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1. 9 3 2 Power Distribution Module O F1 F8 F22 7 gt O F2 F9 F23 F10 F24 F4 F11 F25 d F5 F12 F26 F6 F13 F27 K2 K6 K10 F7 F14 F28 F15 F29 F16 230 K7 11 F17 F81 Jk F18 F32 x C F19 mm K4 K8 K12 F20 F34 F21 A Q Fuse Relay Function Amp Rating F1 Right Headlight High 7 5 F2 Right Headlight Low 7 5 F3 Left Headlight High 7 5 F4 Left Headlight Low 7 5 F5 Radio 10 F6 Radio Bat 5 F7 Front Wiper 20 F8 Heater Fan 20 F9 Aux Pwr Socket 15 F10 Air Suspension Seat 10 F11 Ignition 1 10 F12 Left Park Side Lights 7 5 G5 19A G6 23A 9 5 Electrical System F13 Right Park Side Lights 7 5 F14 Front Worklights 15 F15 Rear Worklights 15 F16 Boom Lights 15 F17 Beacon Aux 15 F18 Reserved Switch 15 F19 Reserved Bat 15 F20 Reserved Ignition 10 F21 PCB Bat 10 F22 Ignition 2 15 F23 LMI Joystick 10 F24 PCB Ignition 15 F25 Rear Wiper 20 F26 Flasher Pwr 15 F27 Key Bat 15 F28 Brake Lights 15 F29 A C Compressor 7 5 F30 Driving Lights Bat 1 20 F31 Driving Lights Bat 2 20 F32 Shift Steer 15 F33 Engi
2. G5 19A G6 23A 081 E us owes E Er Ls m mu 3AWA10H1NOO E al en Hh nh FET E ARAARA oh Ti mao Tey YYYY LE bE EL EE bE bE bE EE EE ER BE 11 BE RE ES EE Ee EF ALIVE B Lr icsecosa _ Ea E 9 P E tn gt mue AES o lt lt lt 1 ar m T 2 o me 7 mam D gt a o ELE bEbEEb k a KEK i EBBE Y 19 vtIIl 19 vtIl x t F F F
3. 7 7 7 9 Engine Coupler 575 da fake ge px SRM Oa AXE LP Ed bn 7 9 7 10 iroubleshootirig i221 7 10 Section 8 Hydraulic 22 22 4 4 559994444444 8 1 8 1 Hydraulic Component Terminology 2 4 1 8 2 8 2 Safety Information Rae ner eee 8 3 8 3 Specifications c Em eem RE pea Rome ea ee 8 3 8 4 Hoses Tube Lines Fittings 8 3 8 5 Hydraulic Pressure Diagnosis 8 4 8 6 Hydraulic Schematic 2 8 6 8 7 Hydraulic 2 8 8 8 8 Hydraulic System 2 8 8 8 9 Front Dive PUMP a serre carece Rat Gah VENERINT HIE Med 8 10 8 10 Valves and 0 8 11 8 11 Hydraulic Cylinders 1 8 16 Section 9 Electrical System eae ee ee EGGS RR eae 9 1 9 1 Electrical Component 9 3 9 2 Specifications nce X KDE uen ebd EIE 9 4 9 3 Fuses and Relays
4. SD CAB HARNESS PREHEAT RELAY X44 DEUTSCH HD36 18 8SE POWERIGND HARNESS 4 0 MM WIRES IN THIS CONNECTOR ABCDEFGH NA A N N N HARNESS Xa K4 Ko kn IGN FRONT IGN IGN IGN WORK BOOM REAR HEATER WIPER PWR 1 PWR2 PWR 3 LIGHTS LIGHTS WIPER FAN RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY 5 2 E 5 Fb DRIVING LIGHTS BAT 1 amp Fer KEY BAT gt Fat PCB BAT gt REAR WIPER 5 _ RESERVED BAT to m HORN PWR HEATER FAN FRONT WIPER rs RADIO BAT ES FLASHER PWR 5 md 9 w 2 2 2 8 2 b 5 5 z E E 3 E E 5 8 o gt 3 TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO HARNESS POWER DISTRIBUTION MODULE ad x00 VVVVVVVVV VV VV VV VVVVVVVVVVVVVV VVVV VV VV VV VV VV 1234567 8 91011 12 13 14 15 12345678 91011 12 13 14 15 1234567 8 91011 12 13 14 15 12345678 91011 12 13 14 15 D I d gt lt CAB HARNESS cn S g CAB HARNESS a CAB HARNESS lt Xo5 5 5 3 n x00 gt lt 2 2 E lt 3 5 FLSH PWR m RADIO OPT gt lt gt lt 511 gt lt RA HAZARD gt lt 3 SWITCH OPT gt 1 lt
5. 9 4 9 4 Electrical System Schematics 1 9 7 9 5 Circuit Breakdowns 9 13 9 6 Engine Start 9 17 9 7 Charging Circuit a eee eet eei ei vs 9 18 9 8 Electrical System Components 9 19 9 9 Window 4 9 20 9 10 Cab Heaterand RE RR be RR RES GU Y 9 21 9 11 Switches Solenoids and 9 22 9 12 Controller tes M eM aa EEG EEG ace TU 9 25 9 13 iroubleshootirig 3 a lt eg etandi deleted nga weds 9 25 ij G5 19A G6 23A Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1 1 Introduction i ieee 1 2 1 2 Disclaimer 22 5 42 4 4 dae eee dees eee 1 2 1 3 Operation amp Safety 1 2 1 4 Do Not Operate 1 2 1 5 Safety 1 3 1 5 1 Safety Alert System and Signal 1 3 1 6 Safety Instructions
6. 8 3 8 5 Hydraulic Pressure 8 4 8 5 1 Pressure Checks and 8 4 8 5 2 Main Control Valve Pressure 0 8 5 8 5 3 Charge Pressure 0 8 5 8 5 4 Drive Pressure Checking 8 5 8 5 5 Steering Pressure 0 8 5 8 5 6 Brake Pressure 0 8 5 8 6 Hydraulic 8 6 8 7 Hydraulic Reservoir 4 4 4 4 8 8 8 7 1 Hydraulic Oil Reservoir 0 8 8 8 7 2 Hydraulic Oil Reservoir 0 8 8 8 8 Hydraulic System 8 8 8 8 1 Implement Pump Failure 8 8 8 8 2 Implement Pump 8 8 8 9 Front Drive Pump 8 10 8 10 Valves and Manifolds 8 11 8 10 1 Main Control 8 11 8 10 2 Service Brake 8 12 8
7. ABCDEFGHJKLMNOPQRSTUVWX 123 4 5 6 7 8 9 1011 1213 14 15 16 17 18 19 20 21 22 23 HARNESS pe HARNESS REVERSE LEFT REAR DRIMING LIGHT RIGHT REAR DRIVING LIGHT ALARM TAIL BACK TURN STOP TAIL BACK TURN STOP R REV OUT HYDROSTATIC DRIVE PUMP FWD ENGINE HARNESS REAR CHASSIS HARNESS MAH1210 G5 19A G6 23A 9 15 Electrical System 9 5 4 ENGINE HARNESS CAB PWR 4 Constant Power Circuit Breakdown CAB PWR 3 CAB PWR 2 POSITIVE CABLE TO BATTERY STARTER CAB PWR 1 PREHEAT PWR ALT BAT STRT PWR ALT BAT STARTER RELAY ALTERNATOR o B 240 o ENGINE GLOWPLUGS CONTROL STRT PWR PREHEAT PWR ENGINE HEATER FUSE 50A SLO BLO
8. DASH BOARD G5 19A G6 23A D BATTERY TO IGN SGN MAH1180 9 13 Electrical System 9 5 2 Start Circuit Breakdown CAB HARNESS ALL 1 0 MM WIRES IN THIS CONNECTOR Kev SWITCH sis KEY BAT 1 BAT KEY BAT 1 KEY IGN 1 KEY IGN 1 KEY STRT INTLK CAB HARNESS x00 TO POWER DIST MODULE STRT INTLK v vvvvv 1234567 8 9 1011 12 1314 15 AAAAN POWER DISTRIBUTION MODULE eam BATTERY POSITIVE STRT RLY HARNESS STRTRLY 12345678 910112131415 AAAKAAKAAKAAAAAN NEUT STRT INTLK STRT RLY BEJ KEY STRT BATTERY NEGATIVE 9 14 START INTLK RELAY ENGINE HARNESS OO TO HARNESS xor vvvvvvv ABCDEFGHJKLMNOPQRSTUVWX INAAANANNNNNNNNNA AKAAKAA STRTRLY STRTPWR STRT SOL STRT RLY STRTRLY GND 14 GND 15 PREHEAT RLY ENGINE GLOWPLUGS CONTROL GND 14 TO ENGINE GLOWPLUGS EXCESS STRTRLY 5 START FUEL STRT
9. 1 3 1 6 1 Personal Hazards se css eee eae Ge ee Re x n 1 3 1 6 2 Equipment Hazards sose eee Ree De tha Rs e ER RE 1 3 1 6 3 General 1 4 1 6 4 Operational 1 4 1 7 Safety 5 2 Ue eoe 1 4 G5 19A G6 23A 1 1 Safety Practices 11 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures Following the procedures in this manual will help assure safety and equipment reliability Read understand and follow the information in this manual and obey all locally approved safety practices procedures rules codes regulations and laws These instructions cannot cover all details or variations in the equipment procedures or processes described nor provide directions for meeting every possible contingency during operation maintenance or testing When additional information is desired consult the local JLG distributor Many factors contribute to unsafe conditions carelessness fatigue overload inattentiveness unfamiliarity even drugs and alcohol among others For optimal safety encourage everyone to think and to act safely Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work fo
10. ES 1509001 REGISTERED COMPANY MAP 015 Service Manual Models 65 194 amp G6 23A P N 31200193 Revised November 17 2006 AJ LG lx EFFECTIVITY PAGE March 24 2006 A Original Issue Of Manual November 17 2006 B Added Controller procedure in Section 9 31200193 G5 19A G6 23A EFFECTIVITY PAGE G5 19A G6 23A SECTION CONTENTS Section Subject Page Section 1 Safety Pr cticas qc RR Rc on Cl INDE C TR Ce GR LN 1 1 1 1 1 2 1 2 IRE E 1 2 1 3 Operation amp Safety 1 1 2 1 4 Do Not Operate 0 1 2 1 5 Safety Information 1 1 3 1 6 Safety 1 1 3 1 7 Safety Decals us E etae obw 1 4 Section 2 General Information and Specifications 2 1 2 1 Replacement Parts and Warranty 2 2 2 2 TOrques deese eR ERE Be 2 3 2 3 Specifications sz 4 12 IRIS Dee EIE 2 6 2 4 Fluids Lubricants and Capacities 2 8 2 5 Maintenance 2 9 2 6 Lubricatio
11. zc E g co amp 123 4 5 6 7 8 9 10 11 12 13 14 15 PINS 4 7 2 5MM ALL OTHERS 1 0MM CAB ROOF HARNESS x43 TO CAB HARNESS 0060 G5 19A G6 23A 9 7 XOUSAOT SuOLOSNNOO QN ELS 21 1170 Usd OAHXNWINOD nae panna usn ao a Cab Harness Schematic Electrical System 9 4 2 G5 19A G6 23A 9 8 orton sa te v0 THOS uy Electrical System TE TOSS SE TERS EWS TESSRNTSUER OA TOON EE I WEE San MEER STOTT THOR TER SINON SUFRE UE TASTE EESTI TRUNG GEROSGEDSEY AD ISSN ENN TROU UU EUNT pom Leno TOA CLOSET GHUANHS ELSE FELL 29 S UHHAUOUESISSTETI Power Distribution Module Schematic 9 4 3 9 9 MAHO0070 G5 19A G6 23A ua
12. 2 7 2 3 5 ted ut rut OR Tee 2 7 2 4 Fluids Lubricants and 2 8 2 5 Maintenance Schedules 2 9 2 5 1 8 1st 50 Hour Maintenance Schedule 2 9 2 5 2 50 250 amp 500 Hour Maintenance Schedule 2 9 2 5 3 1000 amp 1500 Hour Maintenance Schedule 2 9 2 6 Lubrication Schedules 2 10 2 6 1 8 Hour Lubrication 2 10 2 6 2 50 Hour Lubrication 2 111 G5 19A G6 23A 2 1 Ay General Information and Specifications 2 1 REPLACEMENT PARTS AND WARRANTY INFORMATION Before ordering parts or initiating service inquiries make note of the machine serial number The machine serial number plate is located as indicated in the figure 1230 IMPORTANT The replacement of any part on this machine with any other than a JLG authorized replacement part can adversely affect the performance durability or safety of the machine and will void the warranty JLG disclaims liability for any claims or damages whether regarding property damage personal injury or death arising out of the use of unauthorized replacement parts A warranty re
13. 3 1 BOOM SYSTEM COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the boom system The following illustration identifies the components that are referred to throughout this section Compensating Cylinder First Boom Section Second Boom Section Access Panel Extend Retract Cylinder Cylinder MAHO140 Quick Switch 3 2 G5 19A G6 23A Boom C ad 3 2 BOOM SYSTEM TWO SECTION BOOM 3 2 1 The boom operates via an interchange among the electrical hydraulic and mechanical systems Components involved include the joystick tilt cylinder extend retract cylinder lift lower cylinder compensating cylinder electronic sensors various pivots supporting hardware and other components Boom System Description G5 19A G6 23A 3 3 BOOM ASSEMBLY MAINTENANCE The boom assembly consists of the first and second section booms and supporting hardware IMPORTANT Boom replacement must be completed in sequence one boom section at a time as described in these instructions IMPORTANT Before removing the boom the carriage or any other attachment must be removed from the quick attach Before beginning conduct a visual inspection of the machine and work area and review the task about to be un
14. Transmission 6 6 This Page Intentionally Left Blank G5 19A G6 23A Section 7 Engine Deutz BF 4M 2012 Contents PARAGRAPH TITLE PAGE 7 1 Introduction 1 clle lv Rx x 7 2 7 1 1 Disclaimer and 7 2 7 1 2 Component 7 2 7 2 Engine Serial 7 4 7 3 Specifications and Maintenance 7 4 7 4 Engine Cooling System 7 4 7 4 1 Radiator Pressure 7 4 7 4 2 Radiator Oil Cooler and Coolant Heater Replacement 7 4 7 5 Engine Electrical 7 5 7 6 Fuel System ec umm RE SRI EINER eR ae aces 7 5 7 6 1 Diesel Fuel 7 5 7 6 2 Fuel Hydraulic Oil 7 6 7 6 3 After Fuel System Service 7 6 7 7 Engine Exhaust and Air Cleaner System 7 6 7 8 Engine 22 22 22 4 7 7 7 8 1 Engine 7 7 7 8 2 Engine Disassembly Inspection and 7 8 7 8 3 Engine inst
15. 22522 max ee ete neces 9 4 9 3 Fuses and Relays 9 4 9 3 1 Engine Compartment Relays and Fuses 9 4 9 3 2 Power Distribution Module 9 5 9 4 Electrical System 9 7 9 4 1 Roof Schematic i ski eva deka ee IR EG E Rer E 9 7 9 4 2 Cab Harness 9 8 9 4 3 Power Distribution Module 9 9 9 4 4 Front amp Rear Chassis Battery Boom Harness Schematic 9 10 9 4 5 Engine Harness 9 11 9 4 6 Dashboard 9 12 9 5 Circuit 9 13 9 5 1 Charge Circuit Breakdown 9 13 9 5 2 Start Circuit Breakdown 9 14 9 5 3 Drive Circuit 9 15 9 5 4 Constant Power Circuit 9 16 9 6 Engine Start 9 17 9 6 1 Starte f dais 9 17 9 7 Charging Circuit RR RR i E ERE RR nimis 9 18 9 7 1 Alternator eect atone eR
16. 9 13 3 Analyzer Diagnostic Help Messages The table below lists Diagnostic Help Messages that the Control System communicates to the Analyzer Diagnostics Submenu Parameter Parameter Value Description Displayed on Analyzer 1st Displayed Displayed on Analyzer Line on Analyzer 2nd Line 2nd Line GROUND INPUT JYSTK ON OFF Display status of joystick lockout LOCK LMI ON OFF Displays status of LMI Cutout CUTOUT LMI ON OFF Displays status of LMI Override OVERRIDE AUX HYD FRNT REAR Displays if front or rear auxiliary hydraulics is active AUX HYD Displays if aux or aux II outlet is active GROUND OUTPUT TELE IN OUT Displays telescope switch direction amp demand LIFT UP DOWN Displays lift direction amp demand FORK TILT UP DOWN Displays fork lift direction amp demand AUX HYD XXX Displays whether Auxiliary Hydraulics 1 1OR2 or 2 is active and demand percentage 9 28 G5 19A G6 23A Electrical System Diagnostics Submenu Parameter Parameter Value Description Displayed on Analyzer 1st Displayed Displayed on Analyzer Line on Analyzer 2nd Line 2nd Line JOYSTICK X POSITION Displays position in percentage for this axis X NEUTRL IN NEUTRAL Indicates whether joystick is in neutral NOT NEUTRAL position for this axis ERROR Y POSITION Displays position in percentage for this a
17. Close and secure the engine cover G5 19A G6 23A 4 3 4 Inching Valve Inching Valve Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Disconnect the battery negative cable at the battery negative terminal Remove the lower dash panel Remove the nut holding the inching valve adjusting rod 12 to the brake pedal bracket 13 Label and disconnect all hoses attached to the valve cap all fittings and plug hoses to keep dirt amp debris from entering hydraulic system Remove the two bolts securing the inching valve to the inside of the cab Inching Valve Installation Install the inching valve with the two bolts inside the cab Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations Point the pin 14 on the pivoting part of the valve towards the top T port Be sure the brake pedal is in the UP position Mount the inching valve lever 15 to the inching valve The lever should be 135 x1 to the Install the adjustable rod 12 to the lever The lever should be set to approximately 5 125 i
18. S XC E ROGER C EROR 9 18 9 8 Electrical System 9 19 9 8 1 Back Up Alal ox m SE EE 9 19 9 8 2 Instrument 9 19 9 9 Window 9 20 9 9 1 Windshield Wiper 9 20 9 9 2 Windshield Washer Reservoir and 9 20 9 10 Heater and 9 21 9 10 1 Cab Heater 9 21 9 11 Switches Solenoids and 9 22 9 11 1 Ignition Key 9 22 9 11 2 Dash SWilclies RR dk ass d E EN De OE 9 22 9 11 3 Fuel Level Indicator and Fuel Level 9 22 9 11 4 Hourtneter cure ERR UG RR S 9 23 9 11 5 Coolant Temperature Sender 9 23 9 11 6 Fuel Shut off 9 24 9 41 7 Oil Pressure 9 24 9 11 8 Main Control Valve 0 9 25 G5 19A G6 23A 9 1 Electrical System 9 2 9 12 9 13
19. 8V9 10387 8 2 KEJ EEJ i6 FEM av was 1 ONS 855 TONS EVO TONS EVO m E Lu BEER EES E B LE FH pe p REEERE BBBBBBBB 3443444 BRR EEEE oam FFFFFFFF RELIVE NO 193NNOOSIQ AUBLIVE OL J OL 5 H9343G028v 3 0193NNOO NI S3MIM WA Or TIY SS3NHYH QN9 H3MOd 3588 9 HOS1n3d SSINYVH 80 OL 3 0193NNOO SIHL NI S3SIM WA O L TIV SSINYVH ANION 3852 9290 HOSLNI0 SSINYVH 80 OL 90797 NOSS3HdWOO OV 910797 105715907 STON Ino 3H TONS UN HOLIMS 3unssaua ov dd d G A Oa OLLVLSONQAH 0090 9 11 G5 19A G6 23A Electrical System 9 4 6 9 12 Dashboard Schematic DASHBOARD LOW FUELLED TO BE 1 BiCKUeHT 2 T TA FUELLEVEL LOWFUEL_ WAT
20. for tightening guidelines for the head gland 8 If applicable thread the new counterbalance valve into the block on the cylinder barrel 8 17 Hydraulic System 0160 SY 8 11 6 General Cylinder Installation 1 Grease the bushings at the ends of the hydraulic cylinder Using an appropriate sling lift the cylinder into it s mounting position Align cylinder bushing and install pin lock bolt or retaining clip Uncap and connect the hydraulic hoses in relation to the labels or markings made during removal Before starting the machine check fluid level of the hydraulic fluid reservoir and if necessary fill to full mark with Mobilfluid amp 424 ISO Grade 46 Tractor Fluid Start the machine and run at low idle for about one minute Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil Inspect for leaks and check level of hydraulic fluid in reservoir Add hydraulic fluid if needed If no leaks are present operate the hydraulic function at least twenty times at full throttle to bleed any air from the cylinder and hoses Note To bleed air from the tilt cylinder operate the tilt function along with the lift cylinder as described above More operation cycles may be required to clear all air from the system 8 18 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools
21. 8 Uncap and reconnect the extend retract cylinder fittings and plugs from extend retract cylinder hoses Attach each hose to the extend retract cylinder fittings and tighten until wrench tight Mark the fitting then tighten each hose firmly 1 to 1 5 flats 9 Uncap and reconnect both the tilt and auxiliary hoses Attach both sets to their appropriate tubes until wrench tight Mark the fitting then tighten each hose firmly 1 to 1 5 flats 10 Start the engine and operate all boom functions several times to bleed any air out of the hydraulic system Check for fluid leaks Check the hydraulic fluid level in the tank and add fluid as required 11 Clean up all debris hydraulic fluid etc in on near and around the machine 12 Close and secure the engine cover 3 6 3 4 BOOM WEAR PADS The wear pads on this machine are flat rectangular wear pads with metal inserts On the G5 19A and G6 23A total of 16 wear pads are installed on the outer boom 3 4 1 Inspect all wear pads 3 for wear If the angle indicators 4 on the ends of the wear pads are visible the wear pads can be reused If the pads show uneven wear front to back they should be replaced Replace pads as a set if worn or damaged Wear Pad Inspection 4 4 3 MA2070 3 4 2 When replacing a wear pad on the boom replace both wear pads on that side of the boom e g replace top front left and top front right wear pads at the same
22. 9 Close and secure the engine cover 8 11 7 Steering Cylinders The steering cylinders are attached to each axle center housing The steer cylinders are covered in the appropriate Carraro axle literature G5 19A G6 23A Hydraulic System 8 11 8 Hydraulic Cylinder Torque Specifications Description G5 19A G6 23A All Cylinder Set Screws 15 18 Ib ft 20 25 Nm 15 18 Ib ft 20 25 Nm Lift Lower Cylinder Head Gland 369 406 Ib ft 500 550 Nm 516 553 Ib ft 700 750 Nm Piston 1593 1630 Ib ft 2160 2210 Nm 1940 1977 Ib ft 2630 2680 Nm Extend Retract Cylinder Head Gland 221 258 Ib ft 300 350 Nm 221 258 lb ft 300 350 Nm Piston 406 443 Ib ft 550 600 Nm 406 443 Ib ft 550 600 Nm Tilt Cylinder Head Gland 295 332 Ib ft 400 450 Nm 516 553 Ib ft 700 750 Nm Piston 948 985 Ib ft 1285 1335 Nm 1940 1977 Ib ft 2630 2680 Nm Compensating Cylinder Head Gland 295 332 Ib ft 400 450 Nm 295 332 Ib ft 400 450 Nm Piston 822 859 Ib ft 1115 1165 Nm 822 859 Ib ft 115 1165 Nm G5 19A G6 23A 8 19 Hydraulic System This Page Intentionally Left Blank 8 20 G5 19A G6 23A Section 9 Electrical System Contents PARAGRAPH TITLE PAGE 9 1 Electrical Component 9 3 9 2
23. Cold running Incorrect tappet adjustment Sticking valves Incorrect high pressure pipes Worn cylinder bores Pitted valves and seats Broken worn or sticking piston ring s Worn valve stems and guides Restricted air cleaner Worn or damaged bearings Insufficient oil in sump Inaccurate gauge Oil pump worn Pressure relief valve sticking open Pressure relief valve sticking closed Broken relief valve spring Faulty suction pipe Restricted oil filter Piston seizure pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors if fitted Coolant level too low Blocked sump strainer Broken valve spring G5 19A G6 23A Section 8 Hydraulic System Contents PARAGRAPH TITLE PAGE 8 1 Hydraulic Component 8 2 8 2 Safety 2 22 8 3 8 3 SPecilications se 8 3 8 4 Hoses Tube Lines Fittings 8 3 8 4 1 Replacement Considerations 8 3 8 4 2 Hose Tube Line and Fitting
24. Controller C 9 25 9 12 1 Joystick Functionality Setting 9 25 Troubleshooting 12 1 See eee nus 9 25 9 13 1 Analyzer eR rea EP IR ES Een ER RC 9 25 9132 25 died EU bre e REFER 9 26 9 13 3 Analyzer Diagnostic Help Messages 9 28 G5 19A G6 23A Electrical System 9 1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety operation and service information presented in this section it is necessary that the operator mechanic be familiar with the name and location of the electrical components of the machine The following illustration identifies the components that are referred to throughout this section Back up Alarm Power Distribution Module Engine Compartment Engine Harness Connections 1071 G5 19A G6 23A 9 3 Electrical System 9 2 SPECIFICATIONS Electrical system specifications are listed in Section 2 General Information and Specifications 9 4 9 3 FUSES AND RELAYS 9 3 1 Engine Compartment Relays and Fuses There are two relays and one buss bar located inside the engine compartment mounted on a bracket behind the engine The relays control the starter 1 and engine preheat 2 480 G5 19A G6 23A Electrical System
25. G5 19A 8 4 quarts 7 9 liters G6 23A 8 5 quarts 8 liters Differential Housing Capacity Rear G5 19A 5 3 quarts 5 liters G6 23A 8 3 quarts 7 8 liters Wheel End Capacity G5 19A 0 84 quarts 0 8 liters G6 23A 0 7 quarts 0 65 liters Type of Fluid Mobilube HDLS 80W 90 Brakes Master Cylinder Capacity 0 7 quarts 0 7 liters Type of Fluid ATF Hydraulic System System Capacity G5 19A 28 gallons 106 liters G6 23A 35 gallons 133 liters Reservoir Capacity to FULL Mark G5 19A 17 gallons 65 liters G6 23A 23 gallons 87 liters Type of Fluid Mobilfluid 424 Tractor Hydraulic Fluid ISO 46 2 8 G5 19A G6 23A General Information and Specifications 2 5 MAINTENANCE SCHEDULES 2 5 1 8 amp 1st 50 Hour Maintenance Schedule valle 63 Ol oO Mi Check Fuel Check Tire Air Filter Check Engine Check Hydraulic Level Pressure Restriction Oil Level Oil Level Indicator Check Brake Lubrication Fluid Level Schedule 0 0 Lee pa ty Change Change Wheel nd Oil Check Wheel Axle Oil Lug Nut Torque Oil amp Filter OAH08402 Note In order to gain access to the engine fuel filter the oil filter must be removed It is best to replace both of these filters at the same time G5 19A G6 23A 2 5 2 50 250 amp 500 Hour Maintenance Schedule EV
