW A-A 3-56 G6-42P 91404001...
  • Page 105 ADAPTER 91043126 DUST CAP 24431386 CLAMP 88201037 HEX HD SCREW, 3/8-16 88561004 FLAT WASHER 91034377 SCREW 1001094695 ADAPTER GUSSET 88501006 HEX NUT, 3/8-16 88551011 LOCKWASHER, 3/8 S/N PLATE STOP TUBE 91403339 6 FT MAST 91034374 LOAD ROLLER 91404001 G6-42P 3-57...

  • Page 106: Foot Standard Mast

    S/N 0160037689 & After ATTACHMENTS Figure 3-21 8 Foot Standard Mast PAP11330 3-58 G6-42P 91404001...
  • Page 107 S/N 0160037689 & After ATTACHMENTS Figure 3-21 8 Foot Standard Mast (Continued) 48 55 44 51 PAP3740 91404001 G6-42P 3-59...
  • Page 108 FLAT HD CAPSCREW 70022994 CHAIN ANCHOR PIN 70022992 COTTER PIN 70022985 SHEAVE SHAFT 70023009 LIFT CHAIN 70022932 P.O. CHECK VALVE ASSY, (includes items 45 thru 47) MANIFOLD 70022931 P.O. CHECK VALVE CARTRIDGE 70023010 P.O. CHECK 70022934 FITTING, 90 DEGREE 3-60 G6-42P 91404001...
  • Page 109 SEAL KIT, MAIN LIFT CYLINDER, (includes items 8, 9, 13, 14, 16, 17, 19, 21, 23, 24 & 25) 70023006 CHECK VALVE KIT, (includes items 18, 19, 20, 21 & 23) 70023007 SHIM KIT 70023015 MAST COMMON PARTS KIT, (includes items 27 thru 41) 91404001 G6-42P 3-61...

  • Page 110: Foot Side Tilt Electric Mast

    S/N 0160037689 & After ATTACHMENTS Figure 3-22 8 Foot Side Tilt Electric Mast PAP11320 3-62 G6-42P 91404001...
  • Page 111 S/N 0160037689 & After ATTACHMENTS Figure 3-22 8 Foot Side Tilt Electric Mast (Continued) PAP3720 91404001 G6-42P 3-63...
  • Page 112 70022994 CHAIN ANCHOR PIN 70022992 COTTER PIN 70022985 SHEAVE SHAFT 70023009 LIFT CHAIN 70022932 P.O. CHECK VALVE ASSY, (includes items 45, 46 & 47) MANIFOLD 70022931 P.O. CHECK VALVE CARTRIDGE 70023010 P.O. CHECK 70022933 SOLENOID VALVE BANK 3-64 G6-42P 91404001...
  • Page 113 FORK PIN KEEPER 70022949 LOCKWASHER, M10 70022991 STRAIGHT THREAD ELBOW, 90 DEGREE 70022998 CAPSCREW, M10X20 70022966 GREASE FITTING 70022979 HOSE ASSY 70022990 FORK PIN 70022965 SHEAVE 70022997 LOCKWASHER, M12 70022967 HOSE CLAMP 70022962 BAR ASSY 70023002 CAPSCREW, M6X25 91404001 G6-42P 3-65...
  • Page 114 CHECK VALVE KIT, (includes items 18, 19, 20, 21 & 23) 70023007 SHIM KIT 70023015 MAST COMMON PARTS KIT, (includes items 27 thru 41) 8035831 SEAL KIT, TILT CYLINDER 70023013 IHR COMMON PARTS KIT, (includes items 93 thru 109) 70022986 IHR KIT, (includes items 93 thru 110) 3-66 G6-42P 91404001...
  • Page 115 S/N 0160037689 & After ATTACHMENTS Figure 3-22 8 Foot Side Tilt Electric Mast (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 3-67...
  • Page 116 ATTACHMENTS This Page Intentionally Left Blank 3-68 G6-42P 91404001...
  • Page 117 SECTION 4 ENGINE & ATTACHING PARTS 91404001 G6-42P...
  • Page 118 FUL SOL PS IGN OIL PRESSURE SWITCH WIRING TORQUE TO 27-37 LB-FT CLT TMP FUL SOL OIL GAG TO CAB NOTES: PAP23380 ® 1. USE LOCTITE (14403364) ON ALL BOLT THREADS ® 2. USE LOCTITE (14404043) ON ALL FITTINGS. G6-42P 91404001...
  • Page 119 83191032 HEX HD CAPSCREW, M12X1-3/4X35, (torque to 66-76 lb-ft) 83191010 LOCKWASHER, M12 91401227 ACCELERATOR CABLE BRACKET, (S/N 0189001 thru 0160001379) 91411060 ACCELERATOR CABLE BRACKET, (S/N 0160001388 thru 0160001775) 83191038 HEX HD CAPSCREW, M10X1-1/2X20 91403293 HEX HD CAPSCREW, M14X2X25 91404001 G6-42P...
  • Page 120 FLAT WASHER, M10 14403364 LOCTITE ® 14404043 LOCTITE ® 91473222 EXHAUST GASKET 91405102 ENGINE FILTER KIT, (includes all items) 91404005 OIL FILTER ELEMENT 91404004 FUEL FILTER 91403103 AIR FILTER SAFETY ELEMENT 91403102 AIR FILTER ELEMENT 91083218 FUEL STRAINER G6-42P 91404001...
  • Page 121 S/N 0189001 thru 0189345 & 0160000230 thru 0160001775 ENGINE & ATTACHING PARTS Figure 4-1 Engine Assembly, LH View (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P...
  • Page 122 Figure 4-1 Engine Assembly, LH View HR MTR FUL SOL PS IGN OIL PRESSURE SWITCH WIRING TORQUE TO 27-37 LB-FT NOTES: PAP23370 ® 1. USE LOCTITE , 14403364, ON ALL BOLT THREADS. ® 2. USE LOCTITE , 14404043, ON ALL FITTINGS. G6-42P 91404001...