26. IMPORTANT Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 If the axle will be disassembled after removal the oil will have to be drained Loosen the breather to release possible internal pressure then tighten breather with a torque wrench to 9 Ib ft 12 Nm 6 If the axle will be disassembled after removal place a suitable receptacle under the axle 1 and wheel 5 4 hubs 2 drain plugs Remove the drain plugs and allow the axle oil to drain into the receptacle Transfer the used axle oil into a suitable covered container and label the container as Used Oil Dispose of the used oil at an approved recycling facility MAH0440 0990 7 Label disconnect and cap the steering and brake lines at the axle Wipe up any spilled oil 8 Block the front and rear of both tires on the axle that is not being removed Ensure that the machine will remain in place during axle remo
27. Part Description Approximate Price and Number Weight Availability 80904003 Hydraulic Pressure Test Kit 10 Ibs Consult Factory 8 4 Pressure Checks and Adjustments In general follow the steps below whenever conducting pressure checks and performing adjustments 1 Park the machine on a firm level surface Engage the park brake place the transmission control lever in N NEUTRAL place the neutral lock lever in the N NEUTRAL LOCK position level the boom and turn the engine OFF 2 Pressure tee fittings are conveniently located in each hydraulic circuit Install a pressure gauge capable of measuring at least 10 more pressure than that which the circuit being checked operates under 3 Start the engine Operate machine functions several times to allow hydraulic oil to reach operating temperature The hydraulic oil temperature should be between 100 120 F 38 49 C If a temperature gauge or thermometer is unavailable the hydraulic oil reservoir should be warm to the touch 4 Fully depress the accelerator pedal as required Place and hold the joystick in the position needed to operate the particular machine function being checked Continue holding the joystick in position until pressure readings are taken 5 Check the pressure gauge reading It should read as described in the appropriate section If the reading is not as specified turn the engine OFF and check other components in the system Verify tha
28. 3 Use a suitable hoist or overhead crane Remove the 4 motor mount bolts that attach the engine to the frame Carefully lift the engine from the machine Avoid causing damage to the surrounding parts Lift the engine clear of the machine and lower it onto suitable supports or stand Secure the engine so that it will not move or fall 7 7 Engine Deutz BF 4M 2012 7 8 2 Engine Disassembly Inspection and Service Engine disassembly internal inspection service repair and assembly procedures are covered in the Deutz BF 4M 2012 service manual Several special engine service tools are required to properly service the Deutz engine Contact your local Deutz AG Service partner for further information Note If the engine is being replaced there may be external components that will be required to be transferred from the original engine to the replacement engine depending upon who you purchase the new engine from and the configuration of your replacement engine Refer to the appropriate Deutz user manual for detailed procedures that cover the transfer of original engine components to the replacement engine 7 8 3 Note Refer to Section 2 2 Torques for specific fastener torque specifications Engine Installation 1 Position engine in engine compartment being sure to line up the 4 motor mount holes Replace bolts and torque to 71 Ib ft 97 Nm 2 Connect the hydraulic reservoir fill tube
29. 82 891 091 081 sien 20420 02 i 000200 c iip 0080 vc 771070 9 009100 07910 ze 3 5101070 Ob 606000 08210 ze 3 1990070 1 8y 209000 0110 ov y 8TNI 81 NI 0 NI HOlWd 292 292 vauv HONI 19 207 13M 901 GWOT 30272 31901 gn 311201 GVOT 30 22 an 3111901 844 371 LNOHLIM 311201 ANG 311201 awy19 1108 SQHL 310301 310401 310301 ELRES AIIE SLAN 0961 ONVHENN SLOAN 8 3039 3 1108 8 8 1109 SM3U9S dV 31 14 KINO SHINILSW4 31VWOHH MOTTIA d31V 1d INIZ 803 SANTWA G5 19A G6 23A General Information and Specifications ASTM Fastener Torque Chart Metric 2 2 2 8 dQvuo AVS S 3Q0vuo9 AVS s19uajsej pajejd uiniupeo Ajdde jou op sanjea anbio 1987 000891 2266 9986 909 1 8 00227 8LLE 9 92 vocc 862 00228 o1 n eSt 2219 0050 oere 0026 009921 59 0 6 52 6 61 0690 0008 osor 9 0996 80 OOSLEL 1907 G 62 99 2 989 00181L 6165 2702 80 1 8 00 0007 0461 TN 2995 16 009911 6556 9850 1226 000 0 8902 6 1 6 61 009 09911 9 10
30. G6 23A Safety Practices 1 5 SAFETY INFORMATION To avoid possible death or injury carefully read understand and comply with all safety messages In the event of an accident know where to obtain medical assistance and how to use a first aid kit and fire extinguisher fire suppression system Keep emergency telephone numbers fire department ambulance rescue squad paramedics police department etc nearby If working alone check with another person routinely to help assure personal safety 1 5 1 Safety Alert System and Signal Words A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury G5 19A G6 23A 1 66 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on the telehandler Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs For all safety messages carefully read understand and follow the instructions before proceeding 1 6 1 Personal Hazards PERSONAL SAFETY GEAR Wear all the protective clothing and personal safety gear necessary to perform the j
31. Note The first shim next to the pad needs to be the one with holes instead of the slots 3 5 QUICK SWITCH ASSEMBLY This machine is equipped with a quick switch system for easy attachment changes MAH1250 3 5 1 Connecting with a Mechanical Quick Switch Device 1 Retract quick switch device to provide clearance Check to be sure the retainer pin 8 is out 2 Align attachment pin 10 with recess in attachment 9 Raise boom slightly to engage attachment pin in recess 3 Engage quick switch device 4 Shut off engine Exit cab and insert lock pin and secure with retainer pin 5 If attachment is equipped connect auxiliary hydraulic hoses See Section 3 5 3 Connecting with a Quick Switch to a Hydraulic Operated Attachment 3 7 Boom 1250 1270 3 5 3 Connecting with a Quick Switch to Hydraulic Operated Attachment 3 5 2 Connecting with a Hydraulic Quick y P Switch Device 1 Lower attachment to ground and set parking brake 1 Retract quick switch device to provide clearance 2 Quickly depress and release button 14 to relieve Check to be sure lock pin is disengaged pressure at the male auxiliary fitting 2 Align attachment pin 10 with recess in 3 Connect to the male auxiliary fitting 13 attachment 9 Raise boom slightly to engage 4 Quickly depress and release button 15 to relieve attachment pin in recess pressure at the f
32. d bd bh b tt jn o C IL III gelo am ae A 5 o Ws Me TT xum 9 4 4 9 10 Electrical System Engine Harness Schematic 9 4 5 140 oy LSLE S3HSVMIM SIONS HOLMS z aunssaud i SONS WALT GAH zi TON semauo To fl ae HOLMS 1 331055344 lt a TIONS 35 2 dnd OAH owors wos asna 1 Whe VI Toa ug Utd TELS downs e TIONS NMOGLAHS e gt TUE J 6 DEJE CERRI XI IVSHGEd Sondawo19 gt 5 f gt KEMIS gt gt gt gt 2j TONS 1 90 3108 7303 uvis M AT THIS 1 830X4 TIONS HOLIMS WAL he 41009 bm wa0Nas i WOUCHONE HOLMS 38155334 5 2 I03N9N3 1110983 MIW TONS 105 5 009 1 YMd HIS 0387 9 7051815 Tari Tose
33. sealing rings or o rings ALWAYS use a new complete seal kit when rebuilding hydraulic components Consult the parts manual for ordering information 8 11 3 1 Discard all seals back up rings and o rings Replace with new items from complete seal kits to help ensure proper cylinder function Cylinder Cleaning Instructions 2 Clean all metal parts with an approved cleaning Solvent such as trichlorethylene Carefully clean cavities grooves threads etc Note white powdery residue is present on threads and parts it can be removed Clean the residue away with a soft brass wire brush prior to reassembly and wipe with loctite cleaner before reinstallation 8 11 4 1 Inspect internal surfaces and all parts for wear damage etc If the inner surface of the tube does not display a smooth finish or is scored or damaged in any way replace the tube Cylinder Inspection 2 Remove light scratches on the piston rod or inner surface of the tube with a 400 600 grit emery cloth Use the emery cloth in a rotary motion to polish out G5 19A G6 23A and blend the scratch es into the surrounding surface 3 Check the piston rod assembly for run out If the rod is bent it must be replaced 8 11 5 1 Use the proper tools for specific installation tasks Clean tools are required for assembly General Cylinder Assembly 2 Install new seals back up rings and o rings 2 on the piston 4 and the head gland 6 Not
34. transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration 6 Remove the four capscrews 1 and four locknuts securing the yoke flange 2 to the front axle flange 7 Remove the four capscrews securing the flange yoke to the rear axle flange 8 Remove the drive shaft assembly 3 G5 19A G6 23A To Front Axle 0450 5 4 4 1 Disassemble and clean all parts using an approved cleaning fluid Allow to dry Drive Shaft Cleaning and Drying 2 Remove any burrs or rough spots from all machined surfaces Re clean and dry as required 5 4 5 IMPORTANT To help ensure optimum performance the drive shaft assemblies are specially balanced as a unit at the factory When servicing order a complete assembly if components are bent or damaged Refer to the appropriate parts manual for ordering information 1 Raise the drive shaft assembly 3 into position The slip yoke end of the drive shaft mounts toward the front axle If reinstalling a drive shaft previously removed align the flange yokes according to the alignment marks made during removal IMPORTANT Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration Drive Shaft Installation 2 Install the four capscrews 1 and four locknuts securing the y
35. 0 9L 1 0096 vt 12 vt 0225 92 6L 92 00 6 08500 greg BUE gE yt 0726 Ly 0 02 7 92 22 gL 075 050 0 gL 81 NI 05 02 6L 0798 79600 92 8L 091 91500 20540 02 m 000200 050971 00610 2 0L 7100 9 00100 07910 25 a 510100 Ob e 25 1990070 8p 70900012070 Ov 05 HO LWd H91Vd 292 2 292 vauv HONI 13 901 13M 901 0901 3111901 ani 3111901 01 272 3111501 ani 3111901 qvoi 93915 via udd 371 HLM LNOHLIM 3101901 AUG dINW19 311201 AH 412 FTISNAL 310301 3n0uH01 310801 1370 SM3U3S 4 2 aav dun SLAN 8 LU EP 8 SI108 8 AGVYD AVS KINO SHANALSW4 31V WOHH MOTT3A 031 14 2 17 SANTWA C TEE CERE G5 19A G6 23A 2 4 General Information and Specifications CLASS 8 8 METRIC BOLTS amp CLASS 8 METRIC NUTS 2 2 3 Metric Fastener Torque Chart TENSILE stress CLAMP pry or SIZE PITCH area LOAD Loctite TORQUE 263 LOCTITE 262 LOCTITE 242 OR 271 VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 10 9 METRIC BOLTS amp CLASS 10 METRIC NUTS TORQUE DRY OR LOCTITE LOCTITE LUB P
36. 10 3 Parking 8 13 8 10 4 Brake Test iode cusa t cR ded EA RUD Ee aee a 8 14 8 10 5 Steering Orbitrol Valve 8 14 8 10 6 Steer Select 8 14 8 11 Hydraulic 8 16 8 11 1 General Cylinder Removal 8 16 8 11 2 General Cylinder Disassembly 8 16 8 11 3 Cylinder Cleaning Instructions 8 17 8 11 4 Cylinder 8 17 8 11 5 General Cylinder 8 17 8 11 6 General Cylinder 8 18 8 11 7 Steering 8 18 8 11 8 Hydraulic Cylinder Torque Specifications 8 19 G5 19A G6 23A 8 1 Hydraulic System 81 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety operation and service information presented in this section it is necessary that the operator mechanic be familiar with the name and location of the hydraulic components of the machine The following illustration identifies the components that are referred to throughout this section Tilt Cylin
37. 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal WARNING cooling system is under pressure and escaping coolant can cause severe burns and eye injury To prevent personal injury NEVER remove the radiator cap while the cooling system is hot Wear safety glasses Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely 5 Place a suitable container beneath the radiator drain plug or petcock Slowly turn the cap on the coolant overflow bottle to allow any pressure to escape Remove the overflow bottle cap 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Open the radiator drain plug or petcock and allow the coolant to drain Replace the drain plug or close the petcock 7 Transfer the coolant into a suitable covered container and label as Used Coolant Dispose of used coolant at an approved recycling facility Label all hoses to ensure correct installation 8 Remove the seat from the cab to expose the heater defroster element 1 9 Loosen the hose clamps and disconnect the two heater hoses 4 7 Cab and Covers 10 11 12 1 Install the h
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39. FAN 9 10 1 Note If the suspect component is found to be within the heater box the heater box must be removed as a complete unit and replaced For additional information on the removal and installation of the heater box refer to Section 4 3 9 a Heater Assembly Removal Cab Heater Controls The cab heater controls are located to the right of the seat The control panel consists of a variable speed fan control knob and a temperature control knob a CabHeater Controls Removal Note After determining which control knob is not functioning remove only the suspect control knob In order to remove either knob the cab heater and fan control panel must be removed from the dash panel 1 Open the engine cover 2 Disconnect the battery negative cable at the battery negative terminal 3 Remove the setscrew from the variable speed fan control knob or temperature control knob 4 Remove the right side control panel screws 5 Remove the screws and backing locknuts from the cab heater and fan control panel G5 19A G6 23A 6 Pull the control panel out from the dash panel and if removing variable speed fan control remove the cab harness connector 7 If removing the temperature control knob disconnect the cable connector and remove control knob 8 Remove the hex locknut from the suspect control shaft 9 Remove the control from the panel b Disassembly DO NOT disassemble the cab heater and fan con
40. Manual for complete teardown instructions The minimum tolerance for the brake disc gap is 0 016 in 4 10 mm 5 11 Axles Drive Shafts Wheels and Tires 5 12 This Page Intentionally Left Blank G5 19A G6 23A Section 6 Transmission Contents PARAGRAPH TITLE PAGE 6 1 Transmission Assembly Component Terminology 6 2 6 2 Transmission Description 6 3 6 3 Transmission Specifications 6 3 6 3 1 Transmission 6 3 6 4 Transmission 6 3 6 4 1 Transmission 6 3 6 4 2 Transmission 6 4 6 4 3 Transmission 5 6 4 6 4 4 After Transmission Replacement 6 4 6 5 Towing a Disabled 6 5 G5 19A G6 23A 6 1 Transmission TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY 6 1 To understand the safety operation and maintenance information presented in this section itis necessary that The following illustration identifies the components that locations of the major assemblies of the transmission are refer
41. PWR PREHEAT PWR SOLENOID ENGINE PREHEAT RLY HEATER FUSE 50A SLOBLO PREHEAT PWR POSITIVE CABLE 6 NEGATIVE CABLE BATTERY DISCONNECT OR BATTERY S mm BLK PREHEAT PWR STRT SOL ENGINE HARNESS 810 G5 19A G6 23A Electrical System 9 5 3 Drive Circuit Breakdown CAB HARNESS POWER DISTRIBUTION MODULE gt lt gt lt gt lt REV gt lt 85 s 2 5 ov 8 REVERSE c gt T SHETISTR PWR 225 REVOUR TRAVEL D gt lt REY gt lt 87a gt lt m gt lt gt 5 SHFT STEER m REV OUT 2 REV OUT asf Sil m REV 5 REV 87 PWR3 i a RELAY gt lt CAB HARNESS HARNESS 87a X05 X05 gt lt gt lt gt lt gt lt gt lt 8 lt NEUT NEUT Sl START SHFT STR PWR SHFT STR PWR 87 RELAY gt In lt 30 gt lt 87a gt ja lt gt lt lt 5 lt gt lt TO BATTERY POSITIVE e e gt lt S CAB HARNESS CAB HARNESS B p X00 gt 1 1 lt HARNESS HARNESS 06
42. Reduction 2 6 G5 19A G6 23A General Information and Specifications 2 3 4 Engine Performance Specifications Description G5 19A amp G6 23A Engine Make Model Deutz BF 4M 2012 Low Idle 925 x50 rpm High Idle 2370 x50 rpm Horsepower 100 4 BHP 74 9 kW 2200 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements 2 3 5 Tires Description Tire Air Pressure 405 70 24 MPT 04 G6 23A only 58 0 psi 4 0 Bar 405 70 20 MPT 04 G5 19A only 50 7 psi 3 5 Bar 12 5 18 MPT 02 G5 19A only 73 psi 5 Bar Note Standard wheel lug nut torque is 221 Ib ft 300 Nm G5 19A G6 23A 2 7 Ay General Information and Specifications 2 4 FLUIDS LUBRICANTS AND CAPACITIES Engine Crankcase Oil Capacity w Filter Change 9 6 quarts 9 0 liters Filter Capacity 1 05 quarts 1 0 liter Oil Type 15W 40 CE Fuel Filters Primary Fuel Filter Capacity Approx 0 26 quarts 1 0 liter Fuel Filter Capacity 0 16 quarts 0 6 liters Fuel Tank Capacity G5 19A 25 gallons 95 liters G6 23A 27 gallons 102 liters Type of Fuel U S A 2 Diesel Cooling System System Capacity w o Heater 10 6 quarts 10 liters Type of Fluid 50 50 mix of ethylene glycol amp water Axles Differential Housing Capacity Front
43. Replacement Label disconnect and cap all hydraulic hoses attached to engine and radiator cap all fittings and plug hoses to keep dirt amp debris from entering hydraulic system Disconnect the fuel inlet 1 and return lines Install a plug in the end of each line Remove hydraulic and fuel filters windshield washer fluid reservoir and filter bracket assembly Remove radiator overflow bottle Unbolt and remove the fan safety shroud Remove bolts securing the radiator and lift it clear of engine compartment Refer to section Section 7 4 2 Radiator Oil Cooler and Coolant Heater Replacement Mark the engine fan orientation Remove the engine fan G5 19A G6 23A 20 21 22 23 24 25 26 27 28 29 MAH0620 Unbolt the relay distribution panel behind the engine Label any loose wire connections Unplug the necessary harness plugs that go into the cab Carefully pull wires through engine compartment wall and place on engine Mark the location of the throttle cable 2 at the engine throttle lever Disconnect the throttle cable Detach exhaust and air cleaner hoses from the engine Cover air inlets to protect from dirt amp debris Remove air cleaner assembly from engine compartment Completely disconnect exhaust pipe Remove the hydraulic reservoir fill tube Secure the engine with a lifting strap or chain from the appropriate lifting points
44. Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove belly pan of engine compartment 5 Thoroughly clean the engine and surrounding area including all hoses and fittings before proceeding 6 Disconnect the battery negative cable from the battery negative terminal 7 Slowly turn the coolant overflow bottle cap and allow any pressure to escape Remove the overflow bottle cap 8 Place a suitable container beneath the radiator petcock 9 Place a funnel at the base of the radiator to channel the drained coolant into the container Open the radiator petcock and drain the coolant into the funnel Transfer the fluid into a properly labeled G5 19A G6 23A Engine Deutz BF 4M 2012 container Dispose of properly if coolant needs to be replaced Close the radiator petcock 10 Label disconnect and cap all coolant hoses attached to the radiator Cap all fittings and openings to keep dirt amp debris from entering the cooling system 11 Label disconnect and cap all hydraulic hoses attached to the radiator Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system 12 Detach the fan safety shroud 290 13 Remove the two brackets 1 at the front of the radiator attached to the frame 14 Remove the locknuts holding the
45. as required Uncap reattach and secure the three hoses 3 Check the routing of all hoses for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required 4 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 5 Inspect the park brake valve and connections for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF 6 Replace the brake valve cover 7 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 Close and secure the engine cover Note The park brake valve circuit will need to be bled after installation Refer to Section 8 10 4 Brake Test 8 10 4 Brake Test Carefully bleed the brake lines as soon as the brake valve is installed on the machine Air in the system will not allow the brakes to apply properly There are four brake bleeder locations 3 on the front axle The outside bleeders are used for the park brake circuit The inside bleeders are used for the service brake circuit Work with an assistant to perform this procedure 1 Place the transmission control lever in N NEUTRAL engage the park brake and start the engine 1060 2 Remove the plastic cap from the brake bleeder Attach one end of a length of transparent tubing over th
46. brake is secured with two capscrews 1 and lockwashers 2 at the left side of the seat base Parking Brake 1260 a Park Brake Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Loosen and remove the three bolts and washers holding the park brake valve cover Remove the cover 5 Label disconnect and cap the hydraulic hoses on each side and bottom of the park brake valve Disconnect and cap all hoses fittings etc 6 Remove the two capscrews and two lockwashers mounting the park brake valve to the left side of the seat base Note DO NOT disassemble the park brake valve The park brake valve is not serviceable and must be replaced in its entirety if defective b Park Brake Valve Installation 1 Install the park brake valve with the two lockwashers and two capscrews to mount the park brake valve to the left side of the seat base Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 8 13 Hydraulic System n 2 Use new oiled o rings