  • Page 123 83191032 HEX HD CAPSCREW, M12X1-3/4X35, (torque to 66-76 lb-ft) 83191010 LOCKWASHER, M12 91411060 ACCELERATOR CABLE BRACKET 83191038 HEX HD CAPSCREW, M10X1-1/2X20 91403293 HEX HD CAPSCREW, M14X2X25 83191014 LOCKWASHER, M14 91143315 OIL PRESSURE SENDER 91406026 LH FRONT ENGINE MOUNT 91404001 G6-42P...
  • Page 124 91143172 TEST COUPLING 14403364 ® LOCTITE 14404043 ® LOCTITE 91473222 EXHAUST GASKET 91415035 ENGINE FILTER KIT, (includes all items) 91404005 OIL FILTER ELEMENT 91404004 FUEL FILTER 80273042 AIR FILTER SAFETY ELEMENT 80273010 AIR FILTER ELEMENT 91083218 FUEL STRAINER G6-42P 91404001...
  • Page 125 S/N 0160001921 thru 0160003058 excluding 0160002657 ENGINE & ATTACHING PARTS Figure 4-1 Engine Assembly, LH View (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P...
  • Page 126 APPLY LOC-TITE SUPERFLEX 587 ULTRA BLUE SILICON, (14404067), 1/8 CONTINUOUS BEAD. SECTION VIEW OF PUMP MOUNT & COUPLING VIEW A-A PAP23250 NOTE: ® USE LOCTITE 14403364, ON ALL BOLT THREADS. ® 2. USE LOCTITE 14404043, ON ALL FITTINGS. 4-10 G6-42P 91404001...
  • Page 127 91163011 PUMP MOUNT & COUPLING 2220472 ELBOW, 90 DEGREE HYDRAULIC PUMP, (see Figure 9-9 for details) 88201066 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5, (torque to 68-78 lb-ft) 90027471 HARDENED WASHER 91053020 MINI-CHECK, (includes item 65) 91403454 HYDRAULIC TUBE 91404001 G6-42P 4-11...
  • Page 128 OIL FILTER ELEMENT 91404004 FUEL FILTER 1101313 AIR FILTER SAFETY ELEMENT 1101312 AIR FILTER ELEMENT 91083218 FUEL STRAINER 91534006 OIL FILTER SEAL 2915179 1000 HOUR FILTER KIT, (includes 91415084 & the following) 1001093626 HYDRAULIC RETURN 1340021 HYDRAULIC BREATHER 4-12 G6-42P 91404001...
  • Page 129 S/N 0160003213 & After including 0160002657 ENGINE & ATTACHING PARTS Figure 4-1 Engine Assembly, LH View (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-13...
  • Page 130 SECTION A-A ENGINE REMOVED FOR CLARITY SEE FIGURE 4-1 FOR DETAILS TUBES NOT SHOWN FOR CLARITY PY3580 NOTES: ® 1. USE LOCTITE , 14403364, ON ALL BOLT THREADS ® 2. USE LOCTITE , 14404043, ON ALL FITTINGS. 4-14 G6-42P 91404001...
  • Page 131 HARDENED WASHER, 3/4 91163011 PUMP MOUNT & COUPLING 83191006 HEX HD CAPSCREW, M10X1-1/2X40, (torque to 38-48 lb-ft) 83191013 LOCKWASHER, M10 77133089 MINI-CHECK, (includes item 45) 83763056 VITON O-RING, (lubricate lightly) 91403523 SPECIAL FITTING 2220497 STRAIGHT THREAD CONNECTOR 91404001 G6-42P 4-15...
  • Page 132 ELBOW, 90 DEGREE, (swivel nut) 91163098 TUBE ASSY 88201065 HEX HD CAPSCREW, 1/2-13X1, GR5 88551013 LOCKWASHER, 1/2 88561006 FLAT WASHER, 1/2 24431386 SUPPORT CLAMP 88551009 LOCKWASHER, 1/4 88201003 HEX HD CAPSCREW, 1/4-20X3/4, GR5 14403364 LOCTITE ® 14404043 LOCTITE ® 4-16 G6-42P 91404001...
  • Page 133 S/N 0189001 thru 0189345 & 0160000230 thru 0160001775 ENGINE & ATTACHING PARTS Figure 4-2 Engine Assembly, RH View (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-17...
  • Page 134 VIEW OF TRACTION LOCK VALVE WITH ENGINE REMOVED FOR CLARITY SEE FIGURE 4-1 FOR DETAILS TUBES NOT SHOWN FOR CLARITY SECTION A-A NOTES: PAP23480 ® 1. USE LOCTITE (14403364) ON ALL BOLT THREADS ® 2. USE LOCTITE (14404043) ON ALL FITTINGS. 4-18 G6-42P 91404001...
  • Page 135 HARDENED WASHER, 3/4 91163011 PUMP MOUNT & COUPLING 83191006 HEX HD CAPSCREW, M10X1-1/2X40, (torque to 38-48 lb-ft) 83191013 LOCKWASHER, M10 77133089 MINI-CHECK, (includes item 45) 83763056 VITON O-RING, (lubricate lightly) 91403523 SPECIAL FITTING 2220497 STRAIGHT THREAD CONNECTOR 91404001 G6-42P 4-19...
  • Page 136 ELBOW, 90 DEGREE, (swivel nut) 91163098 TUBE ASSY 88201065 HEX HD CAPSCREW, 1/2-13X1, GR5 88551013 LOCKWASHER, 1/2 88561006 FLAT WASHER, 1/2 24431386 SUPPORT CLAMP 88551009 LOCKWASHER, 1/4 88201003 HEX HD CAPSCREW, 1/4-20X3/4, GR5 14403364 LOCTITE ® 14404043 LOCTITE ® 4-20 G6-42P 91404001...
  • Page 137 S/N 0160001921 thru 0160003058 excluding 0160002657 ENGINE & ATTACHING PARTS Figure 4-2 Engine Assembly, RH View (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-21...
  • Page 138 STRT-SOL GND-9 GND-12 TO '85' TERMINAL GND-13 CAB GND START-B STRT-SOL TO '86' TERMINAL TO '30' TERMINAL NOTES: ® 1. USE LOCTITE , 14403364, ON ALL BOLT THREADS ® 2. USE LOCTITE , 14404043, ON ALL FITTINGS. 4-22 G6-42P 91404001...
  • Page 139 HYDROSTATIC TRANSMISSION, (see Figure 9-8 for details) 88662070 ELBOW, 90 DEGREE, (includes item 36) 88591210 O-RING 2131216 ELBOW, 90 DEGREE, (includes item 38) 88591209 O-RING 2220671 ELBOW, 90 DEGREE, (includes item 40) 88591206 O-RING 91413005 HYDRAULIC TUBE 91403556 HYDRAULIC TUBE 88551012 LOCKWASHER, 7/16 91404001 G6-42P 4-23...
  • Page 140 80373025 PUSH LOCK FITTING 0791506 WHIZ-LOCK SCREW, 5/16-18X3/4 2750532 114 in FUEL LINE, 3/8 I.D. 2720058 100 in FUEL LINE, 5/16 I.D. 5251016 HEX FLANGE SCREW, 10-15X40mm 3291201 HEX NUT, 12mm-1-3/4 14403364 ® LOCTITE 14404043 LOCTITE ® 4-24 G6-42P 91404001...
  • Page 141 S/N 0160003213 & After including 0160002657 ENGINE & ATTACHING PARTS Figure 4-2 Engine Assembly, RH View (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-25...
  • Page 142 S/N 0189001 thru 0189345 & 0160000230 thru 0160003058 ENGINE & ATTACHING PARTS excluding 0160002657 Figure 4-3 John Deere Engine 4-26 G6-42P 91404001...
  • Page 143 PLUG, VALVE COVER 91404257 GASKET, VALVE COVER 91404258 FILLER CAP, VALVE COVER 91404259 O-RING, VALVE COVER 91404260 COOLANT, PRE-MIX, (2.5 gal) 91404261 COOLANT CONDITIONER 91404262 FUEL TRANSFER PUMP 91404263 THERMOSTAT 91404264 THERMOSTAT COVER SEAL 91474629 ALTERNATOR BRACKET 91404001 G6-42P 4-27...
  • Page 144 S/N 0189001 thru 0189345 & 0160000230 thru 0160003058 ENGINE & ATTACHING PARTS excluding 0160002657 Figure 4-3 John Deere Engine (Continued) Item Part Number Qty. Description Rev. 91474630 ALTERNATOR SUPPORT 91474631 ALTERNATOR STRAP 4-28 G6-42P 91404001...
  • Page 145 S/N 0189001 thru 0189345 & 0160000230 thru 0160003058 ENGINE & ATTACHING PARTS excluding 0160002657 Figure 4-3 John Deere Engine (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-29...
  • Page 146 S/N 0160003213 thru 0160006643 including 0160002657 ENGINE & ATTACHING PARTS excluding 0160006494 & 0160006543 Figure 4-3 John Deere Engine 4-30 G6-42P 91404001...
  • Page 147 91404265 GASKET, TURBOCHARGER 91534005 OIL FILTER 80374036 GASKET, OIL FILTER 91474506 DRAIN PLUG, OIL FILTER HEAD, (includes o-ring) 80374020 O-RING, DRAIN PLUG 91404221 BOLT, BELT TENSIONER 91404222 SCREW, BELT TENSIONER 91404223 SHEAVE, BELT TENSIONER 91474629 ALTERNATOR BRACKET 91404001 G6-42P 4-31...
  • Page 148 S/N 0160003213 thru 0160006643 including 0160002657 ENGINE & ATTACHING PARTS excluding 0160006494 & 0160006543 Figure 4-3 John Deere Engine (Continued) Item Part Number Qty. Description Rev. 91474630 ALTERNATOR SUPPORT 91474631 ALTERNATOR STRAP 4-32 G6-42P 91404001...
  • Page 149 S/N 0160003213 thru 0160006643 including 0160002657 ENGINE & ATTACHING PARTS excluding 0160006494 & 0160006543 Figure 4-3 John Deere Engine (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-33...
  • Page 150 S/N 0160006706 & After including 0160006494 & 0160006543 ENGINE & ATTACHING PARTS Figure 4-3 John Deere Engine 4-34 G6-42P 91404001...
  • Page 151 GASKET, TURBOCHARGER 91404265 GASKET, TURBOCHARGER 91534005 OIL FILTER 80374036 GASKET, OIL FILTER 91474506 DRAIN PLUG, OIL FILTER HEAD, (includes o-ring) 80374020 O-RING, DRAIN PLUG 91404221 BOLT, BELT TENSIONER 91404222 SCREW, BELT TENSIONER 91404223 SHEAVE, BELT TENSIONER 7026921 STARTER 91404001 G6-42P 4-35...
  • Page 152 S/N 0160006706 & After including 0160006494 & 0160006543 ENGINE & ATTACHING PARTS Figure 4-3 John Deere Engine (Continued) Item Part Number Qty. Description Rev. 91474629 ALTERNATOR BRACKET 91474630 ALTERNATOR SUPPORT 91474631 ALTERNATOR STRAP 4-36 G6-42P 91404001...
  • Page 153 S/N 0160006706 & After including 0160006494 & 0160006543 ENGINE & ATTACHING PARTS Figure 4-3 John Deere Engine (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 4-37...
  • Page 154 Before S/N 0160020156 ENGINE & ATTACHING PARTS Figure 4-4 Fuel Tank & Lines RETURN LINE, SUCTION LINE, (FROM LH SIDE (TO RH SIDE OF OF ENGINE) ENGINE) PAP23340 4-38 G6-42P 91404001...
  • Page 155 88711283 HEX SOCKET PIPE PLUG, 1/2 1001113251 ELBOW, 90 DEGREE 88201035 HEX HD CAPSCREW, 3/8-16X1, GR5 91416014 FUEL TANK STRAP WELDMENT 91403437 FUEL GAUGE HARNESS 91404068 PICK-UP TUBE, 6 IN 86883106 HOSE CLAMP 3960616 GASKET, FILLER NECK 91404001 G6-42P 4-39...
  • Page 156 FOR 3 TO 4 MINUTES ON BOTH MATING PARTS. 2. APPLY 1/2 IN. ALL THE WAY AROUND THE FILLER NECK THREADS. APPLY THE ADAPTER TO THE FILLER NECK ON THE TANK. 3. ONCE ASSEMBLED, NO FUEL SHOULD BE ADDED FOR 8 HOURS. PAP23400 4-40 G6-42P 91404001...