47. brake valve to the steering column support Note DO NOT disassemble the service brake valve The service brake valve is not serviceable and must be replaced in its entirety if defective b Service Brake Valve Installation 1 Install the service brake valve to the steering column support with the necessary hardware Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic 2 Use new oiled o rings as required Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations 3 Check the routing of all hoses and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 4 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 5 Inspect the service brake valve and connections for leaks and check the levels of the hydraulic and brake fluid Shut the engine OFF 6 Replace the necessary dash panels 7 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 Close and secure the engine cover Note The service brake valve circuit will need to be bled after installation Refer to Section 8 10 4 Brake Test G5 19A G6 23A n The park
48. etc the printed circuit boards and terminals Disconnect the battery negative cable at its battery terminal before beginning this procedure Failure to comply can result in damage to the operator s instrument cluster and malfunction of the instruments and indicator lights 1 Open the engine cover 2 Disconnect the battery negative cable at the battery negative terminal 3 Remove the two nuts holding the instrument cluster to the dash 4 Slide the instrument cluster out of the operator console 5 Disconnect the wiring harnesses b Installation 1 Connect the instrument cluster wiring harnesses 2 Position the instrument cluster in the operator console 3 Secure to the dash with two nuts 4 Connect the battery negative cable at the battery negative terminal 5 Close and secure the engine cover 9 19 Electrical System 9 9 WINDOW WIPER WASHER 9 9 1 Windshield Wiper Motor a Removal Note It may be necessary to remove several hydraulic hoses from under the dash in order to remove and install the wiper motor housing 1 Open the engine cover 2 Disconnect the battery negative cable at the battery negative terminal 3 Remove the lower access panel below the instrument panel 4 Disconnect the right side defroster hose from dash panel hose connector 5 Disconnect the cab harness connectors from the wiper motor
49. on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Disconnect the battery negative cable at the battery negative terminal 4 Remove the two capscrews Remove the bottom cover 5 Disconnect the electrical connections and remove the four self tapping screws from the bottom of the joystick assembly 6 Remove the joystick assembly b Joystick Assembly Installation 1 Set the joystick assembly into the armrest support 2 Install the four self tapping screws Connect the electrical connections 3 Connect the battery negative cable to the battery negative terminal 4 Close and secure the engine cover 5 Test the boom joystick functions Test the boom joystick functions to ensure they match the control pattern on the joystick decal located inside cab 6 Install the bottom cover and secure using two lens head capscrews G5 19A G6 23A 4 3 7 Windshield Wiper Assembly Refer to Section 9 9 1 Windshield Wiper Motor for removal and installation information 4 3 8 Windshield Washer Assembly Refer to Section 9 9 2 Windshield Washer Reservoir and Pump for removal and installation information 4 3 9 Heater Defroster System a Heater Assembly Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF
50. remove it at this time This will allow the alternator to swivel during belt removal ut O 220 5 Loosen the belt tensioning adjustment bolt at the bottom of the alternator to loosen the fan drive belt 6 Remove the fan drive belt from the alternator 7 Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine 8 While supporting the alternator with one hand remove the upper mounting hardware from the upper alternator mount Remove the alternator from the machine b Alternator Installation 1 Position the alternator and align with the upper alternator mount on the engine bracket Insert the upper mounting hardware through the alternator mount DO NOT tighten completely at this time G5 19A G6 23A Electrical System 2 Align the lower alternator mount hole with the lower mounting bracket on the engine and insert the lower mounting capscrew Be sure to leave enough room to attach the drive belt 3 Attach the fan drive belt to the alternator 4 Adjust the lower belt tensioning bolt to remove excessive slack from the drive belt Check for proper fan belt deflection 5 Reattach the previously
51. represents a major portion of machine operating costs and therefore must be used efficiently ALWAYS use a premium brand of high quality clean diesel fuel Low cost inferior fuel can lead to poor performance and expensive engine repair Diesel Fuel Note Use only diesel fuel designed for diesel engines Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance IMPORTANT Due to the precise tolerances of diesel injection systems keep the fuel clean and free of dirt and water Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles Use ASTM 42 diesel fuel with minimum Cetane rating of 40 2 diesel fuel gives the 7 5 Engine Deutz BF 4M 2012 best economy and performance under most operating conditions Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking Inform the owner operator of the machine to use 2 diesel fuel unless ambient temperatures are below 32 F 0 C When temperatures are below 32 F 0 C a blend of 1 diesel and 2 diesel fuels known as winterized 2 diesel may be used Note 1 diesel fuel be used however fuel economy will be reduced WARNING nonor mix gasoline or alcohol with diesel fuel The mixture can cause an explosion Use a low s
52. second section out to be able to install wear pads in front of the first boom section With the sling still under the boom head install the top wear pads washers and bolts in the front of the G5 19A G6 23A first boom section Apply Loctite 4242 and torque to 66 Ib ft 90 Nm Lower the second boom section and install the bottom wear pads backing plates shims and bolts in the front of the first boom section Apply Loctite 242 and torque to 66 Ib ft 90 Nm Install both left and right side front wear pads backing plates shims and bolts in the front of the first boom section Apply Loctite 242 and torque to 66 Ib ft 90 Nm IMPORTANT Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly 6 10 3 3 4 Tighten all rear wear pad bolts after ensuring the minimum gap requirements have been met Refer to Section 3 4 1 Wear Pad Inspection Insert the pin and clip into the barrel end of the extend retract cylinder Lift the tilt cylinder into place and insert the pins and clips to secure the cylinder to the boomhead Slide the tilt and auxiliary hoses between the boom sections Uncap and reconnect the tilt and auxiliary hoses and attach to their appropriate locations Boom Installation IMPORTANT Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wea
53. 18 19 20 21 22 23 24 25 26 27 31 32 33 8 9 10 12 13 14 18 19 20 25 26 28 29 30 32 11 13 14 16 18 19 20 22 23 24 25 27 28 29 31 32 33 11 13 14 16 18 19 20 22 24 25 27 28 29 31 32 33 4 18 19 20 25 27 31 38 34 35 45 56 4 36 37 38 39 40 42 43 44 58 9 14 18 19 22 26 28 29 31 33 35 36 45 46 59 7 8 9 10 11 12 13 14 20 21 23 26 28 29 30 33 35 45 59 13 14 20 23 25 26 29 30 33 45 47 48 49 4 38 41 11 13 14 18 19 24 25 45 50 51 52 53 54 57 15 11 19 25 28 29 31 32 33 34 46 59 10 25 31 33 34 45 55 11 12 1 Battery charge low 2 Bad electrical connection 3 Faulty starter motor 4 Incorrect grade of lubricating oil 5 Low cranking speed 6 Fuel tank empty 7 Faulty stop control operation 8 Fuel inlet restricted 9 Faulty fuel lift pump Clogged fuel filter 11 Restricted air cleaner Air in fuel system Faulty fuel injection pump Faulty fuel injectors or incorrect type Exhauster or vacuum pipe leak Induction system leaks Broken fuel injection pump drive 18 Incorrect fuel pump timing Incorrect valve timing 20 Poor compression 15 16 17 7 10 Key to Possible Causes Blocked fuel tank vent Incorrect grade of fuel Sticking throttle or restricted movement Exhaust pipe restriction Leaking cylinder head gasket Overheating
54. 242 OR 263 211 1060 27 3 459 286 0 1540 1160 1240 1690 30 3 5 561 349 5 2100 1570 1680 2310 33 3 5 694 432 5 2600 2140 2280 2860 36 4 817 509 0 3660 2750 2930 4020 42 4 5 1120 698 0 5860 4400 4690 6440 Note Thesetorque values do not apply to cadmium plated fasteners METRIC CLASS 8 8 METRIC CLASS 10 9 G5 19A G6 23A 2 5 Ay General Information and Specifications 2 3 SPECIFICATIONS 2 3 1 Travel Speeds G5 19A G6 23A First Gear 6 mph 10 kmph 4 mph 7 kmph Second Gear 21 mph 34 kmph 20 mph 33 kmph 2 3 2 Hydraulic Cylinder Performance Specifications Note Machine with no load engine at full throttle hydraulic oil above 130 F 54 C minimum engine at operating temperature Function Approximate Times sec G5 19A G6 23A Boom Extend 5 66 7 09 Boom Retract 4 51 5 59 Boom Lift 5 87 8 05 Boom Lower 3 79 5 55 Attachment Tilt UP 2 48 4 30 Attachment Tilt DOWN 1 97 3 32 2 3 3 Electrical System Note Refer to Section 9 3 Fuses and Relays for more information Battery Type Rating 12V DC Negative Ground Limited Maintenance Wet Charged Quantity 1 100 Ah Coo Reserve Capacity CCA Q 4 F 880 EN Group Series DIN 600 44 Alternator 14V 70 Amps Starter 12V 8 0 KW Type EV Gear
55. 3 Connect the exhaust pipe to the engine 4 Install the air cleaner assembly into the engine compartment and attach hose to air intake 5 Reconnect throttle cable 2 onto the engine if necessary adjust for full travel 6 Feed engine harness wires through the engine compartment wall and plug into the ports located on the side of the cab 7 Reattach the relay distribution panel and connect any loose wires 8 Install the overflow bottle bracket and secure the expansion tank 9 Attach the engine fan 10 Secure the radiator with the necessary bolts and attach the fan safety shroud Check that the fan top clearance is adequate with regard to the radiator Reattach the previously labeled hoses Refer to Section 7 4 2 Radiator Oil Cooler and Coolant Heater Replacement Fill with a 50 50 mixture of ethylene glycol and water 11 Install the filter bracket assembly Secure the hydraulic and fuel filters and windshield washer fluid reservoir 7 8 12 Connect the fuel inlet line to the fuel filter 1 and reconnect the return fuel line to the engine 13 Uncap and reconnect all hydraulic hoses and fittings to the engine and necessary hydraulic elements Keep hoses free of dirt amp debris 14 Refill the hydraulic reservoir Refer to the appropriate Operation amp Safety Manual for information concerning the hydraulic oil and filter change 620 15 Replace the battery tray and battery and reconnect t
56. 5 3 7 Axle Assembly and Drive Shaft Troubleshooting Problem Cause Remedy 1 Excessive axle noise while 1 Oil level too low 1 Fill oil to correct level Refer to driving Axle and or wheel end housings filled with incorrect oil or oil level low Incorrect alignment of ring and pinion gears Incorrect pinion input shaft bearing preload 5 Worn or damaged bearings Section 2 4 Fluids Lubricants and Capacities 2 Drain axle and or wheel end housings and fill to correct level with Mobilube HDLS 80W 90 Fluid Refer to Section 2 4 Fluids Lubricants and Capacities 3 Correct alignment by adding or removing shims as needed 4 Correct bearing preload by adding or removing shims as needed 5 Replace bearings as needed unbalanced 6 Worn or broken gear teeth 6 Replace gears as needed 7 Contamination in the axle 7 Drain axle and or wheel end housings and fill to correct level with Mobilube HDLS 80W 90 Fluid Refer to Section 2 4 Fluids Lubricants and Capacities 8 Axle housing damaged 8 Replace damaged parts 2 Intermittent noise when 1 Universal joint s worn or 1 Repair or replace universal traveling damaged joints as needed 2 Differential ring and or pinion 2 Determine cause and repair as gears damaged needed 3 Vibration or intermittent noise 1 Drive shaft universal joint s 1 Tighten capscrews to correct when traveling assembly incorrectly tightened tor
57. 7 2 1 Be sure the reservoir is clean and free of all debris Hydraulic Oil Reservoir Filling 2 Install new hydraulic oil filters 3 Fill the reservoir with Mobilfluid 424 ISO Grade 46 oil Refer to Section 2 4 Fluids Lubricants and Capacities 4 Start the machine Run engine to normal operating temperature Operate all hydraulic functions 8 8 HYDRAULIC SYSTEM PUMP 8 8 1 The implement pump is the heart of the hydraulic system and whenever there is a problem in the system the pump often is blamed However implement pump failure is seldom due to failure of pump components Pump failure usually indicates another problem in the hydraulic system Implement Pump Failure Analysis According to pump manufacturer statistics 90 95 percent of pump failures are due to one or more of the following causes Aeration Cavitation Contamination Excessive Heat Over Pressurization Improper Fluid In the event of pump failure investigate further to determine the cause of the problem 8 8 2 Implement Pump Replacement a Implement Pump Removal 1 Park the machine on a firm level surface fully retract the boom support the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Al
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59. 910 6 Remove the linkage attached to the wiper motor 7 Loosen and remove the four bolts holding the wiper motor to the mounting bracket Note Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing 8 Remove the motor from the inside of the cab b Disassembly DO NOT disassemble the motor The motor is not serviceable Replace motor if found to be defective c Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found 9 20 d Installation and Testing 1 Install all required hardware to the motor assembly 2 Align motor with the mounting holes and bolt the motor to the mounting bracket 3 Connect the wiper linkage to the wiper motor shaft Note Align the wiper linkage arm with the flat on the motor shaft to ensure wiper stroke covers window area and it does not swipe past the glass area 4 Connect the cab harness connectors to windshield wiper motor connectors 5 Connect the negative battery cable to the battery negative terminal 6 Close and secure the engine cover 7 Turn ignition key switch to the RUN position and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved 8 Install right side defroster hose to the dash panel hose connector 9 If previously removed install hydraulic hoses under the dash 10 Inst
60. 93 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
61. Align the tilt cylinder pin and screw in the lock bolt 11 Torque to 72 Ib ft 97 Nm G5 19A G6 23A Boom C t 3 6 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom Boom Troubleshooting Problem Cause Remedy 1 Boom will not extend or 1 Broken hydraulic hose s or 1 Locate break replace hose s retract tube s and or connections or tube s tighten connections leaking 2 Extend Retracthydraulic system 2 Refer to Section 8 Hydraulic not operating properly System 3 Faulty extend retract cylinder 3 Repair cylinder Refer to Section 8 11 4 Cylinder Inspection 2 Boom will not fully extend 1 Extend retract hydraulic system 1 Refer to Section 8 Hydraulic not operating properly System 3 Boom shifts to right or left 1 Boom side wear pads 1 Shim wear pads to correct gap when extending improperly shimmed or worn Replace wear pads as needed Refer to Section 3 4 2 Boom Wear Pad Replacement 4 Excessive pivot pin noise 1 Insufficient lubrication 1 Lubricate at regular intervals and or wear Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed 2 Worn bushing s 2 Replace bushing s and lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules 5 Boom will not raise or lower 1 Broken hydraulic hoses or tubes 1 Locate brea
62. Boom System Component 3 2 3 2 Boom System Two Section 3 3 3 2 1 Boom System 1 3 8 3 3 Boom Assembly 3 3 3 3 1 Boom 1 3 4 3 3 2 Second Section Boom 3 4 3 3 3 Second Section Boom Installation 3 5 3 3 4 Boom Installation eee 3 5 3 4 Boom Wear 2 rr rrr RUE Rer ehm ee ce ee ee 3 6 3 4 1 Wear Pad 3 6 3 4 2 Boom Wear Pad 3 6 3 4 8 Boom Wear Pad Lubrication 3 7 3 5 Quick Switch 3 7 3 5 1 Connecting with a Mechanical Quick Switch Device 3 7 3 5 2 Connecting with a Hydraulic Quick Switch Device 3 8 3 5 3 Connecting with a Quick Switch to a Hydraulic Operated Attachment 3 8 3 5 4 Quick Switch Removal 3 8 3 5 5 Quick Switch 1 3 8 3 6 Troubleshooting 2 RR I Rm RR 3 9 G5 19A G6 23A 3 1 ae Boom
63. Brake Valve Installation Refer to Section 8 10 2 b Service Brake Valve Installation for installation information Service Brake Pedal Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF G5 19A G6 23A Cab and Covers Ps Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Disconnect the battery negative cable at the battery negative terminal Remove the lower dash panel 0600 Remove the two capscrews 10 securing the brake pedal to the inching valve Remove the circlip 11 flat washer and the return spring securing the service brake pedal to the cab Remove the clip pin from the brake plunger fork link Remove the service brake pedal from the cab Service Brake Pedal Installation Position the service brake pedal in its mounting location within the cab Install the brake pedal being careful to reposition the brake plunger yoke Install the return spring washer and clip Install clip pin in brake plunger fork link Adjust the brake pedal as needed 4 Install and secure the lower dash cover Connect the battery negative cable to the battery negative terminal
64. ER FUEL m s _ 7 PREHEAT 4 Cy RED AMBER 7 BRAKE A HIBEAM 7 Nes Nae 7 HYDFILTER 2WHEELSTEER 7 7 ENG H20 2 ALL WHEEL STEER 2 pp RED cen CRAB STEER DA GREEN GREEN HYDPUMP amp IMOR 7 np RED a ORANGE Di BATTERY TRAILER i GREEN NE 2 TRALERBRAKE _ ue FLASHER _ m m Dt HRMTR ot SIREN BUZZER SPEEDO s z a g Z Y 7j 9 Yyyy VVVYYYY VVNYYNYYNYNY xn TO CAB HARNESS 1240 G5 19A G6 23A Electrical System 9 5 CIRCUIT BREAKDOWNS 9 5 1 Charge Circuit Breakdown ENGINE HARNESS TO CAB HARNESS X07 POSITIVE CABLE S TO BATTERY NEGATIVE CABLE TO BATTERY DISCONNECT OR BATTERY 50mm BLK STARTER 16mm RED ALT BAT 16mm RED ALTERNATOR ANAA EFGHJKLMNOPQRSTUVWX HARNESS 07 DEUTSCH HD36 24 23SE ENGINE HARNESS ALL 1 0 MM WIRES IN THIS CONNECTOR TO DASH BOARD X11 ALT W ALT D 8833882 2 oo 8 VVVVVVVVVVVVVVVVVVVV VV VV VV VV VV VV VV VV
65. ERY 50x Tel PO Drain Fuel Check Engine Check ater Coolant Level Battery Separator Lubrication Schedule Bg Wa Check Axle Check Wheel Air Filter Check Oil Level End Oil Levels Vacuator Fan Belt Filter Valve Change Engine Oil and Check Boom Bearing Pads Change Fuel Check Wheel ilter Lug Nut Torque 00402 2 5 3 1000 amp 1500 Hour Maintenance Schedule md Change Change Wheel Axle Oil End Oil EVERY 1500 23 d l T O n M A Ft ET Lege Change Change Change Change Engine Coolant Hydraulic Brake Fluid Fluid amp Filters Hydraulic Tank Breather 0050 2 9 General Information and Specifications 2 6 LUBRICATION SCHEDULES 8 Hour Lubrication Schedule 2 6 1 MYSTIK TETRIMOLY NLGI 2 GC LB EVERY 8 820 G5 19A G6 23A 2 10 General Information and Specifications 50 Hour Lubrication Schedule 2 6 2 MYSTIK TETRIMOLY NLGI 2 GC LB EVERY 502 MAH0830 2 11 G5 19A G6 23A General Information and Specifications 2 12 This Page Intentionally Left Blank G5 19A G6 23A C x C iy K Section 3 Boom Contents PARAGRAPH TITLE PAGE 3 1
66. GHT EF PRIORITY FLOW VALVE gt DESCRIPTION PUMP DRIVE MOTOR DRIVE G5 19A MOTOR DRIVE G6 23A MOTOR DRIVE G6 23A PUMP IMPLEMENT WITH PRIORITY VALVE FILTER CHARGE REMOTE MOUNT VALVE STEER SELECT VALVE MAIN CONTROL VALVE LOW RANGE VALVE STEERING VALVE FRONT REAR AUX OPTIONAL VALVE PARK BRAKE VALVE SERVICE BRAKE VALVE 3 BAR CHECK COOLER BYPASS COOLER TRANSMISSION FILTER MAIN RETURN TANK MOUNT VALVE 1ST 2ND FRONT AUX OPTIONAL VALVE TRAILER BRAKES OPTIONAL z o v o zizi z z o m o o B S gt VALVE BRAKE INCHING MAH1150 G5 19A G6 23A Hydraulic System G5 19A G6 23A LEVAGE LIFT COMPENSATION INCLINGISON TILT OUTILLAGE AUX TELESCOPAGE CROWD MAH1160 8 7 Hydraulic System n 8 7 HYDRAULIC RESERVOIR The hydraulic reservoir and fuel tank are part of the frame For this reason neither tank can be removed For cleaning instructions see Section 7 6 2 Fuel Hydraulic Oil Tank Occasionally fluid may seep leak or be more forcefully expelled from the fi
67. PLER 7 9 1 Coupler Removal 1 Remove Hydrostatic transmission 3 Refer to Section 6 4 1 Transmission Removal Be sure to follow all described safety guidelines 2 After transmission has been removed take out the 12 bolts that attach the Flywheel Cover Plate 4 to the engine 3 Pull off the Flywheel Cover Plate to expose the coupler 5 and the flywheel 4 Remove the necessary bolts to detach the coupler and flex plate 6 0630 G5 19A G6 23A 7 9 2 Coupler Installation 1 Attach the coupler 5 and flex plate 6 using the necessary bolts Torque to 155 Ib ft 210 Nm Bolt on the Flywheel Cover Plate 4 over the coupler and flywheel Torque bolts to 37 Ib ft 50 Nm Reattach the hydrostatic transmission 3 Follow all guidelines in Section 6 4 3 Transmission Installation 7 9 Engine Deutz BF 4M 2012 7 10 TROUBLESHOOTING Trouble Possible Causes see key below Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfiring Excessive Fuel Consumption Black Exhaust Blue White Exhaust Low Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops 1 2 3 4 5 6 7 8 9 10 12 13 14 17 18 19 20 22 31 32 33 5 7 8 9 10 11 12 13 14 16 18 19 20 21 22 24 29 31 32 33 8 9 10 11 12 13 14 16
68. Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Label or otherwise mark the hydraulic hoses in relation to the steer select manifold Disconnect and cap all hoses fittings solenoid wire terminal leads etc 5 Remove the capscrews that attach the manifold to the frame G5 19A G6 23A Hydraulic System Remove the steer select manifold with attached steer select valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine Steer Select Valve and Manifold Disassembly Cleaning Inspection and Assembly Place the steer select assembly on a suitable work surface Separate the steer select valve from the manifold by removing the capscrews Discard the old o rings Remove the solenoid valves and cartridges from the steer select housing Clean all components with a suitable cleaner before inspection Inspect the solenoid cartridges for proper operation Check by shifting the spool to ensure that it is functioning properly Check that the spring is intact Inspect the cartridge interior for contamination Inspect internal p
69. SWITCH lt P gt lt B 12345678 2 gt lt 1 2 AAANNAAAA ME 5 H si lt gt lt pat lt lt lt sh gt lt Te le CAB ROOF HARNESS TO CAB ROOF HARNESS lt tel S 516 lt 5 HEAD LIGHTS SIGNAL LEVER e sperem 5 PD Hee 2 Hop men Ep ere CT i CAB HARNESS En ROOF HARNESS 9 16 G5 19A G6 23A Electrical System 9 6 ENGINE START CIRCUIT 9 6 1 The starter 1 is located on the left side of the engine the left side of the machine underneath a heat shield attached to the flywheel Starter 210 a Testing the Starter on the Engine If the starter does not engage when the ignition key switch is turned check the following 1 The main fuse may be blown requiring replacement Check for the cause of the blown fuse 2 There may be a defect in the ignition key switch ignition wiring or starter solenoid 3 Check battery condition Clean the battery posts and the connectors at each end of the battery cables 4 Check for broken wiring and damaged insulation on the wiring Replace all broken or damaged wiring 5 Check all connections at the starter solenoid key switch and wiring harness plugs Clean and tighten all connections 6 If the starter still does not operate after these checks have been performed c
70. alation enuia moaia nak k aa ee eee 7 8 7 9 Engine Coupler s Ha eae ee 7 9 7 9 1 Coupler Removal 7 9 7 9 2 Coupler 5 7 9 7 10 Troubleshooting 7 10 G5 19A G6 23A 7 1 O Engine Deutz BF 4M 2012 7 1 INTRODUCTION 7 1 1 These instructions are written for worldwide use In territories where legal requirements govern engine smoke emission noise safety factors etc apply all instructions data and dimensions provided herein in such a way that after maintenance service and repair of the engine engine operation does not violate local regulations IMPORTANT These instructions cover only the routine maintenance removal installation and troubleshooting of the engine For assistance with comprehensive engine diagnosis repair and component replacement contact your local Deutz AG Service partner Disclaimer and Scope 7 2 A gradual running in break in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F 60 C Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds DO NOT apply an overload to the engine 7 1 2 To understand the safet
71. all the lower dash panel 11 Close and secure the engine cover 9 9 2 Windshield Washer Reservoir and Pump The windshield washer motor and reservoir is located in the engine compartment as a unit and cannot be serviced separately a Removal 1 Open the engine cover 2 Disconnect the battery negative cable at the battery negative terminal 3 Remove the nuts and the lockwashers from the washer mounting studs 4 Pull the washer reservoir out and away from the mounting studs 5 Rotate the washer reservoir label and remove the cab harness connectors from the washer reservoir connectors 6 Remove the windshield washer hoses from the reservoir G5 19A G6 23A Electrical System b Disassembly DO NOT disassemble the pump The pump is not serviceable Replace pump if found to be defective c Installation and Testing 1 Connect the windshield washer hoses to the reservoir 2 Connect the cab wiring harness connectors to the reservoir connectors Install the reservoir tank onto the mounting studs Install the lockwashers and nuts and secure Fill the washer fluid reservoir with washer fluid gt Connect the battery negative cable to the battery negative terminal 7 Close and secure the engine cover 8 Turn the ignition key switch to the RUN position and press the washer switch Verify that fluid is sprayed on the windshield 9 10 CAB HEATER AND
72. amp visu ode Satur deka VER 5 10 5 6 Steering 5 11 5 7 ac ccc 5 11 G5 19A G6 23A Section Subject Page Section 6 Transmission a docendo a c keene a an en E C D i QM D e D QD ER 6 1 6 1 Transmission Assembly Component Terminology 6 2 6 2 Transmission 6 3 6 3 Transmission 6 3 6 4 Transmission 1 6 3 6 5 Towing a Disabled 1 6 5 Section 7 Engine Deutz BF 4M 2012 7 1 7 1 death Sealed 7 2 7 2 Engine Serial 2 7 4 7 8 Specifications and Maintenance 7 4 7 4 Engine Cooling 7 4 7 5 Engine Electrical 7 5 7 6 Fuel System c ope E E 7 5 7 7 Engine Exhaust and Air Cleaner 7 6 7 8 Engine
73. assageways of the steer select manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil 7 1 Install the solenoid valves and cartridges in the steer select housing Attach the steer select valve to the manifold using new oiled o rings and socket head capscrews Steer Select Manifold and Valve Installation Attach the steer select manifold and valve to the mounting plate on the frame using the socket head capscrews Connect the hydraulic hoses fittings solenoid wire terminal leads etc to the steer select valve and manifold Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps G5 19A G6 23A 4 5 0020 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions Inspect for leaks and check the level of the hydraulic fluid in
74. attempting service When removing hydraulic components plug hose ends and connections to prevent excess leakage and contamination Place a suitable catch basin beneath the machine to capture fluid run off Check and obey all Federal State and or Local regulations regarding waste storage disposal and recycling 1 6 4 ENGINE Stop the engine before performing any service unless specifically instructed otherwise Operational Hazards VENTILATION Avoid prolonged engine operation in enclosed areas without adequate ventilation SOFT SURFACES AND SLOPES NEVER work on a machine that is parked on a soft surface or slope The machine must be on a hard level surface with the wheels blocked before performing any service FLUID TEMPERATURE NEVER work on a machine when the engine cooling or hydraulic systems are hot Hot components and fluids can cause severe burns Allow systems to cool before proceeding FLUID PRESSURE Before loosening any hydraulic or diesel fuel component hose or tube turn the engine OFF Wear heavy protective gloves and eye protection NEVER check for leaks using any part of your body use a piece of cardboard or wood instead If injured seek medical attention immediately Diesel fluid leaking under pressure can explode Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin cause infection gangrene and other serious personal injury Relieve all pressure before disconnecting any c
75. b 4 3 4 2 2 Serial Number 4 3 4 3 Cab 2 22222 8 4 lt 16 4 3 4 3 1 Steering 4 3 4 3 2 Steering Column Valve 4 4 4 3 8 Brake Pedal and Valve 4 4 4 3 4 INCHING 4 5 4 3 5 Throttle Pedal 4 6 4 3 6 Joystick Assembly 4 7 4 3 7 Windshield Wiper 4 7 4 3 8 Windshield Washer 4 7 4 3 9 Heater Defroster 4 7 4 4 Cab Removal eT 4 8 4 5 Cab Installation 222 eee Ree 4 10 G5 19A G6 23A 4 1 Ps Cab and Covers 41 6 AND COVERS COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers The following illustration identifies the components that are referred to throughout this section Transmissi
76. ck for proper fluid level 4 Start the engine allow it to reach operating temperature and observe the operator s instrument cluster for warning indication If the sender is not defective the problem could be elsewhere possibly 9 23 Electrical System in a shorted wire improper running engine improper or low coolant obstructed or faulty radiator coolant pump loose fan belt defective instrument display etc 5 Close and secure the engine cover 9 11 6 Fuel Shut off Solenoid The fuel shut off solenoid 2 is located on the top of the engine near the fuel filter a Fuel Shut off Solenoid Removal 1 Open the engine cover Allow engine to cool 2 Disconnect the battery negative cable at the battery negative terminal 3 Disconnect the wiring connector at the fuel shut off solenoid lead 4 Remove the fuel shut off solenoid from the engine b Fuel Shut off Solenoid Disassembly DO NOT disassemble a fuel shut off solenoid Replace a defective fuel shut off solenoid with a new part c Fuel Shut off Solenoid Inspection and Replacement Use a 12 volt DC source and ground to test the solenoid Energize the solenoid and watch for the plunger to retract If the plunger does not retract replace the fuel shut off solenoid with a new solenoid d Fuel Shut off Solenoid Installation 1 Clean the exterior of the fuel shut off solenoid engine location 2 Install the fuel shut off so
77. clamps must be tight 8 Install the belly pan 9 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 10 Inspect for leaks and check all fluid levels Note Check for leaks and repair as required before continuing 11 Close and secure the engine cover g Pump Test 1 Perform a flow meter test on the pump 2 Check the load sense 3 Check the system functions 8 10 8 9 FRONT DRIVE PUMP For internal service instructions and detailed specifications contact your local JLG distributor for a copy of the Rexroth Repair Manual P N 31200123 520 a Front Drive Pump Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Drain the hydraulic reservoir or attach a vacuum adapter fitting to the reservoir fill tube to reduce oil spillage 5 Label and disconnect all hydraulic hoses attached to the pump cap all fittings and plug hoses to keep dirt amp debris from entering hydraulic system 6 Support the pump and remove the four bolts attaching the pump to the f
78. curately count the number of turns each bolt makes as you perform the procedure 3 Alternately screw the release bolts clockwise in 1 2 turn increments Turn until resistance is felt 4 Turn the tow option engagement screw 2 on the hydrostatic transmission counterclockwise three turns 5 Carefully remove the blocking from each tire and tow the machine to a secure location Note This procedure does not alter any relief settings 780 G5 19A G6 23A 770 After the machine has been towed to a secure location reactivate the parking brake 1 Block all four wheels WARNING stock ALL Four WHEELS Failure to do so could result in death or serious injury from machine roll away 2 Turn the tow option screw 2 on the hydrostatic transmission clockwise three turns 3 Using a torque wrench alternately unscrew the brake release bolts 1 outward in 1 2 turn increments until the torque drops off sharply 4 Again alternately unscrew the bolts outward until you feel the bolts flange begin to contact against the special screw 5 Screw the bolts inward clockwise 1 4 turn 6 The parking brake should now be reactivated and the front wheels locked 7 Remove the blocks from the four tires 8 Verify that the parking brake works Note If the parking brake does not work check all activation operations step by step 6 5
79. der Extend Retract Cylinder Slave Main Control Cylinder Valve Lift Lower Cylinder Hydraulic Reservoir Main Pump Hydraulic Filter Implement Pump 241 x Steering Cylinder 8 2 G5 19A G6 23A Hydraulic System n 8 2 SAFETY INFORMATION WARNING sevice the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Failure to follow the safety practices may result in death or serious injury Petroleum based hydraulic fluids are used in this machine The temperature of hydraulic fluid increases during the operation of various hydraulic functions A heated petroleum based hydraulic fluid presents a fire hazard especially when an ignition source is present Accordingly periodically inspect all hydraulic system components hoses tubes lines fittings etc Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard If in doubt replace the component Whenever you disconnect a hydraulic line coupler fitting or other component slowly and cautiously loosen the part involved A hissing sound or slow seepage of hydraulic fluid may occur in most cases After the hissing sound has ceased continue removing the part Any escaping oil should be directed into an appropriate container Cap or otherwis
80. dertaken Read understand and follow these instructions During service of the boom perform the following 1 Check wear pads Refer to Section 3 4 1 Wear Pad Inspection 2 Apply grease at all lubrication points grease fittings Refer to Section 2 6 Lubrication Schedules 3 Check for proper operation by operating all boom functions through their full ranges of motion several times 3 3 Boom 3 3 1 Boom Removal 1 Remove any attachment from the quick switch assembly 2 there is enough room in front of the machine to allow the boom sections to be removed Park the machine on a hard level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 3 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Remove the battery negative cable from the battery negative terminal 5 Open the engine cover Allow the system fluids to cool 6 Remove the quick switch assembly Refer to Section 3 5 4 Quick Switch Removal 7 Support the front of the boom by placing a sling behind the boom head Support the lift lower cylinder and remove the lock bolt and then the rod end pin Lower the lift lower cylinder onto the frame rails 8 Label and disconnect the tilt and auxiliary hydraulic hoses attached to
81. ding area including all hoses and fittings before proceeding 5 Place a suitable container to catch hydraulic fluid drainage beneath the frame 6 Label disconnect and cap all the hydraulic hoses attached to the main control valve Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system 7 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 8 Remove the four bolts securing the main control valve to the frame bracket G5 19A G6 23A b Main Control Valve Disassembly 1 To disassemble the individual sections of the main control valve remove the nuts from the end of the tie rod Pull the tie rods out through the sections 2 Disassemble each section assembly as required Some sections include a pre adjusted relief valve that regulates pressure in a specific circuit IMPORTANT DO NOT adjust any of the relief valve assemblies Tampering with a relief valve will irrevocably alter pressure in the affected circuit requiring recalibration or a new relief valve Load Sense Section 720 Disassemble each Valve Section 1 Carefully separate the load sense outlet section from the crowd section 2 Remove the o rings from between the two sections 3 Carefully separate each remaining section being careful not to lose the load sense shuttle ball 4 Remove both end caps from each end of the valve sections then remove each control
82. disconnected or removed carefully and slowly lift the cab and remove it from the frame Readjust the position of the sling as needed to help balance the cab during removal When the cab is completely clear of the machine carefully lower it to the ground Block up or support the cab Inspect the condition of the fittings clamps hydraulic hoses etc Replace parts as indicated by their condition Inspect and replace other machine parts that are exposed with the cab removed Repair or replace as required 4 9 Cab and Covers a 4 5 INSTALLATION 1 Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab installation 2 Attach a sling with suitable lifting capacity through the previously installed eye bolts 3 Use a hoist or overhead crane and sling attached to the cab Carefully begin to align the cab with the mounting holes in the frame Stop and check that wiring hydraulic hoses cables etc will not be pinched or damaged as the cab is positioned Take special note of the fuel fill tube as well Readjust the position of the sling as needed to help balance the cab during installation 4 Install the cab to frame bolts washers and nuts Torque to 110 Ib ft 150 Nm 5 Remove the eye bolts from the top of the cab Bottom of Cab 1140 6 Connect the
83. e machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Failure to follow the safety practices may result in death or serious injury 5 3 4 Axle Maintenance CLEANING Clean parts with machined or ground surfaces such as gears bearings and shafts with emulsion cleaners or petroleum based cleaners DO NOT steam clean internal components and the interior of the planetary hub and axle housing Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Remove old gasket material from all surfaces DRYING Use clean lintless towels to dry components after cleaning DO NOT dry bearings by spinning them with compressed air this can damage mating surfaces due to lack of lubrication After drying lightly coat components with oil or a rust preventive chemical to help protect them from corrosion If storing components for a prolonged period wrap them in wax paper PERIODIC OPERATION REQUIREMENT Every two weeks drive the machine far enough to cause the drive train components to make several complete revolutions This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity SUBMERSION If the machine has been exposed to water deep enough to cover the hubs disassemble the wheel ends and inspect for water damage and contamina
84. e The Crowd cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head 3 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod 5 to prevent any damage to the rod IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 4 Lubricate and slide the head gland 6 over the cylinder rod 5 Install the piston head 4 on to the end of the cylinder rod Loctite and install the setscrew 3 in the piston head Refer to Section 8 11 8 Hydraulic Cylinder Torque Specifications for tightening guidelines for the piston head and the set screw IMPORTANT Avoid using excessive force when clamping the cylinder barrel in a vise Apply only enough force to hold the cylinder barrel securely Excessive force can damage the cylinder barrel 5 Place the cylinder barrel 1 in a soft jawed vise or other acceptable holding equipment if possible IMPORTANT When sliding the rod and piston assembly into the cylinder barrel prevent the threaded end of the cylinder barrel from damaging the piston head Keep the cylinder rod centered within the barrel to prevent binding 6 Carefully insert the cylinder rod assembly into the tube 7 Screw the head gland 6 into the cylinder barrel 1 and tighten with a spanner wrench Refer to Section 8 11 8 Hydraulic Cylinder Torque Specifications
85. e block off the part to prevent further fluid seepage Hydraulic system maintenance will at times require that the engine be operated Always follow safety precautions A major cause of hydraulic component failure is contamination Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs Sand grit and other contaminants can damage the finely machined surfaces within hydraulic components If operating in an exceptionally dirty environment change filters and inspect the fluid more often When servicing the system cap or plug hydraulic fittings hoses and tube assemblies Plug all cylinder ports valves and the hydraulic reservoir and pump openings until installation occurs Protect threads from contamination and damage Some hydraulic functions are actuated by interfacing with electrical system components switches solenoids and sensors When the hydraulic system is not functioning properly check the electrical aspect of the malfunctioning circuit also 8 3 SPECIFICATIONS Refer to Section 2 3 Specifications for hydraulic system specifications G5 19A G6 23A 8 4 HOSES TUBE LINES FITTINGS ETC There are numerous hydraulic hoses tubes fittings etc used on this machine Periodically inspect all of these and carefully examine any signs of wear abrasion and or deterioration Determine whether any further use of the component would constitute a hazard If in doubt replace the co
86. e brake bleeder Place the other end of this tubing in a suitable transparent container that is partially 8 14 filled with hydraulic oil The end of the tubing must be below the oil level in the container 3 DO NOT open the brake bleeder without holding the tubing firmly on the bleeder There is pressure at the brakes Carefully open the bleeder with a 12 mm wrench Have an assistant depress the brake pedal Close the brake bleeder when air bubbles no longer appear in the oil Release the brake pedal Remove the tubing from the brake bleeder 4 Repeat steps 2 and 3 for the remaining brake bleeder 5 If bleeding the service brake circuit install a vacuum pump on the brake reservoir and remove the remainder of the trapped air from the brake system 6 Check brake fluid level and add fluid if necessary Refer to Section 2 4 Fluids Lubricants and Capacities 7 Conduct a pressure and function check of the brake 8 10 5 Refer to Section 4 3 2 Steering Column Valve Replacement for details Steering Orbitrol Valve 8 10 6 Steer Select Valve The steer select valve is attached to a manifold mounted on amounting plate inside the frame near the front drive motor Verify the correct operation of the steer select valve solenoids before considering replacement of the valve The housing of the steer select valve is not serviceable and must be replaced if defective a Steer Select Manifold and Valve Removal 1