  • Page 157 FUEL TANK STRAP, (not shown) 88201036 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 88561004 FLAT WASHER, 3/8 88551011 LOCKWASHER, 3/8 88201035 HEX HD CAPSCREW, 3/8-16X1, GR5, (not shown) FUEL LINE, (see Figure 4-1 for details) FUEL LINE, (see Figure 4-1 for details) 91404001 G6-42P 4-41...
  • Page 158 S/N 0189001 thru 0189345 & 0160000230 thru 0160003058 ENGINE & ATTACHING PARTS excluding 0160002657 Figure 4-5 Radiator Assembly 4-42 G6-42P 91404001...
  • Page 159 91401322 RADIATOR SUPPORT BRACKET, (S/N 0189001 thru 0160001448) 91471108 RADIATOR SUPPORT BRACKET, (S/N 0160001470 thru 0160003058) 88201036 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 88561004 FLAT WASHER, 3/8 90027470 HARDENED WASHER, 3/8 88551011 LOCKWASHER, 3/8 88501006 HEX NUT, 3/8-16 91404001 G6-42P 4-43...
  • Page 160 S/N 0160003213 & After including 0160002657 ENGINE & ATTACHING PARTS Figure 4-5 Radiator Assembly 4-44 G6-42P 91404001...
  • Page 161 FLAT WASHER, 5/16 83683308 SHOCK MOUNT 90205918 SPECIAL WASHER 88521206 HEX LOCKNUT, 3/8-16 91471108 RADIATOR SUPPORT BRACKET 88201036 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 88561004 FLAT WASHER, 3/8 90027470 HARDENED WASHER, 3/8 88551011 LOCKWASHER, 3/8 88501006 HEX NUT, 3/8-16 91404001 G6-42P 4-45...
  • Page 162 S/N 0189001 thru 0189345 & 0160000230 thru 0160001775 ENGINE & ATTACHING PARTS Figure 4-6 Air Cleaner & Installation 4-46 G6-42P 91404001...
  • Page 163 HEX LOCKNUT, 5/16-18 91413096 AIR INTAKE ELBOW 90028488 BAND CLAMP 91083128 RUBBER ELBOW, 90 DEGREE 91403471 AIR INTAKE TUBE 91403515 AIR INTAKE TUBE 24921332 MUFFLER CLAMP 91403512 AIR INTAKE HOOD, (includes clamp) 91403244 STRAIGHT HUMP 91403125 AIR INTAKE TUBE 91404001 G6-42P 4-47...
  • Page 164 S/N 0160001921 thru 0160003058 excluding 0160002657 ENGINE & ATTACHING PARTS Figure 4-6 Air Cleaner & Installation PAP21950 4-48 G6-42P 91404001...
  • Page 165 FLAT WASHER, 3/8 88551011 LOCKWASHER, 3/8 88201033 HEX HD CAPSCREW, 3/8-16X3/4, GR5 24921332 MUFFLER CLAMP 91163129 BAND CLAMP 91403244 STRAIGHT HUMP 91473102 AIR INTAKE TUBE 90028488 HOSE CLAMP 91403240 RUBBER ELBOW 77143006 WHIZ-LOCKNUT, 5/16-18 91163137 BAND CLAMP 91404001 G6-42P 4-49...
  • Page 166 S/N 0160003213 & After including 0160002657 ENGINE & ATTACHING PARTS Figure 4-6 Air Cleaner & Installation PY4070 4-50 G6-42P 91404001...
  • Page 167 LOCKWASHER, 3/8 0641606 HEX HD CAPSCREW, 3/8-16X3/4, GR5 24921332 CLAMP 91403244 STRAIGHT HUMP 91473103 AIR INTAKE TUBE 91083126 AIR INTAKE ELBOW 77383790 BAND CLAMP 88561108 FLAT WASHER, 5/16 77143006 WHIZ-LOCKNUT, 5/16-18 91163137 BAND CLAMP 0100011 ® LOCTITE 91404001 G6-42P 4-51...
  • Page 168 S/N 0189001 thru 0189345 & 0160000230 thru 0160003058 ENGINE & ATTACHING PARTS excluding 0160002657 Figure 4-7 Exhaust Installation 4-52 G6-42P 91404001...
  • Page 169 Qty. Description Rev. 91403484 EXHAUST ELBOW 88201038 HEX HD CAPSCREW, 3/8-16X1-3/4, GR5 88551011 LOCKWASHER, 3/8 88501006 HEX NUT, 3/8-16 83683175 MUFFLER CLAMP 91413031 FLEXIBLE TUBING 91163268 FLEXIBLE TUBE CLAMP 91403510 EXHAUST TUBE 91083250 MUFFLER 91403488 TAIL PIPE 91404001 G6-42P 4-53...
  • Page 170 S/N 0160003213 & After including 0160002657 ENGINE & ATTACHING PARTS Figure 4-7 Exhaust Installation 4-54 G6-42P 91404001...
  • Page 171 ENGINE & ATTACHING PARTS Figure 4-7 Exhaust Installation Item Part Number Qty. Description Rev. 91403485 EXHAUST TUBE 91403216 V-BAND CLAMP 24921332 MUFFLER CLAMP 91403601 FLEXIBLE TUBE CLAMP 91413030 FLEXIBLE TUBING 91403511 EXHAUST TUBE 91163035 MUFFLER 91403489 TAIL PIPE 91404001 G6-42P 4-55...
  • Page 172 ENGINE & ATTACHING PARTS This Page Intentionally Left Blank 4-56 G6-42P 91404001...
  • Page 173 SECTION 5 DRIVE TRAIN 91404001 G6-42P...
  • Page 174 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-1 Front Axle Assembly - Rockwell G6-42P 91404001...
  • Page 175 ELBOW, 90 DEGREE, (swivel nut) HYDRAULIC MOTOR, (see Figure 9-10 for details) 90027473 HARDENED WASHER 77383580 HIGH NUT 88201616 HEX HD CAPSCREW, 3/4-16X3-1/2, GR5 91413002 BRAKE TUBE, (park) 84719217 HOSE ASSY 91413003 BRAKE TUBE, (service) 84719218 HOSE ASSY 91404001 G6-42P...