87. e brake off at full throttle The pressure reading should be 6381 to 6671 psi 440 to 460 bar Do NOT adjust any relief settings The unit is preset at the factory and should not be tampered with If the proper pressure is not read the unit may be defective Drive Pressure Checking G5 19A G6 23A n Attach a pressure gauge to the test fitting 4 on the appropriate hose of the implement pump The pressure reading should be 2610 psi 180 bar with the steering wheel fully turned to one direction Steering Pressure Checking Do NOT adjust any relief settings The unitis preset atthe factory and should not be tampered with If the proper pressure is not read the unit may be defective 850 8 5 6 Attach a pressure gauge to the test fitting b on the brake valve in the cab to check system pressure The pressure reading should be 435 psi 30 bar with the brake pedal fully depressed Brake Pressure Checking Do NOT adjust any relief settings The unitis preset atthe factory and should not be tampered with If the proper pressure is not read the unit may be defective 8 5 Hydraulic System 8 6 HYDRAULIC SCHEMATIC 8 6 LEFT REAR STEERING CYLINDER RIGHT LEFT FRONT STEERING CYLINDER RI
88. e end main control valve section 2 Stand the end main control valve section on end 3 Install proper o rings and load sense shuttle on the inner face of the end main control valve section Align the Crowd section over the three tie rods and slide onto the end main control valve section 4 Using proper o rings and load sense shuttle repeat step three for the remaining sections 5 Install the washers and nuts on the tie rods and torque to 18 5 Ib ft 25 Nm f Main Control Valve Installation 1 Loosely install the four main control valve mounting bolts through bracket on the rear of the machine 2 Install the main control valve onto the bracket aligning the bolts with the holes in the end sections of the main control valve Slide the main control valve into position and tighten the bolts 3 Prime the main control valve by filling the inlet openings with fresh filtered hydraulic oil from a clean container before attaching the hoses 8 12 4 Use new oiled o rings as required Uncap and reattach and secure all hoses clamps etc to the main control valve 5 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 6 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic funct
89. eater assembly to its original orientation MAH1120 Remove the button head capscrews nuts and lockwashers securing the heater assembly to the cab Carefully pull out the heater assembly Label and disconnect the wiring harness connections at the blower Remove the heater assembly Heater Assembly Installation Connect the wiring harness connections at the blower Install the button head capscrews nuts and lockwashers to secure the heater assembly to the cab 4 Reconnect the two heater hoses 4 8 Refill the cooling system at the coolant overflow bottle with a 50 50 mixture of ethylene glycol and water allowing time for the coolant to fill the engine block See Section 2 4 Fluids Lubricants and Capacities for system capacities Connect the battery negative cable at the battery negative terminal Start the engine run it briefly at low idle and check the machine for any visual sign of fluid leakage STOP the machine immediately if any leakage is noted and make any necessary repairs before continuing Install the seat in the cab 9 Check the coolant level Add or remove fluid as required 10 Close and secure the engine cover 4 4 REMOVAL IMPORTANT help ensure safety and optimum performance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information Before performing any inspection maintenance or service operatio
90. ed and housing planet carrier o rings damaged or missing tighten plugs to 59 Ib ft B0 Nm 2 O ring between hub and 2 Replace o ring housing planet carrier damaged or missing 3 Shaft seal damaged or missing 3 Replace seal and or fork joint and or worn or damaged shaft shaft sealing surfaces 4 Housing capscrews loose 4 Tighten housing capscrews to 41 Ib ft 55 Nm 5 Housing planet carrier damaged 5 Replace housing planet carrier 6 Oil leaking from steering 1 Hose fittings loose 1 Tighten fittings cylinder 2 Steering cylinder o rings and or 2 Replace o rings and seals seals worn or damaged 3 Piston rod seal worn or 3 Replace piston rod seal damaged 4 Oylinder tube damaged 4 Replace cylinder tube G5 19A G6 23A 5 7 hs Axles Drive Shafts Wheels and Tires 5 3 7 Axle Assembly and Drive Shaft Troubleshooting Continued Problem Cause Remedy 7 Axle overheating 1 Oil level too high 1 Fill oil to correct level with Mobilube HDLS 80W 90 fluid Refer to Section 2 4 Fluids Lubricants and Capacities damaged leaking Axle and or wheel end housings 2 Drain axle and or wheel end filled with incorrect oil or oil housing and fill to correct level contaminated or oil level low with Mobilube HDLS 80W 90 Fluid Refer to Section 2 4 Fluids Lubricants and Capacities 8 High steering effort required Steering hydraulic system
91. emale auxiliary fitting 3 Engage quick switch device 5 Connect to the female auxiliary fitting 13 4 Press the button 12 and at the same time move the joystick to engage or to disengage the quick 3 5 4 Quick Switch Removal switch device 1 Remove the lock bolt 11 holding the tilt cylinder rod end to the quick switch assembly Remove the tilt cylinder pin 2 Support the quick switch assembly Remove the pin from the quick switch assembly from either side 3 Inspect the above pin for nicks or surface corrosion Use fine emery cloth to fix minor nicks or corrosion 5 Raise the boom to eye level and visually check that If damaged or if it cannot be repaired the pin must be the quick switch pin protrudes through the hole If the replaced pin does not protrude through the hole place the attachment on the ground and return to step 2 3 5 5 Quick Switch Installation 6 If attachment is equipped connect auxiliary 1 Assemble the quick switch to the boom head Line hydraulic hoses See Section 3 5 3 Connecting with up the quick switch between the mounts on the a Quick Switch to a Hydraulic Operated Attachment boom head The quick switch should be centered in the boom head 2 Coat the quick switch pivot pin with an anti seize compound Insert the quick switch pivot pin through the quick switch and boom head 3 Align the quick switch with the tilt cylinder rod end 3 8 and insert the tilt cylinder pin
92. er diameter etc without written factory recommendations may result in unsafe condition regarding stability The tires are filled with air only when the machine leaves the factory JLG does not recommend the use of hydrofill as a tire fill substance because of possible environmental impact Large bore valve stems are used to help expedite tire inflation and deflation An inner tube may be used if a tire does not provide an airtight seal Check tire inflation pressures when the tires are cold When mounting a tire on the wheel the tire must be mounted on the wheel respective of the directional tread pattern of the tire this produces a left or right tire and wheel assembly The wheel and tire assemblies must be installed with the directional tread pattern arrows 4 facing in the direction of forward travel 5 10 4 N V QULLU D MAH0890 5 5 1 Removing Wheel and Tire Assembly from Machine 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed 4 Place a suitable jack under the axle pad closest to the wheel being removed Raise the mac
93. event damage to the parts Carefully inspect the integrity of all moving parts bearings yokes tubes gears shafts etc and fasteners nuts bolts washers etc as they are subject to major stress and wear Always replace elastic locknuts and any damaged worn cracked seized or otherwise improper parts that could affect the safe and proper functioning of the machine axles and drive shafts 5 3 AXLE ASSEMBLIES 5 3 1 The axle serial number plate is located on the inside of the right yoke Information on the serial number plate is required in correspondence regarding the axle Axle Serial Number Plate Supply information from the axle serial number plate when communicating about an axle assembly or axle components 5 3 2 General axle specifications are found in Section 2 General Information and Specifications Axle differential housing fluid information is found in Section 2 4 Fluids Lubricants and Capacities Axle Specifications G5 19A G6 23A 5 3 3 Detailed axle service instructions covering the axle differential brakes and wheel end safety repair disassembly reassembly adjustment and troubleshooting information are provided in the following manuals Axle Internal Service Machine Carraro Axle JLG Model MANUAL G5 19A 141154 FRONT 31200119 G5 19A 141155 REAR 31200120 G6 23A 139970 FRONT 31200121 G6 23A 141247 REAR 31200122 WARNING service th
94. flywheel housing Support the starter securely as it is relatively heavy and will fall if not supported 6 Support the starter and remove the fasteners securing the starter to the engine Remove the negative ground cable from its starter mounting bolt 7 Remove the starter 1 from the machine d Starter Cleaning and Drying 1 While the starter is being removed wipe away any grease or dirt that has accumulated around the starter mounting opening 2 If reinstalling the starter clean the exterior of the starter with an approved solvent DO NOT submerse the starter or allow the solvent to contact the starter bushings 3 Dry the starter with a clean lint free cloth e Starter Periodic Maintenance A starter requires no routine maintenance beyond the occasional inspection of the electrical connections which must be clean and tight Note DO NOT disassemble the starter The starter is not serviceable and must be replaced in its entirety if defective 9 17 Electrical System f Starter Installation 1 Position the starter in its mounting opening on the flywheel housing Position the ground cable over the correct starter mounting bolt Secure the starter with fasteners Torque fasteners to 32 Ib ft 43 Nm 2 Connect the positive battery cable to the upper solenoid stud Install the wires to the upper solenoid stud and secure with lockwasher and nut 3 Connect the wire to the solenoid
95. gistration form must be filled out by the JLG distributor signed by the purchaser and returned to JLG when the machine is sold and or put into use Registration activates the warranty period and helps to assure that warranty claims are promptly processed To guarantee full warranty service verify that the distributor has returned the business reply card of the warranty registration form to JLG 2 2 G5 19A G6 23A General Information and Specifications ASTM Fastener Torque Chart English TORQUES 2 2 2 2 1 2 3 8 3avu5 avs 9 3Qvu9 AVS sJauajse pajejd uiniupeo 0 Ajdde jou op anbio 95941 910N 009 0725 000891 6268 0992 0958 00227 0062 v16L 0991 0022 078 00881 2 Spee oroe 00007 6 95 0654 0952 091 009921 5202 55 1 097 061 00084 0507 9 6895 Ortz 006181 000 6912 0702 0272 00181 06 1 9091 0921 0891 0002 oset ge 0992 024524 009911 5090 2061 08 1 082 000 0 5061 2061 001 097 00179 09911 9 0 02 0881 008 01 0022 0191 0091 0002 00996 0081 026 0721 00969 04 01 2 5261 05 1 00696 0002 0951 0281 002 8 S LL 6001 0 8 021 00955 06960
96. he battery terminals being sure to start with the positive terminal 16 Check that all hydraulic electrical cooling fuel and exhaust system connections are correct and connected tightly 17 Run engine to normal operating temperature then shut off the engine While the engine is cooling check for leaks 18 Allow the engine to cool Check the radiator coolant level and top off with a 50 50 mixture of ethylene glycol and water Replace the radiator cap 19 Check for leaks from the engine main hydraulic pump and lines transmission hydraulic reservoir and fuel tank Check the levels of all fluids and lubricants Fill as required IMPORTANT During the full throttle check DO NOT operate any hyaraulic function DO NOT steer or apply any pressure to the steer ing wheel Keep the transmission in NEUTRAL 20 Obtain and connect an appropriate engine analyzer or tachometer Check the engine rpm at full throttle G5 19A G6 23A Engine Deutz BF 4M 2012 C If the rpm is not 2370 50 rpm readjust the throttle limit stop screw at the throttle pedal within the cab 21 Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times Check the hydraulic oil level 22 Check for proper operation of all components 23 Turn the engine OFF 24 Install the belly pan 25 Install the engine cover Close and secure the cover 7 9 ENGINE COU
97. he hex jam nut and flat washer onto the end of the throttle cable Secure the cable to the throttle pedal Secure the cable to the throttle pedal with the clip pin 2 Align the throttle pedal assembly with its mount holes on the cab floor 3 Install three capscrews securing the throttle pedal assembly to the cab floor Torque the capscrews to 9 12 Nm 4 Connect the battery negative cable to the battery negative terminal 5 Close and secure the engine cover c Throttle Adjustment 1 From within the cab lightly depress the accelerator pedal 21 to the full throttle position As needed adjust the limit stop screw 22 until it touches the pedal Tighten the locknut 23 01912 IMPORTANT During the full throttle check DO NOT operate any hyaraulic function DO NOT steer or apply any pressure to the steer ing wheel Keep the transmission NEUTRAL 2 Check the engine rpm at full throttle If the rpm is not 2370 x50 rpm readjust the throttle limit stop screw at the throttle pedal within the cab G5 19A G6 23A Cab and Covers 4 3 6 Joystick Assembly Replacement a Joystick Assembly Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag
98. he hydraulic system Remove the clip from barrel end of tilt cylinder pin Remove the tilt cylinder pin and lift the tilt cylinder out of the boomhead 3 Atthe access panel on the bottom front of the boom unscrew the tilt and auxiliary hoses Plug the hose ends to prevent dirt and debris from entering the hydraulic system Note Tag or identify each hose to the corresponding fitting it was removed from 4 Carefully pull the tilt auxiliary and extend retract hydraulic hoses 3 through the rear of the second boom section 5 Remove the two snap rings and pin from barrel end of the extend retract cylinder MAHO0660 G5 19A G6 23A Boom C t Pull the second boom section out 6 in to 8 in 15 cm to 20 cm to be able to loosen and remove all the bolts and remove all the wear pads backing plates and shims from the front inside of the first section boom Tag each pad backing plate shim and bolts from each location WARNING never weld or drill the boom unless approved in writing by JLG The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling Failure to comply can result in death or severe personal injury Remove the clip and pin from the rod end of the extend retract cylinder and pu
99. heck the starting circuit b Starter Circuit Checks 1 Check wires and connections for looseness corrosion damage etc 2 If a whirring noise is heard but the engine does not turn over the starter is spinning but not engaging the flywheel The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine G5 19A G6 23A 3 If the starter only clicks it may indicate that the battery is discharged or that there is a loose or corroded battery cable connection Check the battery state of charge and battery condition first then check the cables and cable connections 4 Foradditional information on the starting circuit refer to Section 9 4 4 Front amp Rear Chassis Battery Boom Harness Schematic c Starter Removal Remove the starter only if it fails To remove the starter 1 Open the engine cover 2 Disconnect the battery negative cable at the battery negative terminal 3 Remove the bolts that secure the starter heat shield Disconnect the shield 4 Remove the wires from the solenoid stud Remove the red positive battery cable from the starter Label and disconnect the wire from the starter solenoid housing stud Record how the wires are installed to ensure correct installation later 5 Loosen but DO NOT remove the fasteners securing the starter to the
100. hine and position a suitable support beneath the axle Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly 5 Lower the machine onto the support 6 Remove lug nuts and lug washers in an alternating pattern 7 Remove the wheel and tire assembly from the machine G5 19A G6 23A hs Axles Drive Shafts Wheels and Tires 5 5 2 Installing Wheel and Tire Assembly onto Machine IMPORTANT The wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel Tread arrows must point forward Install tires onto wheels to rotate in proper direction 460 1 Position wheel onto studs on wheel end of axle 2 Install wheel lug washers 3 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 4 Tighten lug nuts in an alternating pattern as indicated in figure Torque to 221 Ib ft 300 Nm 5 Remove machine from supports G5 19A G6 23A 5 6 STEERING ADJUSTMENT 5 6 1 Steering angle adjustment instructions can be found in the appropriate Carraro Repair Manual Steering Angle Adjustment 5 7 BRAKES 5 7 1 Check the brake disks for wear every 1 000 hours of operation or yearly Brake Disk Inspection The service brakes can only be checked by performing a teardown of the axle Refer to the appropriate Carraro Repair
101. ick system startup or S4 on being set to neutral X and Y and Knurl the joystick closed and S4 and S1 and S2 becomes open TELE OUT OPEN FAULT 4 1 Open on pin J1 21 None Fault shall be latched and only reset upon power down of the controller TELE IN OPEN FAULT 4 2 Open on pin J1 22 None Fault shall be latched and only reset upon power down of the controller TILT UP OPEN FAULT 4 3 Open on pin J1 23 None Fault shall be latched and only reset upon power down of the controller TILT DOWN OPEN FAULT 4 4 Open on pin J1 24 None Fault shall be latched and only reset upon power down of the controller LIFT DOWN OPEN FAULT 4 5 Open on pin J1 25 None Fault shall be latched and only reset upon power down of the controller LIFT UP OPEN FAULT 4 6 Open on pin J1 26 None Fault shall be latched and only reset upon power down of the controller 9 26 G5 19A G6 23A Electrical System Help Message Flash Code Fault Condition Action AUX HYD 1 OPEN FAULT 4 8 Open on pin J1 8 None Fault shall be latched and only reset upon power down of the controller AUX HYD 2 OPEN FAULT 4 7 Open on pin J1 28 None Fault shall be latched and only reset upon power down of the controller TELE OUT SHORT 5 1 Short to plus on pin J1 21 Disable Telescope Out output Fault FAULT shall be latched and only reset upon power down of the controller TELE IN SHORT FAULT 5 2 Short to plus on pin J1 22 D
102. in on near or around the machine 8 11 2 1 Clean the cylinder with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder General Cylinder Disassembly 2 Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holding equipment if possible IMPORTANT Avoid using excessive force when clamping the cylinder in a vise Apply only enough force to hold the cylinder securely Excessive force can damage the cylinder tube 3 If applicable remove the counterbalance valve from the side of the cylinder barrel 8 16 160 IMPORTANT DO NOT tamper with or attempt adjust the counterbalance valve cartridge If adjustment is necessary replace the counterbalance valve with a new part 4 Extend the rod 5 to allow access to the base of the cylinder IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 5 Using a pin spanner wrench unscrew the head gland 6 from the barrel 1 A considerable amount of force will be necessary to remove the head gland Carefully slide the head gland down along the rod toward the rod eye end away from the cylinder barrel IMPORTANT When sliding the rod and piston assembly out of the tube prevent the threaded end of the tube from damaging the piston Keep the rod centered within the tube to help prevent binding 6 Carefully pull the rod assembly along w
103. inal bores 4 Replace the second balance plate into its original position Be sure the small holes are to the low pressure side fit the channel seal and back up ring b Fitthe o ring into its groove in the mounting flange and apply a small amount of Loctite to the lower front face of the body 8 9 Hydraulic System n 6 Carefully fit the mounting plate in its original position The drain hole in the rear face must be to the low pressure side DO NOT DAMAGE THE SEAL ON THE SHAFT 7 Fit washers and nuts to studs and torque to 65 70 Ib ft 88 95 Nm 8 Pour a small amount of clean hydraulic fluid into the inlet port and check that the shaft can be turned without undue force f Implement Pump Installation 1 Position pump in the mounting position Note Use new o rings where required Never reuse o rings 2 Use the two Allen head bolts to secure the pump into place Torque to 70 Ib ft 95 Nm 3 Install the engine oil filter Check engine oil level Add oil as required 4 Uncap and reconnect previously labeled hydraulic hoses to their proper locations 5 Fill the hydraulic reservoir with clean filtered hydraulic oil 6 Prime the pump by filling the case drain port with fresh filtered hydraulic oil from a clean container before installing the case drain connector and hose 7 Check all routing of hoses and tubing for sharp bends or interference with any rotating members tube and hose