  • Page 176 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-2 Front Axle - Rockwell G6-42P 91404001...
  • Page 177 CENTER HOUSING ASSY, (includes item 9) BRAKE ASSY, (see Figure 5-4 for details) CARRIER ASSY, (see Figure 5-3 for details) 91144327 DRAIN PLUG 91144328 VENT PLUG 91144329 LUBE FITTING 91084046 BUSHING 91084047 TRUNNION OIL SEAL 91141511 COVER 88711284 LEVEL PLUG 91144332 CAPSCREW, M8X1-1/4X16 91404001 G6-42P...
  • Page 178 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-3 Carrier Assembly - Rockwell 17 18 28 27 26 25 36 35 PAP23880 G6-42P 91404001...
  • Page 179 SHIM, (1.45), (included in shim kit) Use Kit K3 SHIM, (1.50), (included in shim kit) 91144401 BEARING CONE 91144402 BEARING CUP 91144403 MOTOR ADAPTER FLANGE 83483584 WASHER 91144404 CAPSCREW, 3/8-16UNC-2AX1-1/4 91144405 DRIVEN SLEEVE 91144406 PINION NUT, M24X1-1/2 91144407 DRIVE SLEEVE 91144408 SNAP RING 91404001 G6-42P...
  • Page 180 91144382 LIMITED SLIP PLATE STACK KIT, (includes items 10, 11, 12, 13 & 14) 91144383 PINION CAGE SHIM KIT, (includes item 23) 91144384 DRIVE PINION SHIM KIT, (includes item 27) 91144385 LIMITED SLIP SHIM KIT, (includes item 12) G6-42P 91404001...
  • Page 181 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-3 Carrier Assembly - Rockwell (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P...
  • Page 182 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-4 Brake Assembly - Rockwell PAP23750 5-10 G6-42P 91404001...
  • Page 183 BRAKE SEAL KIT, (includes items 6, 7 & 14) 91144369 BRAKE PISTON PLATE KIT, (includes items 15 thru 18) 91144370 BRAKE PLATE & SEAL KIT, (includes items 6, 7 & 14 thru 18) 91144371 PISTON BRAKE SHIM KIT, (includes item 8) 91404001 G6-42P 5-11...
  • Page 184 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-5 Left & Right Housing & Axle & Wheel Flange Assemblies - Rockwell 5-12 G6-42P 91404001...
  • Page 185 PLANETARY PINION SHAFT 91144361 WASHER 91144362 SNAP RING 91144363 PLANETARY PINION 91144364 SUN GEAR, 287mm, (right side), (shown) 91144365 SUN GEAR, 247mm, (left side), (not shown) 91144366 RING GEAR 91144367 ADJUSTING NUT 91144368 CAPSCREW, (adjusting nut lock) 91404001 G6-42P 5-13...
  • Page 186 S/N 0160000230 & After DRIVE TRAIN Figure 5-6 Front Axle Assembly - Carraro 5-14 G6-42P 91404001...
  • Page 187 HEX HD CAPSCREW, M20-2-1/2X65 90027473 HARDENED WASHER 91413107 PARK BRAKE TUBE LINE 91413106 SERVICE BRAKE TUBE LINE 77363046 CONNECTOR, (includes item 11) 91403258 ELBOW, 90 DEGREE, (includes item 11) 84719217 HOSE ASSY 84719218 HOSE ASSY 88591202 O-RING 91404001 G6-42P 5-15...
  • Page 188 S/N 0160000230 & After DRIVE TRAIN Figure 5-7 Front Axle - Carraro 5-16 G6-42P 91404001...
  • Page 189 Figure 5-7 Front Axle - Carraro Item Part Number Qty. Description Rev. 91363158 FRONT AXLE, (includes all items) HOUSING ASSY, (see Figure 5-8 for details) BRAKE ASSY, (see Figure 5-9 for details) CARRIER ASSY, (see Figure 5-10 for details) 91404001 G6-42P 5-17...
  • Page 190 S/N 0160000230 & After DRIVE TRAIN Figure 5-8 Carrier Assembly - Carraro PAP23540 5-18 G6-42P 91404001...
  • Page 191 BOLT, M12X60 91364077 FLANGE 91364078 PIN, 12X25 91364079 SEAL RING 91364080 BEARING 91364081 BOLT 91364082 WHEEL HUB KIT, (includes wheel hub & item 34) 91474155 O-RING 91364083 SPACER 91364084 RING NUT, M130X2 91474157 RING 91364085 RING GEAR CARRIER 91404001 G6-42P 5-19...
  • Page 192 91364093 38.4 NEEDLE BEARINGS, (by tens) 91364094 GEAR 91364095 THRUST WASHER 91364096 THRUST WASHER 91364097 PLANETARY CARRIER KIT, (includes planetary carrier & locking pad) 91474037 PLUG, M30X2 7028492 SCREW 91364098 DIFFERENTIAL KIT, (includes items 12 thru 15) 5-20 G6-42P 91404001...
  • Page 193 S/N 0160000230 & After DRIVE TRAIN Figure 5-8 Carrier Assembly - Carraro (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 5-21...
  • Page 194 S/N 0160000230 & After DRIVE TRAIN Figure 5-9 Brake Assembly - Carraro 5-22 G6-42P 91404001...
  • Page 195 91474151 O-RING 91364043 SELF-ADJUST KIT, (includes the following) WASHER WASHER BOLT, M14X65 SPACER 91364044 HALF SHAFT 91474142 SLEEVE 91474141 DRIVE PLATE 91474140 BRAKE DISK 91474139 DRIVE PLATE 91364045 BRAKE PISTON 91474137 O-RING 91474136 O-RING 91474146 BRAKE PISTON 91404001 G6-42P 5-23...
  • Page 196 S/N 0160000230 & After DRIVE TRAIN Figure 5-10 Axle Housing Assembly - Carraro 5-24 G6-42P 91404001...
  • Page 197 91364034 BUSHING 91364035 SEAL RING 91364036 BUSHING 91364037 RH AXLE HOUSING 91474061 NUT, M16X2 91474060 STUD, M16X2 91364038 RELEASE PIN 91474066 BOLT, M16X1-1/2 91474065 O-RING 91474064 SCREW, M22X1-1/2 91474075 PLUG, M16X1-1/2 91364039 PLUG, M10X1 91364040 CENTRAL BODY 91404001 G6-42P 5-25...
  • Page 198 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-11 Rear Axle Drive Hub 5-26 G6-42P 91404001...
  • Page 199 70021146 PRIMARY CARRIER SUB-ASSY, (includes items 22 & 23) 91414019 PRIMARY SUN GEAR 91414020 RETAINING RING 91414021 THRUST WASHER 91414022 THRUST WASHER 7024177 O-RING 91414024 COVER 7017094 MAGNETIC PIPE PLUG 91414026 HEX HD BOLT 91414027 RETAINING RING 91404001 G6-42P 5-27...
  • Page 200 S/N 0160000230 & After DRIVE TRAIN Figure 5-11 Rear Axle Drive Hub NOTE: TO SERVICE ITEM 15, BEARING NUT, A SPECIAL WRENCH IS REQUIRED. ORDER 91404449 WRENCH. 5-28 G6-42P 91404001...
  • Page 201 70021146 PRIMARY CARRIER SUB-ASSY, (includes items 22 & 23) 91414019 PRIMARY SUN GEAR 91414020 RETAINING RING 91414021 THRUST WASHER 91414022 THRUST WASHER 7024177 O-RING 91414024 COVER 7017094 MAGNETIC PIPE PLUG 91414026 HEX HD BOLT 91414027 RETAINING RING 91404001 G6-42P 5-29...
  • Page 202 S/N 0189001 thru 0189345 DRIVE TRAIN Figure 5-12 Tires & Rims 5-30 G6-42P 91404001...
  • Page 203 LUG NUT 91083385 VALVE 8780031 TIRE, (not shown), 13.00X24, 12 PLY, G-2 TRACTION 91363202 WHEEL, 24X9 91043084 TIRE, (not shown), 14.00X24 BIAS, DIRECTIONAL 91033321 TIRE, (not shown), 13.00R24 RADIAL, NON-DIRECTIONAL 91043295 TIRE, (not shown), 14.00R24 RADIAL, NON-DIRECTIONAL 91404001 G6-42P 5-31...
  • Page 204 S/N 0160000230 & After DRIVE TRAIN Figure 5-12 Tires & Rims TREAD PATTERNS MAY VARY PW0030 5-32 G6-42P 91404001...
  • Page 205 TIRE & WHEEL ASSY, 14.00-24, ROCK TREAD, FOAM FILLED, 720#, (includes items 2, 3, 7 & 12) 4520490 TIRE SET, 14.00-24 RADIAL, FOAM FILLED 91365076 TIRE & WHEEL ASSY, 14.00-24, RADIAL, FOAM FILLED, (includes items 2, 3 , 9 & 12) 91404001 G6-42P 5-33...
  • Page 206 TIRE, 13.00-24 BIAS, ROCK TREAD, NON-DIRECTIONAL 91043084 TIRE, 14.00-24 BIAS, DIRECTIONAL 91543002 TIRE, 14.00-24 BIAS, ROCK TREAD, NON-DIRECTIONAL 8780264 TIRE, 13.00-24 RADIAL, NON-DIRECTIONAL 91363215 TIRE, 14.00-24 RADIAL, NON-DIRECTIONAL 4520646 RH SOLID TIRE & WHEEL ASSY 4520647 LH SOLID TIRE & WHEEL ASSY 5-34 G6-42P 91404001...
  • Page 207 S/N 0160000230 & After DRIVE TRAIN Figure 5-12 Tires & Rims (Continued) Item Part Number Qty. Description Rev. 91404001 G6-42P 5-35...
  • Page 208 DRIVE TRAIN This Page Intentionally Left Blank 5-36 G6-42P 91404001...
  • Page 209 SECTION 6 91404001 G6-42P...
  • Page 210 Figure 6-1 Open Cab G6-42P 91404001...
  • Page 211 OPEN CAB ASSY, (includes all items) 91404108 CAB WELDMENT 91404109 RH SIDE WINDOW WITH BORDER 80364009 URETHANE SEALANT 91404110 REAR WINDOW WITH BORDER 80264031 SETTING BLOCK, 1/8X1/4X2 SERIAL TAG 91164094 ROPS WARNING DECAL 91164087 HOLE PLUG, 3/4 91164086 HOLE PLUG, 3/8 91404001 G6-42P...
  • Page 212 S/N 0189001 thru 0189345 & 0160000230 thru 0160015436 Figure 6-2 Cab Enclosure With Heater Option FRONT WIPER INSTALLATION G6-42P 91404001...
  • Page 213 HEX SCREW, 1/4-28X3/4 1001081311 WET ARM KIT 1001081308 WIPER ARM 80384213 WIPER BLADE 91334135 SPACER 80384203 WIPER DRIVE ARM SERIAL TAG 1001081307 WIPER ARM ADAPTOR 91404297 WASHER 91404298 RIVET 91404299 EMERGENCY EXIT DECAL 80364023 STRIKER BOLT 91334024 HEX BOLT, 3/8-16X7/8 91404001 G6-42P...
  • Page 214 BAT FAN WAS WSW WIPER-HEATER OPT HARNESS ATTACH TO WASHER BOTTLE MOUNTED ON REAR CAB SPARE GNDS CABGND WALL GNDS MOUNT WASHER BOTTLE BEHIND SEAT ATTACH GROUND STRAP TO LOWER RH BOLT HOLE PAP23290 OF WASHER BOTTLE MOUNT G6-42P 91404001...
  • Page 215 REMOVE COVER PLATE AND DISCARD. ATTACH VENT TO ACCESS COVER USING EXISTING HARDWARE. REMOVE COVER PLATE AND DISCARD. ATTACH VENT TO ACCESS COVER USING EXISTING HARDWARE. SUPPLY RETURN ATTACH HEATER RETURN TO WELD NUTS SUPPLY IN CAB FLOOR 91404001 G6-42P...