104. ings and suitably labeled pieces of tape Select an appropriate marking method for the conditions and proceed accordingly NEVER replace a hydraulic hose or other component with a part not specifically designed for this machine Use only factory approved parts for best performance and safety Removal and replacement of hoses tube lines fittings etc usually involves straightforward procedures When removing a hydraulic hose or other component be aware that o rings are used throughout the hydraulic system 8 3 Hydraulic System n ALWAYS replace a used o ring with a new part Check all routing of hoses wiring and tubing for sharp bends or interference with any rotating members Install appropriate protective devices such as tie wraps and conduit to help shield hoses from damage All tube and hose clamps must be tight 85 HYDRAULIC PRESSURE DIAGNOSIS JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting the JLG Pressure Test Kit The kit is in a durable polyethylene carrying case for demanding field service conditions Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system The kit includes e Gauges for testing high and low pressure circuits Fittings couplers and hoses Durable carrying case Contact your local JLG distributor for ordering information 8 5 1
105. ions 7 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 9 Install the rear panel g Main Control Valve Test Conduct a pressure check of the hydraulic system in its entirety Adjust pressure s as required Refer to Section 8 5 2 Main Control Valve Pressure Checking 8 10 2 The service brake valve is at the base of the steering column support concealed by the lower dash cover Service Brake Valve The service brakes themselves are part of the front axle Refer to Section 5 Axles Drive Shafts Wheels and Tires for further information a Service Brake Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the necessary dash panels 5 Label disconnect and cap the hydraulic hoses connected to the service brake valve Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system G5 19A G6 23A Hydraulic System MAHO0030 6 Remove the bolts that mount the service
106. isable Telescope In and Telescope Out outputs Fault shall be latched and only reset upon power down of the controller TILT UP SHORT FAULT 5 3 Short to plus on pin J1 23 Disable Tilt Up and Tilt Down outputs Fault shall be latched and only reset upon power down of the controller TILT DOWN SHORT 5 4 Short to plus on pin J1 24 Disable Tilt Down output Fault shall be FAULT latched and only reset upon power down of the controller LIFT DOWN SHORT 5 5 Short to plus on pin J1 25 Disable Lift Down and Lift Up outputs FAULT Fault shall be latched and only reset upon power down of the controller LIFT UP SHORT FAULT 5 6 Short to plus on pin J1 26 Disable Lift Up output Fault shall be latched and only reset upon power down of the controller AUX HYD 1 SHORT 5 8 Short to plus on pin J1 8 Disable Aux Hyd 1 output Fault shall FAULT be latched and only reset upon power down of the controller AUX HYD 2 SHORT 5 7 Short to plus on pin J1 28 Disable Aux Hyd 2 output Fault shall FAULT be latched and only reset upon power down of the controller CAN COMMUNICATION 6 6 Open circuit short to plus Disable all outputs The fault shall be or short to minus on pins cleared upon all 3 axes of the joystick J1 11 or J1 12 being set to neutral X and Y and Knurl and S4 and 61 and S2 becomes open EEPROM FAULT 9 9 eeprom None Fault shall be latched and only reset upon power down of the controller G5 19A G6 23A 9 27 Electrical System
107. isolator mounts at the bottom of the machine 15 Connect a lifting strap to the radiator oil cooler and carefully lift the radiator oil cooler out of the engine bay G5 19A G6 23A b Radiator Oil Cooler Installation 1 Install the isolator mounts to the bottom of the radiator Insert radiator through the machine frame and secure to the radiator mount plate with new locknuts 2 Be sure the engine fan has clearance in regard to the radiator Install the two brackets 1 on the front of the radiator to the frame 3 Attach the fan safety shroud 4 Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations 5 Uncap and reconnect all previously labeled coolant hoses to the appropriate locations 6 Fill the coolant overflow bottle with a 50 50 mixture of ethylene glycol and water 7 Connect the battery negative cable to the battery negative terminal 8 Run the engine to operating temperature Visually check for leaks with the engine running Check the coolant level in the overflow bottle and fill or drain as necessary Check the hydraulic fluid level in the tank and add fluid as required 9 Attach the belly pan of the engine compartment 10 Close and secure the engine cover 7 5 ENGINE ELECTRICAL SYSTEM The engine electrical system including the starter alternator and primary wiring is described in Section 9 Electrical System 7 6 FUEL SYSTEM 7 6 1 Fuel
108. ith the head gland out of the cylinder barrel 7 Fasten the rod end in a soft jawed vise and put a padded support under and near the threaded end of the rod to help prevent damage to the rod 8 Remove the set screw 3 from the piston 4 G5 19A G6 23A Hydraulic System n Note It be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed Some cylinder parts are sealed with a special organic sealant and locking compound Before attempting to disassemble these parts remove any accessible seals from the area of the bonded parts Wipe off any hydraulic oil then heat the part s uniformly to break the bond A temperature of 300 400 F 149 204 C will destroy the bond Avoid overheating or the parts may become distorted or damaged Apply sufficient torque for removal while the parts are still hot The sealant often leaves a white powdery residue on threads and other parts which must be removed by brushing with a soft brass wire brush prior to reassembly 9 Remove the piston head 4 from the rod 5 and carefully slide the head gland 6 off the end of the rod 10 Remove all seals back up rings and o rings 2 from the piston head and all seals back up rings and o rings from the head gland Note The head gland bearing will need to be inspected to determine if replacement is necessary DO NOT attempt to salvage cylinder seals
109. k replace hose s and or connection leaks or tube s tighten connections 2 Lift lower hydraulic system not 2 Refer to Section 8 Hydraulic operating properly System 3 Faulty Lift cylinders 3 Repair cylinder Refer to Section 8 11 4 Cylinder Inspection 4 Seized boom pivot pin bushing 4 Replace bushing G5 19A G6 23A 3 9 D Boom Troubleshooting Continued Problem Cause Remedy 6 Rapid boom pad wear 1 Incorrect wear pad gap Rapid cycle times with heavy loads Contaminated corroded or rusted wear pad sliding surfaces Operating in extremely dusty abrasive conditions 1 Check wear pad gaps and correct as needed Refer to Section 3 4 2 Wear Pad Replacement Reduce cycle times Remove contamination and or corrosion from wear pad sliding surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s Clean equipment frequently 7 Auxiliary hydraulics will not operate Auxiliary hydraulic system not operating properly Refer to Section 8 Hydraulic System 3 10 G5 19A G6 23A Section 4 Cab and Covers Contents PARAGRAPH TITLE PAGE 4 1 Operator s Cab and Covers Component 4 2 4 2 Operators Cab cellis rx DRE Rs Rahman ee E cx 4 3 4 2 1 Operator s Ca
110. l 4 Connect the battery negative cable to the battery negative terminal Close and secure the engine cover 4 3 Cab and Covers a 4 3 2 Steering Column Valve Replacement a Steering Column and Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 Remove the steering wheel 4 Refer to Section 4 3 1 Steering Wheel transmission control lever 6 and accessory lever 5 6 Remove the steering column tilt lever 7 7 Remove the lower dash panel 8 Label disconnect and cap the hydraulic hoses 8 and fittings on the steering orbitrol valve 9 MAH1100 9 Remove the two pivot bolts for the steering column and steering orbitrol valve 10 Pull the steering column assembly from the machine cab 11 Remove the four hex flange capscrews connecting the orbitrol valve to the steering column Note DO NOT disassemble the steering orbitrol valve The steering orbitrol valve is not serviceable and must be replaced in its entirety if defective 4 4 b S
111. l joints or U joints A few moments spent doing this can help prevent further problems and down time later Drive Shaft Inspection Inspect area where the drive shaft flange yoke and slip yoke mount to the drive shaft Attempt to turn drive shaft in both directions Look for excessive looseness missing parts cracks or other damage Worn or damaged drive shaft and cross and bearing assembly may cause an excessive amount of vibration or noise 5 4 2 Refer to Section 2 6 Lubrication Schedules for information regarding the lubrication of the grease fittings on the drive shafts Drive Shaft Maintenance 5 4 3 IMPORTANT To help ensure optimum performance the drive shaft assemblies are specially balanced as a unit at the factory When servicing order a complete assembly if components are bent or damaged Refer to the appropriate parts manual for ordering information Drive Shaft Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 The drive shaft assembly is a balanced assembly Mark the yoke and axle
112. labeled electrical wires to the alternator 6 Connect the positive and negative battery cables to the battery terminals 7 Close and secure the engine cover 9 8 ELECTRICAL SYSTEM COMPONENTS 9 8 1 The back up alarm is located at the rear of the machine Back up Alarm When the transmission shift control switch transmission control lever is shifted to the R REVERSE position the back up alarm will automatically sound Place the transmission control lever in R REVERSE to test the back up alarm The back up alarm must not sound when the transmission control lever is in N NEUTRAL or F FORWARD Also with the ignition key switch in the RUN position the back up alarm will sound when the transmission control lever is shifted into the R REVERSE position a Disassembly DO NOT disassemble the back up alarm Replace a defective or faulty alarm with a new part b Inspection and Replacement Inspect the wiring harness connector and alarm terminals for continuity and shorting Test the alarm by turning the ignition key switch to the RUN position and shifting the transmission control lever into the REVERSE position The alarm should sound Replace a defective or faulty alarm with a new part G5 19A G6 23A 9 8 2 Instrument Cluster MAH1090 a Removal A CAUTION static electricity can cause damage to the operator s instrument cluster Avoid any manner of touching hands tools
113. lays ground module hardware version GM SN XXXXXX Displays ground module serial number JYSTK SW XX X Displays joystick software version ANALYZER VX XXXX Displays Analyzer software version 9 30 G5 19A G6 23A Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Customer Support Toll Free 877 554 5438 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 25 England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 6
114. lenoid on the engine Do Not Over Tighten 3 Connect the wiring connector at the fuel shut off solenoid lead 4 Connect the battery negative cable to the battery negative terminal 5 Start the engine If the engine starts the fuel shut off solenoid is functioning If the engine fails to start the fuel shut off solenoid may have a poor ground connection Visually check the wiring at the fuel shut off solenoid leads and or check for continuity with a voltmeter as required 6 Check for fuel and or oil leakage around the solenoid 7 Close and secure the engine cover 9 24 9 11 7 The oil pressure sender 3 is located on the engine near the oil filter Oil Pressure Sender a Oil Pressure Sender Removal 1 Open the engine cover Allow the engine to cool 2 Disconnect the battery negative cable from the battery negative terminal 3 Disconnect the wiring connector at the oil pressure sender lead 4 The oil pressure sender is threaded into the engine Remove the sender b Oil Pressure Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part c Oil Pressure Sender Installation and Testing 1 Thread the oil pressure sender into the engine housing snugly then connect the sender connector to the wiring harness connector 2 Connect the battery negative cable to the battery negati
115. ll through the rear of the second boom section 8 Pull out the remainder of the second boom section 3 3 3 1 Inspect the boom and welds Consult your local JLG distributor if structural damage is detected Inspect hoses hardware wear pads mounting points and other components visible with the first boom section Replace any item if damaged Inspect all wear pads for wear Refer to Section 3 4 1 Wear Pad Inspection Second Section Boom Installation Insert the extend retract cylinder through the rear of the second boom section and attach the pin and clip to the rod end Install the bottom rear wear pads washers and bolts into the first boom section Apply Loctite 242 and torque to 66 Ib ft 90 Nm Install the bottom rear left and right side wear pads backing plate and bolts do not shim or tighten bolts Install top rear wear pads backing plates and bolts front bolts are drilled and tapped for zerk fittings do not shim or tighten bolts Grease the inside of the first boom section on areas where the second boom section wear pads will slide Using a suitable sling carefully slide the second boom section 3 ft to 4 ft 1 m to 1 5 m into the front of the first boom section Set the second boom section head onto suitable supports and reset sling under the boom head of the second section Carefully slide the second section into the first section Leave 6 in to 8 in 15 cm to 20 cm of the
116. low the system fluids to cool 4 Drain the hydraulic oil reservoir Refer to Section 8 7 1 Hydraulic Oil Reservoir Draining 5 Remove the belly pan G5 19A G6 23A Hydraulic System n 2 AS 270 6 Thoroughly clean the pump 1 and surrounding area including all hoses and fittings before proceeding 7 Label disconnect and cap all hydraulic hoses attached to the pump cap all fittings and plug hoses to keep dirt amp debris from entering the hydraulic system 8 Remove the engine oil filter 2 9 Remove the two bolts that hold the pump in place b Implement Pump Disassembly 1 Mark the position of the body and flange to ensure correct reassembly 2 Remove the nuts and washers attaching the flange to the body If necessary carefully separate with a soft faced hammer 3 Remove the retaining circlip and shaft seal from the flange 4 Pull out the main shaft assembly Mark the position of the drive gear and balance plate Remove the drive gear and balance plate 5 Discard all seals and clean off all sealant from the flange body interface c Implement Pump Cleaning Clean all pump components with a suitable cleaner such as trichlorethylene G5 19A G6 23A d Implement Pump Inspection Inspect internal pump components for wear damage etc If inner surfaces of the pump DO NOT display an ultra smooth polished finish or are damaged in any way replace the damaged par
117. lter head when system pressure exceeds the rating of the filter head or breather If the return filter becomes plugged return hydraulic oil will bypass the filter when pressure reaches 22 psi 1 5 bar and return to the reservoir unfiltered Carefully examine fluid seepage or leaks from the hydraulic reservoir to determine the exact cause Clean the reservoir and note where any seepage occurs Leaks from a cracked or damaged reservoir require that the reservoir be flushed completely with water and repaired by a certified welder using approved techniques If these conditions cannot be met the reservoir must be replaced in its entirety Contact your local JLG distributor should reservoir welding be required 8 7 1 1 Park the machine on a firm level surface fully retract the boom support the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF Hydraulic Oil Reservoir Draining 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the drain plug at the bottom of the hydraulic oil reservoir 5 Transfer the used hydraulic oil into a suitable covered container and label as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the drain plug 6 Wipe up any spilled hydraulic oil 8 8 8
118. ly onto 5 11 5 6 Steering 6 5 11 5 6 1 Steering Angle 5 11 5 7 5 11 5 7 1 Brake Disk Inspection 5 11 G5 19A G6 23A 5 1 ES Axles Drive Shafts Wheels and Tires 5 1 AXLE DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the axles drive shafts wheels and tires The following illustration identifies the components that are referred to throughout this section Rear Axle Assembly Steering Cylinder Rear Steering Cylinder Front Front Axle Assembly 0190 G5 19A G6 23A 5 2 Axles Drive Shafts Wheels and Tires 5 2 GENERAL INFORMATION Before performing any inspection maintenance or service operation thoroughly clean the unit The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and pr
119. ly ratings Always use matched sets according to machine specifications MAJOR COMPONENTS Never alter remove or substitute any items such as counterweights tires batteries or other items that may reduce or affect the overall weight or stability of the machine BATTERY DO NOT charge a frozen battery Charging a frozen battery may cause it to explode Allow the battery to thaw before jump starting or connecting a battery charger 1 7 SAFETY DECALS Check that all safety decals are present and readable on the machine Refer to the Operation amp Safety Manual supplied with machine for information G5 19A G6 23A Section 2 General Information and Specifications Contents PARAGRAPH TITLE PAGE 2 1 Replacement Parts and Warranty Information 2 2 2 2 eee Cera Reed Rad Re YE 2 3 2 2 1 ASTM Fastener Torque Chart English 2 3 2 2 2 ASTM Fastener Torque Chart Metric 2 4 2 2 8 Metric Fastener Torque 2 5 2 3 Specifications exG 3e pee Ex 2 6 2 3 1 Travel Speed s d E NER 2 6 2 3 2 Hydraulic Cylinder Performance 2 6 2 3 3 Electrical System s arria set eaaa e RR ye cee EE 2 6 2 3 4 Engine Performance
120. ment 2 Check the hydraulic oil level and add oil as required IMPORTANT DO NOT use flushing compounds for cleaning purposes 3 Reassemble all components and fill the hydraulic reservoir with clean fresh oil DO NOT overfill 4 Runthe engine for two minutes at idle to help bleed any air from the hydraulic system 5 Operate all boom functions to ensure any air is removed from the hydraulic system 6 Retract and level the boom recheck the level of the fluid in the reservoir 7 Addoil as necessary to bring the fluid level up until it reaches the FULL mark on the reservoir Recheck the oil level when it reaches operating temperature 180 200 F or 83 94 C 8 Recheck all drain plugs lines connections etc for leaks and tighten where necessary G5 19A G6 23A Transmission 6 5 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort after exhausting all other options Make every effort to repair the machine and move it under its own power Towing is only possible by using the towing feature built into the hydrostatic pump and disengaging the park brake on the front axle 1 Securely block all four wheels WARNING stock ALL Four WHEELS Failure to do so could result in death or serious injury from machine roll away 2 Locate the six brake release bolts 1 at the base of the front axle Mark a line on the socket so you can ac
121. mission Tighten the axle oil drain plug loosen and remove the axle oil fill plug Fill axle with the appropriate oil Refer to Section 2 4 Fluids Lubricants and Capacities for proper oil and capacities Rotate wheel hubs 90 degrees so the drain plug becomes the fill plug Fill wheel hubs with the appropriate oil Refer to Section 2 4 Fluids Lubricants and Capacities for proper oil and capacities G5 19A G6 23A 10 15 16 17 18 Install the wheel and tire assemblies Refer to Section 5 5 2 Installing Wheel and Tire Assembly onto Machine Carefully remove the jack hoist or overhead crane and sling supporting the axle Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the machine to the ground Remove the blocks from the front and rear of both tires on the other axle Uncap and reconnect the steering and brake lines at their axle fittings Refer to Section 8 10 4 Brake Test for brake bleeding procedures Check the hydraulic reservoir oil level Connect the battery negative cable to the battery negative terminal Close and secure the engine cover Start the engine Turn the steering wheel several times lock to lock and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary 5 5 hs Axles Drive Shafts Wheels and Tires
122. mounting stud 4 Reattach the starter heat shield 5 Connect the battery negative cable to the battery negative terminal 6 Close and secure the engine cover 9 7 CHARGING CIRCUIT Before using a battery charger an attempt can be made to recharge the battery by jump starting the machine Refer to the appropriate Operation amp Safety Manual Allow the engine to run which will enable the alternator to charge the battery If the engine alternator charging warning indicator illuminates perform the following checks 1 Check the all battery cable connections at the battery and verify that they are clean and tight 2 Check the external alternator wiring and connections and verify that they are in good condition 3 Check the fan belt condition and tension 4 Verify that the alternator mounting hardware is tight 5 Run the engine and check the alternator for noise loose drive pulley loose mounting hardware worn or dirty internal alternator bearings a defective stator or defective diodes can cause noise Replace a worn or defective alternator 9 18 9 7 1 Alternator a Alternator Removal 1 Open the engine cover 2 Disconnect the positive and negative battery cables at the battery terminals 3 Label and disconnect the wires attached to the alternator Note Hecord how the alternator is installed to ensure correct installation later 4 Loosen the top mounting bolt but don t