  • Page 216 77133279 CLAMP SET 77133137 COVER PLATE 88201023 HEX HD CAPSCREW, 5/16-18X1-3/4 91403280 HEATER UNIT, (Before S/N 0160037689), (no longer available, use 1001114282 for replacement) 1001114282 HEATER UNIT, 3 SPEED, (S/N 0160037689 & After) 88261015 BUTTON HD CAPSCREW, 1/4-20X5/8 G6-42P 91404001...
  • Page 217 Figure 6-2 Cab Enclosure With Heater Option (Continued) Item Part Number Qty. Description Rev. 91413053 RECTANGULAR VENT 91403596 VENT REDUCER 80363106 CIRCULAR VENT 91403608 DEFROSTER FAN 91401443 FAN BASE PLATE 91033425 RUBBER GROMMET 88211030 SOCKET HD CAPSCREW, #10-24X3/4 77143017 WHIZ-LOCKNUT, #10-24 91404001 G6-42P...
  • Page 218 Figure 6-3 Cab Enclosure 6-10 G6-42P 91404001...
  • Page 219 DOOR HOLD OPEN UPPER DOOR GLASS, (see Figure 6-4 for details) 91404323 SLAM LATCH STRIKER 91404324 HEX BOLT, 5/16-18X5/8 91404302 ACTIVATOR, SIKA 91334032 FLAT WASHER, 5/16X3/4X.06 80364009 SEALANT 91344046 SEALANT/ADHESIVE LH SIDE GLASS WINDOW, (see Figure 6-4 for details) 91404001 G6-42P 6-11...
  • Page 220 Figure 6-4 Cab Enclosure Front of Machine 6-12 G6-42P 91404001...
  • Page 221 91413142 SKYLIGHT WINDOW 91404109 RH SIDE WINDOW WITH BORDER 91404110 REAR WINDOW WITH BORDER 80364030 LH SIDE DOOR WINDOW 91404322 UPPER DOOR GLASS 91404291 FRONT WINDOW 80364009 SEALANT 91404302 ACTIVATOR 91404296 HOLE PLUG, 1-1/4 80364012 CLEAR SEALANT 91404001 G6-42P 6-13...
  • Page 222 S/N 0160015465 & After Figure 6-5 Suspension Seat PAP23910 6-14 G6-42P 91404001...
  • Page 223 SEAT BELT, 3 IN, (California Only), (not included with 91563158) 7026906 TETHER KIT 7026901 SEAT CUSHION KIT 7026799 KNOB KIT 7026798 SLIDE KIT 1001101085 SUSPENSION SEAT WITH 2 IN SEAT BELT 70023139 SEAT BELT KIT, 3 IN, (California only), (includes retractor & female ends) 91404001 G6-42P 6-15...
  • Page 224 Figure 6-6 Dash Assembly FUEL QUARTZ TEMP VOLTS WORK TRAVEL VIEW A-A STEERING COLUMN NOT SHOWN FOR CLARITY SECTION VIEW LOOKING INTO ORBITROL MOUNTING BRACKET PAP23670 6-16 G6-42P 91404001...
  • Page 225 91473163 RUBBER GUARD 88521004 LOCKNUT, 1/4-20 91473212 DASH, (enclosed cab) 90206194 54 in TRIM-LOCK 77133497 CLAMP SET 77133498 COVER PLATE 88201007 HEX HD CAPSCREW, 1/4-20X1-1/2 88521005 STOVER LOCKNUT, 5/16-18 91023098 FENDER WASHER, 5/16 91413130 NYLON HOLE PLUGS 91404001 G6-42P 6-17...
  • Page 226 PLUG PRK BRK PLUG CONNECTOR END VIEW CONNECTOR END VIEW PLUG WORK PLUG TRC LOC PLUG PLUG OPT-3 REV AL PLUG NOTE: BLACK PLASTIC PANEL NOT AVAILABLE FOR SERVICE. MUST ORDER COMPLETE INSTRUMENT PANEL, 91403461, FOR REPLACEMENT 6-18 G6-42P 91404001...
  • Page 227 4X4 SWITCH, (includes item 22) 77363265 RELAY 77363268 FUSE, 15 AMP 77363267 FUSE, 10 AMP 91404333 SMALL GAUGE BRACKET 80963060 CONNECTOR 80963057 CONNECTOR 91364013 CONNECTOR 91404331 CONNECTOR 91334038 CONNECTOR 90205688 HOURMETER 91404349 ACTUATOR 91404350 ACTUATOR 91404351 ACTUATOR 91404001 G6-42P 6-19...
  • Page 228 REV-A WORK ORANGE/BROWN PLUG WORK LT YELLOW/BLUE TRC LOC PLUG ALT EXC-B FWD-A WEATHER PACK SHROUD TR SW (3-WIRE) PLUG PS IGN CAB GND PLUG PLUG CAB GND CAB GND WORK TRC LOC PLUG REV AL PAP23230 6-20 G6-42P 91404001...
  • Page 229 FUSE, 10 AMP 91404332 LARGE GAUGE BRACKET 91404333 SMALL GAUGE BRACKET 91404334 LAMP ASSY, (includes item 12) 91404335 BULB 80963060 CONNECTOR 80963057 CONNECTOR 91364013 CONNECTOR 91334038 CONNECTOR 91474463 STRAIN RELIEF, 90 DEGREE 91404331 CONNECTOR 91033317 IGNITION SWITCH 77384578 91404001 G6-42P 6-21...
  • Page 230 This Page Intentionally Left Blank 6-22 G6-42P 91404001...
  • Page 231 SECTION 7 CONTROLS 91404001 G6-42P...
  • Page 232 CONTROLS Figure 7-1 Tilt & Sway G6-42P 91404001...
  • Page 233 JOYSTICK, (see Figure 7-7 for details) 88201005 HEX HD CAPSCREW, 1/4-20X1, GR5 88551009 LOCKWASHER, 1/4 91401168 LH TILT/SWAY BRACKET 91416006 WELD NUT PLATE 91403309 CONTROL CABLES 88201065 HEX HD CAPSCREW, 1/2-13X1, GR5 88551013 LOCKWASHER, 1/2 88561107 FLAT WASHER, 1/4 91404001 G6-42P...