123. mponent 8 4 1 Conditions including but not limited to the following are sufficient for considering component replacement Replacement Considerations 1 Any evidence of hydraulic fluid leakage at the surface of a flexible hose or its junction with the metal and couplings 2 Any blistering or abnormal deformation to the outer covering of a hydraulic hose 3 Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by normal tightening or other recommended procedures 4 Evidence of excessive abrasion or scrubbing on the outer surface of a hose rigid tube or hydraulic fitting Modification must be made to eliminate the interference of the elements in contact with one another or to otherwise protect the components from contact with one another Slightly moving a hose or adjusting a plastic tie wrap may often be all that is necessary to eliminate interference evaluate each situation and proceed as required by the individual circumstances 8 4 2 Hose Tube Line and Fitting Replacement Before removing a hydraulic hose or component always mark or otherwise label the related parts and the exact location of the hose or component to aid in proper reinstallation Hydraulic fluid is a good cleaner and can remove most liquid ink type markings so make sure the mark or label will remain intact Alternative methods to using markers include color coded tie wraps number tag sets alpha numeric stampings or mark
124. n 130 mm in length 135 1000 4 5 Cab and Covers a Note The dimensional values given for inching valve adjustment are to be used as a starting point More thorough adjusting may be required 6 Install and secure the lower dash panel 7 Connect the battery negative cable to the battery negative terminal Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 8 Close and secure the engine cover 4 3 5 Throttle Pedal Replacement a Throttle Pedal Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 Remove three capscrews 16 three lockwashers 17 and three washers 18 securing the throttle pedal assembly to the cab floor 6 Remove the hex jam nut 19 and flat washer 20 securing the throttle cable to the throttle pedal assembly 7 Remove the clip pin from the fork link 8 Remove the throttle pedal assembly from the cab MS0930 4 6 b Throttle Pedal Installation 1 Install t
125. n thoroughly clean the machine DO NOT spray water or cleaning solution in on near or around the operator s dash panels and electrical components Inspect the cab its welds and mounts If modification damage a cracked weld and or fatigued metal is discovered replace the cab Contact your local JLG distributor with any questions about the suitability or condition of a cab IMPORTANT Remove and label cab components as needed before removing the cab from the machine Label disconnect and cap hydraulic hoses Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Block the wheels to ensure that the machine does not move 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal Note Steps 5 through 8 are only required if machine is equipped with heating or heating air conditioning 5 Place a suitable container beneath the radiator drain plug or petcock Slowly turn the cap on the coolant overflow bottle to allow any pressure to escape Remove the overflow bottle cap 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Open the radiator drain plug or petcock a
126. n Schedules 2 10 Section 3 BOO iy nen D eu aca af ar aD ce ee 3 1 3 1 Boom System Component 3 2 3 2 Boom System Two Section 3 3 3 3 Boom Assembly 3 3 3 4 Boom Wear 3 6 3 5 Quick Switch Assembly hed os eden el a 3 7 3 6 Troubleshooting IS REE a A ates 3 9 Section 4 Gab and Covers FP 4 1 4 1 Operator s Cab and Covers Component Terminology 4 2 4 2 Operators Gab a etek Pada UBER eR ER HRS n 4 3 4 3 4 3 4 4 Cab Removal srei uet S Don n hrec 4 8 4 5 Cab Installation 4 10 Section 5 Axles Drive Shafts Wheels and Tires 5 1 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 2 General 5 8 5 8 Axle Assemblies ts 5 3 5 4 Drive Shatts c axe utu Oe we CREE MESE 5 9 5 5 Wheels and
127. n tenth of an hour increments and is located in the instrument cluster Hourmeter The hourmeter is an analog device similar to an odometer and will display 99 999 9 hours before resetting to zero If trouble is suspected time the hourmeter for six minutes to verify that a tenth of an hour has been recorded The hourmeter is built into the instrument cluster and cannot be repaired If the hourmeter is suspect replace G5 19A G6 23A the instrument cluster 9 11 5 The coolant temperature sender 1 is located on the back of the engine towards the rear of the machine Coolant Temperature Sender MAH0620 a Coolant Temperature Sender Removal 1 Open the engine cover Allow the engine to cool 2 Disconnect the battery negative cable from the battery negative terminal 3 Disconnect the wiring connector at the coolant temperature sender lead 4 The coolant temperature sender is threaded into the engine block Remove the sender b Coolant Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part c Coolant Temperature Sender Installation and Testing 1 Thread the coolant temperature sender into the engine housing snugly then connect the sender connector to the wiring harness connector 2 Connect the battery negative cable to the battery negative terminal 3 Che
128. nce criteria is based on full throttle engine speed unless otherwise specified or not applicable Travel Speed no load G5 19A with 405 70 20 tires First gear eec 6 mph 10 km hr Second 21 mph 34 km hr G6 23A with 405 70 24 tires First gear esses 4 mph 7 km hr Second 20 mph 33 km hr G5 19A G6 23A 6 4 TRANSMISSION REPLACEMENT Note Contact your local JLG distributor if internal transmission repair is required during the warranty period IMPORTANT To help ensure safety and optimum performance replace the transmission if it is damaged Refer to the appropriate parts manual for ordering information Cleanliness is of extreme importance Before attempting to remove the transmission thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components 6 4 1 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL turn rear wheels to give easier access to rear of engine compartment engage the park brake and shut the engine OFF Transmission Removal 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that
129. nd allow the coolant to drain Replace the drain plug or close the petcock 7 Transfer the coolant into a suitable covered container and label as Used Coolant Dispose of used coolant at an approved recycling facility G5 19A G6 23A Cab and Covers Ps Bottom of Cab 1140 Note Label all hoses to ensure correct installation 8 Loosen the hose clamps and disconnect the heater hoses from the engine Cap or plug the hoses to prevent debris from entering the heater system 9 Disconnect the cab to wiring harness connectors Note the location and label all cables to ensure correct installation 10 Working underneath the cab label and disconnect the hydraulic hoses at the cab fittings Plug the hoses and cap the fittings 11 Disconnect the throttle cable rod end at the throttle lever extension bracket 1 Route the cable away from the cab to prevent damage during removal 12 Install two lifting eye bolts with a suitable lifting capacity in the existing threaded holes at the top corners of the windshield 13 Remove the cab to frame bolts 2 washers and nuts 0710 G5 19A G6 23A Carefully begin to lift the cab Stop and check that all wiring hydraulic hoses and fasteners are disconnected or removed Do not damage the fuel fill tube When all wiring hydraulic hoses and fasteners are
130. nd appearance They are relatively simple to remove and replace 4 2 2 Serial Number Decal The cab serial number decal is located inside the cab under the seat Information specified on the serial number plate includes the cab model number the cab serial number and other data Write this information down in a convenient location to use in cab correspondence G5 19A G6 23A 4 3 CAB COMPONENTS 4 3 1 Steering Wheel a Steering Wheel Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal 5 Carefully pry the center button 1 out of the steering wheel 6 Mark the steering wheel and shaft to ensure proper installation Remove the nut 2 securing the steering wheel 3 to the splined steering column shaft 7 Use a steering wheel puller to remove the steering wheel 3 from the splined shaft 430 b Steering Wheel Installation Install the steering wheel 3 onto the splined steering column shaft 2 Secure the steering wheel with the nut 2 3 Press the center button 1 onto the steering whee
131. ne coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Note Detailed Deutz engine service instructions covering disassembly inspection internal repair assembly adjustment and troubleshooting information are provided in the appropriate Deutz engine service manual 7 4 7 4 ENGINE COOLING SYSTEM 7 4 1 Radiator Pressure Cap For a 230 F 110 C system use a 13 psi 95 kPa radiator cap An incorrect or malfunctioning cap can result in the loss of coolant and a hot running engine 7 4 2 Radiator Oil Cooler and Coolant Heater Replacement Before considering radiator or oil cooler replacement for other than obvious damage conduct a cooling system pressure test check the coolant specific gravity coolant level fan belt tension and dash panel temperature indicator f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position e f the engine has overheated performance may suffer indicating other damage including a leaking cylinder head gasket cracked cylinder head or block and or other internal engine damage a Radiator Oil Cooler Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate
132. ne Heater Control 7 5 F34 Fuel Solenoid Cold Start 10 K1 Ignition Pwr 4 K2 Reverse Travel K3 Start K4 Front Wiper K5 Flasher K6 Ignition Pwr 1 K7 Ignition Pwr 2 K8 Ignition Pwr 3 K9 Work Lights K10 Boom Lights K11 Rear Wiper K12 Heater Fan 9 6 G5 19A G6 23A Electrical System 94 ELECTRICAL SYSTEM SCHEMATICS 9 4 1 Cab Roof Schematic Note For more detailed schematics contact your local JLG distributor RTFRT LTFRT RTREAR LT REAR BEACON WKLIGHT WKLIGHT WKLIGHT WKLIGHT LIGHT M4 a m 4 alin VV VV VV VV X31 12 X30 12 X29 12 X28 12 X27 12 x33 zo 225 gt 3 gt E 2 ge ge RADIO BAT 28 ES gt 4 5 5 5 5 68 gt 51 gt amp amp amp gt 16 gt 5 RADIO IGN RADIO gt 8 GND 1 OPT 07 X34 2M 2 2 S ls SX gt 4 5 gt 5 Dx gt 6 DX baia gt gt RIGHT DX SPEAKERS DX OPT LEFT SK SX SX SA pm R WIPE IGN REAR WIPER 31 2 GND2 MOTOR gt R WIPE 31B R WIPE PK X37 Doe BRK LTPWR LIGHT 2 GND 1 5155 Shela
133. not 1 Refer to the appropriate Carraro operating properly Repair Manual Excessive joint housing swivel 2 Correct bearing preload by bearing preload adding or removing shims as needed Worn or damaged swivel 3 Replace swivel bearings as bearings needed 9 Slow steering response Steering hydraulic system not 1 Refer to the appropriate Carraro operating properly Repair Manual Steering cylinder leaking 2 Repair or replace steering internally cylinder as needed 10 Excessive noise when brakes Brake discs worn 1 Check brake discs for wear are engaged Refer to appropriate Carraro Repair Manual Brake discs damaged 2 Replace brake discs 11 Brakes will not engage Brake hydraulic system not 1 Refer to the appropriate Carraro operating properly Repair Manual Brake piston o rings and seals 2 Replace o rings and seals damaged leaking 12 Brakes will not hold the Brake discs worn 1 Check brake discs for wear machine or braking power Refer to the appropriate Carraro reduced Repair Manual Brake hydraulic system not 2 Referto the appropriate Carraro operating properly Repair Manual Brake piston o rings and seals 3 Replace o rings and seals 5 8 G5 19A G6 23A Axles Drive Shafts Wheels and Tires hs 5 4 DRIVE SHAFTS 5 4 1 Whenever servicing the machine conduct a visual inspection of the drive shaft and cross and bearing assembly universa
134. ob safely This might include heavy gloves safety glasses or goggles filter mask or respirator safety shoes or a hard hat LIFTING NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards LIFTING OF EQUIPMENT Before using any lifting equipment chains slings brackets hooks etc verify that itis of the proper capacity in good working order and is properly attached NEVER stand or otherwise become positioned under a suspended load or under raised equipment The load or equipment could fall or tip DO NOT use a hoist jack or jack stands only to support equipment Always support equipment with the proper capacity blocks or stands properly rated for the load HAND TOOLS Always use the proper tool for the job keep tools clean and in good working order and use special service tools only as recommended 1 3 Safety Practices 1 6 3 SOLVENTS Only use approved solvents that are known to be safe for use HOUSEKEEPING Keep the work area and operator s General Hazards cab clean and remove all hazards debris oil tools etc FIRST AID Immediately clean dress and report all injuries cuts abrasions burns etc no matter how minor the injury may seem Know the location of a First Aid Kit and know how to use it CLEANLINESS Wear eye protection and clean all components with a high pressure or steam cleaner before
135. oke flange 2 to the front axle Loctite and torque the capscrews to 102 Ib ft 139 Nm 3 Install the four capscrews securing the bearing crosses to the rear axle Loctite and torque the capscrews to 102 Ib ft 139 Nm 4 Connect the battery negative ground cable at the battery negative terminal 5 Close and secure the engine cover 5 9 Axles Drive Shafts Wheels and Tires hs 5 5 WHEELS AND TIRES WARNING nisk of death or serious personal injury Mismatched tire sizes ply ratings or mixing of tire types radial tires with bias ply tires may compromise machine stability and may cause machine to tip over JLG recommends a replacement tire to be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using a JLG approved replacement tire JLG recommends that replacement tires have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or small
136. omponent part line or hose Slowly loosen parts and allow release of residual pressure before removing any part or component Before starting the engine or applying pressure use components parts hoses and pipes that are in good condition connected properly and are tightened to the proper torque Capture fluid in an 1 4 appropriate container and dispose of in accordance with prevailing environmental regulations RADIATOR CAP Always wear steam resistant heat protective gloves when opening the radiator cap Cover the cap with a clean thick cloth and turn slowly to the first stop to relieve pressure FLUID FLAMABILTITY DO NOT service the fuel or hydraulic systems near an open flame sparks or smoking materials NEVER drain or store fluids in an open container Engine fuel and hydraulic fluid are flammable and can cause a fire and or explosion DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause an explosion PRESSURE TESTING When conducting any test only use test equipment that is correctly calibrated and in good condition Use the correct equipment in the proper manner and make changes or repairs as indicated by the test procedure to achieve the desired result LEAVING MACHINE Lower the forks or attachment to the ground before leaving the machine TIRES Always keep tires inflated to the proper pressure to help prevent tipover DO NOT over inflate tires NEVER use mismatched tire types sizes or p
137. on Control and Gear Selector Lever Brake Fluid Reservoir 3 A Kx AS Zs Steering Column Tilt Adjustment Heater Controls Parking Brake 1101 4 2 G5 19A G6 23A Cab and Covers a WARNING senice the machine without following all safety precautions as outlined in the Safety Practices section of this manual Failure to follow the safety practices may result in death or serious injury 4 2 4 2 1 The welded metal cab features a modular design allowing for a relatively quick simple exchange of the entire cab and or component parts The cab is bolted directly to the frame Operator s Cab Description The operator s cab is a protective structure The cab itself contains rollover protective and falling object protective structures ROPS FOPS for the operator DO NOT weld grind drill repair or modify the cab in any way Any modification or damage to cab structural components requires cab replacement The lives of the operator and others are potentially at stake To help ensure optimum safety protection and performance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information The cab contains the seat operating controls numerous panels steering and brake components and more Covers and mirrors on the machine exist for safety protection a
138. pected of giving a false reading perform the following checks 1 If the fuel level indicator needle does not move check the fuel tank for fuel 2 Check for loose or defective wiring faulty ground connections or corrosion on the fuel tank sender and wiring lead 3 If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN position use a test lamp to determine whether current is flowing from the ignition switch to the fuel level sender 4 If the fuel level indicator does not move and a faulty or defective fuel level sender in the fuel tank has been ruled out and in addition wiring and connectors have been checked and ruled out the fuel level indicator is defective and must be replaced 5 Check that the ignition terminal has current and that the fuse in the fuse panel is not blown 6 Check for broken shorted frayed disconnected or damaged wiring between the fuel level indicator wiring at the cab fuse and relay panel ignition key switch and from the fuel level sender on the fuel tank through the wiring in the cab 7 Check the fuel level sender The resistance of the fuel level sender is 31 ohms for a full tank of fuel 101 ohms for 1 2 tank and 255 ohms for an empty tank A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving 9 11 4 The hourmeter is a non repairable instrument that records hours of machine engine operation i
139. que 2 Drive shaft universal joint s 2 Repair or replace universal worn or damaged joints as needed 3 Drive shaft damaged 3 Replace drive shaft as needed 5 6 G5 19A G6 23A hs Axles Drive Shafts Wheels and Tires 5 3 7 Axle Assembly and Drive Shaft Troubleshooting Continued Problem Cause Remedy 4 Oil leaking from axle differential housing and or axle housings 1 Drain plugs loose and or o rings damaged or missing Hose fittings loose Axle shaft seal damaged or missing and or worn or damaged shaft sealing surfaces Input shaft multi seal ring damaged or missing and or worn or damaged pinion input shaft sealing surfaces Axle casing to brake housing and or brake housing to differential assembly o rings and or seals worn or damaged Axle housing mounting nuts and capscrews loose 1 Replace o rings as needed and tighten plugs 59 Ib ft 80 Nm 2 Tighten fittings 3 Replace seal and or joint coupling fork shaft axle shaft Replace multi seal ring and or input shaft Adjust ring and pinion alignment and bearing preload as described in the Carraro Repair Manuals Replace o rings and seals Tighten housing nuts and capscrews to 236 Ib ft 320 Nm 7 Differential and or axle 7 Replace housing s as needed housing s damaged 5 Oil leaking from wheel end 1 Oil level plugs loose and or 1 Replace o rings as need
140. question and push the switch out of the frame b Disassembly DO NOT disassemble the dash switch Replace a defective switch with a new part c Inspection and Replacement Inspect the switch terminals for continuity in both the engaged and disengaged positions Replace a defective or faulty switch with a new switch d Switch Installation 1 Connect the switch to the cab harness connector 2 Position the switch over the rectangular switch bezel and snap into position 3 Replace the frame into the dash 4 Connect the battery negative cable to the battery negative terminal 5 Start the machine and check the replaced switch for proper function 6 Close and secure the engine cover 9 11 3 Fuel Level Indicator and Fuel Level Sender a Fuel Level Indicator Testing 1 The fuel level sender wiring harness leads can be accessed from the top of the fuel tank Disconnect the fuel level sender wiring harness leads With the help of an assistant touch both harness leads together 2 From the operators cab have the assistant turn the ignition key switch to the RUN position DO NOT G5 19A G6 23A Electrical System start the engine Observe the fuel level indicator needle on the operators instrument cluster 3 Turn the ignition key switch to the OFF position The fuel level indicator needle should return to the EMPTY position b Fuel Level Circuit Tests If the fuel level indicator is sus
141. r surfaces lubricated properly Light lubrication of the boom wear surfaces is also recommended when the machine is stored to help prevent rusting 1 Park the machine on a hard level surface place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Using suitable slings turn boom back over to original orientation Note Grease the boom pivot bore compensating cylinder rod ends lift lower cylinder rod end and pins before installing 5 Using suitable slings balance the boom assembly lift and carefully guide the boom into place Align the frame pivot bore with the boom assembly pivot bore 3 5 Boom Install boom pivot pin 1 and lock bolt Apply Loctite 242 and torque to 66 Ib ft 90 Nm 6 With the sling still in place install the compensating cylinder pin 2 and lock bolt Apply Loctite 242 and torque to 66 Ib ft 90 Nm 0140 7 With the sling still in place install the rod end of the lift lower cylinder pin and lock bolt Apply Loctite 242 and torque to 66 Ib ft 90 Nm Note Raising the boom up or down with the sling be necessary so the boom compensating and lift lower cylinder bores can be aligned for easier pin installation