  • Page 234 S/N 0189001 thru 0189345 & 0160000230 thru 0160001370 CONTROLS Figure 7-2 Accelerator Pedal Assembly G6-42P 91404001...
  • Page 235 91083136 BUSHING 88561108 FLAT WASHER, 5/16 91406147 ACCELERATOR PEDAL ARM 88201005 HEX HD CAPSCREW, 1/4-20X1, GR5 88521304 HEX LOCKNUT, 1/4-20 91401423 PEDAL 80263108 PEDAL PAD 88201020 HEX HD CAPSCREW, 5/16-18X1, GR5 88551010 LOCKWASHER, 5/16 88561003 FLAT WASHER, 5/16 91404001 G6-42P...
  • Page 236 S/N 0160001379 thru 0160038344 CONTROLS Figure 7-2 Accelerator Pedal Assembly PAP23640 G6-42P 91404001...
  • Page 237 PIVOT PIN 91083136 BUSHING 88561108 FLAT WASHER, 5/16 91406147 ACCELERATOR PEDAL ARM 88201005 HEX HD CAPSCREW, 1/4-20X1, GR5 88521304 LOCKNUT, 1/4-20 91401423 PEDAL 80263108 PEDAL PAD 88201020 HEX HD CAPSCREW, 5/16-18X1, GR5 88551010 LOCKWASHER, 5/16 88561003 FLAT WASHER, 5/16 91404001 G6-42P...
  • Page 238 S/N 0160038555 & After CONTROLS Figure 7-2 Accelerator Pedal Assembly PAP23900 G6-42P 91404001...
  • Page 239 ACCELERATOR CABLE, (includes items 12 thru 14) 88501006 HEX NUT, 3/8-16 88211073 SOCKET HD CAPSCREW, 3/8-16X1-1/2 70023849 SOCKET HD SHOULDER SCREW 70023850 MACHINE BUSHING 70023851 NYLON WASHER 70023852 BUSHING 70023853 STOP HEX NUT, 5/16-18 70023854 HEX HD CAPSCREW, 5/16-18X7/8 91404001 G6-42P...
  • Page 240 CONTROLS Figure 7-3 Steering Column & Attaching Parts TIE STRAP & BOOT KIT NOTE: PAP23760 WHEN ITEM 8 IS ORDERED, REPLACE SCREWS PROVIDED FROM VENDOR WITH ITEM 9. 7-10 G6-42P 91404001...
  • Page 241 HEX HD CAPSCREW, 3/8-16X3/4, GR5 91123126 STEERING CONTROL UNIT 2220466 ELBOW, 90 DEGREE, (includes item 19) O-RING 2220373 ADAPTER, (includes item 21) O-RING 7026478 SPINNER KNOB 91144448 TIE STRAP & BOOT KIT 91144190 STEERING CONTROL UNIT SEAL KIT 91404001 G6-42P 7-11...
  • Page 242 CONTROLS Figure 7-4 Brake Pedal Assembly PAP23650 7-12 G6-42P 91404001...
  • Page 243 HEX JAM NUT, 3/8-24 91083136 BUSHING 91403247 BUSHING 2220473 ELBOW, 90 DEGREE, (includes item 23) 90027987 SPRING CLEVIS, 3/8 88201018 HEX HD CAPSCREW, 5/16X18X3/4 88551009 LOCKWASHER, 5/16 88561003 FLAT WASHER, 5/16 90206198 20 in TRIM-LOCK, (not shown) 91404001 G6-42P 7-13...
  • Page 244 S/N 0189001 thru 0189345 CONTROLS Figure 7-5 Foot Switch 7-14 G6-42P 91404001...
  • Page 245 S/N 0189001 thru 0189345 CONTROLS Figure 7-5 Foot Switch Item Part Number Qty. Description Rev. 91403478 FOOT SWITCH 88261017 SOCKET BUTTON HD CAPSCREW, 1/4-20X3/4 91404001 G6-42P 7-15...
  • Page 246 S/N 0160000230 & After CONTROLS Figure 7-5 Foot Switch 7-16 G6-42P 91404001...
  • Page 247 S/N 0160000230 & After CONTROLS Figure 7-5 Foot Switch Item Part Number Qty. Description Rev. 91343218 FOOT SWITCH 88261011 SOCKET BUTTON HD CAPSCREW, #10-24X7/8 91404001 G6-42P 7-17...
  • Page 248 CONTROLS Figure 7-6 Boom Joystick Assembly 2&4 1&3 PY4940 7-18 G6-42P 91404001...
  • Page 249 UPPER BODY, (includes item 13) LOWER BODY Use Kit K1 O-RING Use Kit K1 O-RING Use Kit K1 DOWEL PIN Use Kit K1 O-RING Use Kit K1 SCREW ASSY 91404326 SEAL KIT, (includes items 14 thru 18) 91404001 G6-42P 7-19...
  • Page 250 CONTROLS Figure 7-7 Joystick Assembly 7-20 G6-42P 91404001...
  • Page 251 91404097 CABLE LOCK SCREW 91404098 CABLE BUSHING 91404099 RETAINING RING 91404100 RETAINING RING 91404101 CABLE ANCHOR, (outer) 91404102 BUSHING 91404103 SPRING 91404209 SLIDER ASSY 91404105 HEX NUT, 1/4-20 91404106 LOCK WASHER 91404107 HOUSING, (inner) 91404210 JAM NUT 91404001 G6-42P 7-21...
  • Page 252 CONTROLS Figure 7-8 RH Horizontal Control Assembly PAP21900 7-22 G6-42P 91404001...
  • Page 253 RH HORIZONTAL CONTROL ASSY, (includes items 1 thru 6) 91513204 SINGLE VALVE CONTROL 91403308 CABLE 1001092843 BRACKET 88201009 HEX HD CAPSCREW, 1/4-20X2 88501004 LOCKWASHER, 1/4 88551009 HEX NUT, 1/4-20, GR2 0641508 HEX HD CAPSCREW, 5/16-18X1, GR5 4761500 WASHER, 5/16 91123062 CABLE ADAPTER BONNET 91404001 G6-42P 7-23...
  • Page 254 CONTROLS This Page Intentionally Left Blank 7-24 G6-42P 91404001...

Table of Contents