142. r the safety of the operator and for the safe reliable operation of the machine All references to the right side left side front and rear are given from the operator s seat looking in a forward direction Supplementary information is available from JLG in the form of Service Bulletins Service Campaigns Service Training Schools the JLG website other literature and through updates to the manual itself 1 2 1 2 DISCLAIMER All information in this manual is based on the latest product information available at the time of publication JLG reserves the right to make changes and improvements to its products and to discontinue the manufacture of any product at its discretion at any time without public notice or obligation 1 3 OPERATION amp SAFETY MANUAL The mechanic must not operate the machine until the Operation amp Safety Manual has been read amp understood training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator An Operation amp Safety Manual is supplied with each machine and must be kept in the cab In the event that the Operation amp Safety Manual is missing consult the local JLG distributor before proceeding 1 4 DO NOT OPERATE TAGS Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance Remove key and disconnect battery leads G5 19A
143. red to throughout this section the operator mechanic be familiar with the names and Hydrostatic Transmission 7 K x LL Fred Re SY Relief Valve 251 G5 19A G6 23A 6 2 Transmission WARNING service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Failure to follow the safety practices may result in death or serious injury 6 2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications towing maintenance information and transmission removal and installation procedures For internal transmission service instructions and detailed specifications contact your local JLG distributor for a copy of the Rexroth Repair Manual P N 31200124 More information can be obtained from the serial number plate directly mounted on the transmission Information specified on the serial number plate includes the transmission model number the transmission serial number and other data Information on the serial number plate is required in correspondence regarding the transmission 6 3 TRANSMISSION SPECIFICATIONS 6 3 1 The transmission is a hydraulic component and requires the same maintenance as the hydraulic system Refer to Section 2 5 Maintenance Schedules Transmission Maintenance Performa
144. ront axle b Front Drive Pump Installation 1 Install the pump onto the front axle Torque the four bolts to 178 Ib ft 241 Nm Use only new seals 2 Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations 3 Fill the pump with hydraulic fluid through the fill plug 1 before starting the machine 4 Refill the hydraulic reservoir and inspect for leaks around the machine 5 Close and secure the engine cover G5 19A G6 23A Hydraulic System n 8 10 VALVES AND MANIFOLDS 8 10 1 Main Control Valve The main control valve is mounted on the rear of the machine behind the rear access panel The main control valve assembly consists of various working sections with their own valve assemblies each providing a specific hydraulic function The section assemblies are the outlet extend retract 1 auxiliary 2 tilt 3 lift lower 4 and load sense outlet sections FRONT OF MACHINE 0120 a Main Control Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Remove the rear panel Allow the hydraulic fluid to cool 4 Thoroughly clean the main control valve and surroun
145. s Drive Shafts Wheels and Tires Contents PARAGRAPH TITLE PAGE 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 2 General 5 8 5 3 Axle 5 3 5 3 1 Axle Serial Number 5 8 5 3 2 Axle 5 3 5 3 3 Axle Internal Service 5 8 5 3 4 Axle 1 5 3 5 3 5 Axle 2 5 4 5 3 6 Axle Installation 5 ute Re t Rr be Ree es x RUE UR 5 5 5 9 7 Axle Assembly and Drive Shaft Troubleshooting 5 6 5 4 Drive Shafts sscan luco BER ee 5 9 5 4 1 Drive Shaft Inspection 5 9 5 4 2 Drive Shaft Maintenance 5 9 5 4 3 Drive Shaft 5 9 5 4 4 Drive Shaft Cleaning and Drying 5 9 5 4 5 Drive Shaft 5 9 5 5 Wheels and Tires 2 2 45 4 5 10 5 5 1 Removing Wheel and Tire Assembly from 5 10 5 5 2 Installing Wheel and Tire Assemb
146. spool 5 Remove any check valves compensator valves anti cavitation valves or shock valves from each individual valve section if equipped 6 Keep all parts being removed from individual valve sections tagged and kept together c Main Control Valve Parts Cleaning Clean all components with a suitable cleaner such as trichlorethylene before continuing Blow dry 8 11 Hydraulic System n d Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear damage etc If inner surfaces of any component DO NOT display an ultra smooth polished finish or are damaged in any way replace the damaged part Often dirty hydraulic fluid causes failure of internal seals damage to the polished surfaces within the component and wear of and or harm to other parts e Main Control Valve Assembly Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil Assemble each Valve Section 1 Reassemble any check valves compensator valves anti cavitation valves or shock valves from individual valve sections if equipped 2 Install the control spool being careful not to nick or scratch the valve section bore or the control spool 3 Install the end caps on each end of the valve section Assemble the Main Control Valve 1 Place all three tie rods with the washers and nuts through th
147. ssion or surrounding parts 15 Lift the transmission clear of the machine and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service Secure the transmission so that it will not move or fall 6 4 2 Transmission disassembly internal inspection service repair and assembly procedures are covered in the Rexroth Repair Manual P N 31200124 Transmission Disassembly 6 4 3 Transmission Installation A WARNING Risk of severe personal injury NEVER lift a transmission alone enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling 1 Use a lifting strap or chain attached to a hoist or overhead crane to position the transmission within the chassis 2 Insert the two Allen head bolts that attach the transmission to the engine Torque to 154 lb ft 210 Nm 3 Remove the hoist or overhead crane and sling 4 Uncap and reconnect the previously labeled hoses and electrical connections to their appropriate locations 5 Fill hydraulic reservoir and bleed the system 6 Reinstall the battery tray 7 Replace battery into compartment and reconnect battery cables to terminals starting with the positive terminal 8 Reattach access panel to rear of engine compartment 9 Reinstall the belly pan 6 4 10 Close and secure the engine cover 6 4 4 1 Install new hydraulic filters After Transmission Replace
148. t To determine the proper operation of the ignition key switch using the following charts test the wires on the back of the switch for continuity with an ohmmeter Test the ignition key switch for continuity by checking from the ignition 30 wires to each of the following wires in each switch position Continuity X should be present as indicated in the following chart Switch Position Test from 30 wires to OFF RUN START 50 Wire X 1115 Wires X X If all wires do not show proper continuity replace the ignition switch d Ignition Switch Installation 1 Connect the ignition key switch to the cab harness connectors 2 Reach up and under the dash to work the ignition switch into the ignition switch mounting hole on the lower right side of the dash 3 Align the ignition switch so that when it is in the OFF position the key slot is positioned vertically straight 9 22 up and down Install the hex nut securing the ignition switch to the dash DO NOT overtighten 4 Install the lower dash panel 5 Connect the battery negative cable to the battery negative terminal 6 Close and secure the engine cover 9 11 2 Dash Switches a Switch Removal 1 Open the engine cover Allow the engine to cool 2 Disconnect the battery negative cable at the battery negative terminal 3 Pull the frame out of the dash disconnect the harness connector to the switch in
149. t Often dirty hydraulic fluid causes failure of internal pump seals and damage to the polished surfaces within the pump and other hydraulic system components Inspect the o ring groove and shaft seal recess in the mounting flange Be sure they are undamaged and free from burrs The pump must be replaced if 1 The PFE coated bearings in the body and flange are worn through revealing the bronze backing 2 The gear side faces are scored 3 There is a noticeable wear groove on the main shaft where the shaft seal lips run 4 The bronze balance plates are scored Note It is not recommended that damaged gears bodies flanges or balance plates are replaced individually as this will not constitute a good repair Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil e Implement Pump Assembly Note Before assembly all parts must be perfectly clean and lubricated with hydraulic fluid Renew all seals using hyaraulic fluid as a lubricant 1 Fit the shaft seal mounting flange with the garter spring facings into the pump and refit the circlip 2 Fitthe channel seals and back up rings into grooves on balance plate into bore Ensure that the seals remain in their groove and that the two small holes in the balance plate are to the low pressure side of the pump 3 Insert the main shaft and drive gear into their orig
150. t all related hydraulic components and electrical switches sensors solenoids etc are operating correctly 6 a last resort adjust the appropriate relief valve if applicable Turning the adjustment screw clockwise will increase the pressure turning the screw counterclockwise will decrease the pressure Start the engine and check the pressure again Turn the engine OFF operate the auxiliary hydraulic control lever on units equipped with the optional auxiliary hydraulic system then disconnect or remove the pressure gauge from the machine G5 19A G6 23A Hydraulic System 8 5 2 Main Control Valve Pressure Checking Attach 5000 psi 345 bar gauge to the test port 1 on the main control valve port to check the system pressure The main control valve pressure should be 3600 psi 250 5 bar at full throttle 0120 8 5 3 Attach pressure gauge to the test port 2 on the hydrostatic transmission to check the system pressure The pressure should be 362 to 406 psi 25 to 28 bar with the engine at idle Charge Pressure Checking Do NOT adjust any relief settings The unit is preset at the factory and should not be tampered with If the proper pressure is not read the unit may be defective 780 8 5 4 Attach pressure gauge to the test fitting 3 the hydrostatic transmission to check the system pressure Check the drive pressure with the park brake on and the servic
151. t system components reach high temperatures and can cause severe burns DO NOT come into contact with hot exhaust system components When the exhaust or air cleaner systems are removed be sure to cover any open ports to prevent dirt and debris from contaminating engine components A CAUTION never run the engine with only the inner safety element installed G5 19A G6 23A Engine Deutz BF 4M 2012 7 8 7 8 1 1 ENGINE REPLACEMENT Engine Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool 4 Remove belly pan of engine compartment Thoroughly clean the engine and surrounding area including all hoses and fittings before proceeding Disconnect the battery negative cable from the battery negative terminal 7 Remove the engine cover 14 15 16 Remove battery from engine compartment disconnect and remove battery tray Drain hydraulic reservoir Refer to Section 8 7 1 Hydraulic Oil Reservoir Draining Drain radiator and overflow bottle Refer to Section 7 4 2 Radiator Oil Cooler and Coolant Heater
152. teering Column and Valve Installation 1 Install the orbitrol valve onto the steering column Torque the four capscrews to 13 Ib ft 18 Nm Position the steering valve in the cab with the ports pointing toward their original orientation 2 Secure the assembly with the two pivot bolts Note ALWAYS use new o rings when servicing the machine 3 Uncap and install new o rings into the fittings Lubricate the o rings with clean hydraulic oil 4 Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations 5 Install the steering column tilt knob 6 Install the steering wheel Refer to Section 4 3 1 Steering Wheel accessory lever and transmission control lever 7 Connect the battery negative cable to the battery negative terminal 8 Carefully examine all connections one last time before engine start up Rectify any faulty conditions 9 Start the engine and check the operation of all controls Check for fluid leaks Check the hydraulic fluid level in the tank and add fluid as required 10 Install the lower dash panel 11 Close and secure the engine cover c Power Steering Test Conduct a pressure check of the steering hydraulic circuits at the test port on the implement pump Refer to Section 8 5 5 Steering Pressure Checking 4 3 3 Brake Pedal and Valve a Brake Valve Removal Refer to Section 8 10 2 a Service Brake Valve Removal for removal information b
153. th water and agitate the mixture for 10 minutes Drain the tank completely Dispose of contaminated water properly 5 Refill the fuel tank with water until it overflows Completely flush the tank with water Empty the fuel tank and allow it to dry completely c Inspection Note lf a leak is suspected between the fuel and hydraulic oil tank contact your local JLG distributor 1 Inspect the fuel hydraulic oil tank thoroughly for any cracks slices leaks or other damage 2 Plug all openings except one elbow fitting Install the elbow fitting and apply approximately 0 07 0 10 bar 1 1 5 psi of air pressure through the elbow Check the tank for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area d Disassembly and Assembly The fuel hydraulic oil reservoir is a one piece unit integral to the chassis frame and cannot be disassembled 7 6 3 1 Drain and flush the fuel tank if it was contaminated After Fuel System Service 2 Fill the fuel tank with fresh clean diesel fuel as required Note If bleeding of the fuel system is required contact your local Deutz AG Service Partner 7 7 ENGINE EXHAUST AND AIR CLEANER SYSTEM A WARNING exhaust fumes contain carbon monoxide a colorless odorless gas which is fatal when inhaled in a confined area Avoid breathing exhaust fumes and prevent engine operation from becoming a cause of toxic emissions Exhaus
154. the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 Remove battery from engine compartment disconnect and remove battery tray 6 Remove access panel in rear of engine compartment 7 Remove belly pan of engine compartment 8 Drain the hydraulic oil reservoir Refer to Section 8 7 1 Hydraulic Oil Reservoir Draining 9 Label disconnect and cap all hydraulic hoses attached to transmission cap all fittings and openings to keep dirt amp debris from entering hydraulic system 10 Label and disconnect all electrical connections attached to the transmission 11 Wipe up any spilled hydraulic and transmission oil 12 Vertically secure transmission with a lifting strap or chain Use a suitable hoist or overhead crane Operate the hoist or crane to remove slack from the 6 3 Transmission O chain but DO NOT raise the transmission at this time 13 Remove the two Allen head bolts that attach the transmission to the engine A WARNING Risk of personal injury The transmission may move while hoisting it out of the chassis Carefully move the transmission and adjust the sling as needed Keep fingers hands legs and other body parts clear of the transmission 14 Carefully remove the transmission from the machine Avoid causing damage to the transmi
155. the machine at the rear of the boom Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system 9 Label and disconnect the extend retract hydraulic hoses at the extend retract cylinder Note Tag or identify each hose to the corresponding fitting it was removed from 10 Remove the lock bolt and pin 1 from the rod end of the compensating cylinder on the first boom section Rest the cylinder on the machine frame 0140 11 Lower the boom to a level position and place suitable support under the rear of the boom Reposition the slings to each end of the boom 3 4 12 Remove the lock bolt and pivot pin 2 from rear of first boom section 13 Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the bottom of the boom 3 3 2 1 Set the complete boom on level ground and by repositioning the slings turn boom over on to the top side Set the complete boom on suitable stands to begin tear down Second Section Boom Removal Note With the complete boom setting upside down the second boom section tilt cylinder and hoses are made more accessible This also eliminates the need to remove the hose rack on the bottom of the boom 2 Atthe boom head attach a sling through rod end of tilt cylinder Remove both hoses from tilt cylinder Plug the hose ends and cap the tilt cylinder fittings to prevent dirt and debris from entering t
156. the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 6 7 d Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools Close and secure the engine cover Steering Test 1 Conduct a pressure check of the steering hydraulic circuit at the test port on the implement pump Refer to Section 8 5 5 Steering Pressure Checking Check each steering mode for proper function 8 15 Hydraulic System n 8 11 HYDRAULIC CYLINDERS 8 11 1 General Cylinder Removal Instructions 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever NEUTRAL engage the park brake and shut the engine OFF 2 Chock the wheels 3 Place an Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the engine cover Allow the system fluids to cool 5 Label disconnect and cap hydraulic hoses in relation to the cylinder 6 Attach a suitable sling to an appropriate lifting device and to the cylinder Make sure the device used can actually support the cylinder 7 Remove the lock bolt and or any retaining clips securing the cylinder pins Remove the cylinder pins 8 Remove the cylinder 9 Wipe up any hydraulic fluid spillage
157. throttle cable rod end to the throttle extension bracket 1 underneath the cab 7 Uncap and reconnect the hydraulic hoses at the cab locations 8 Secure the throttle cable to the hydraulic hoses using wire ties 9 Uncap and connect the heater hoses to the engine Secure with hose clamps 10 Install the cab to wiring harness connectors on side of the cab 11 Fill the cooling system completely with a 50 50 mixture of ethylene glycol and water allowing time for the coolant to fill the engine block The cooling system capacity is listed in Section 2 4 Fluids Lubricants and Capacities 4 10 12 Connect the battery negative cable to the battery negative terminal 13 Carefully examine all cab components fasteners etc one last time before engine start up Rectify any faulty conditions 14 Start the engine and check the operation of all controls Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required IMPORTANT When the engine is initially started run it briefly at low idle and check the machine for any visual sign of fluid leakage STOP the engine immediately if any leakage is noted and make any necessary repairs before continuing 15 Wait for the engine to cool and check the coolant level Add coolant to the overflow bottle as required to bring the coolant to the proper level 16 Close and secure the engine cover G5 19A G6 23A Section 5 Axle
158. time Boom Wear Pad Replacement Usually shimming will remain the same when installing new wear pads All wear pads are secured to the boom using different capscrews and washers When installing new wear pads apply Loctite 242 to all wear pad mounting capscrews M10 and torque to 36 Ib ft BO Nm Rear upper pads on G6 23A apply Loctite 242 to all wear pad mounting capscrews M10 and torque to 66 Ib ft 90 Nm Grease the new pads and surrounding area The boom wear pads 5 are mounted on the inside of the first boom section and the outside of the second boom section G5 19A G6 23A Boom C D 2 00 870 Use shims 6 under the wear pads as required to maintain a maximum gap of 0 06 in 1 5 mm 7 between the wear pad on the front and sides of the boom The gap at the rear of the boom should be no more than 0 12 in 3 mm Shims are available in four thicknesses 0 02 in 0 5 0 04 in 1 mm 0 06 in 1 5mm and 0 08 in 2 0mm MU4080 G5 19A G6 23A 3 4 3 After replacing any wear pad s or after prolonged periods of inoperation light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly Light lubrication of the boom wear surfaces is also recommended when the machine is stored to help prevent rusting Boom Wear Pad Lubrication
159. tion If the carrier housing was submerged in 5 3 Axles Drive Shafts Wheels and Tires hs water especially if the water level was above the vent tube breather drain the axle and inspect internal parts for water damage and contamination Before assembling and refilling the unit with the specified lubricant s clean examine and replace damaged parts as necessary Note Use a suitable puller for bearing removal Clean inspect and lubricate all bearings just prior to reassembly If replacement of a damaged bearing cup or cone is necessary replace the cup and cone as a set 5 3 5 Axle Removal WARNING an improperly supported machine can fall causing death or severe personal injury Safely raise and adequately support the machine so that it will remain stable and in place before attempting to remove an axle The front and rear axle assemblies differ in that the front axle assembly is equipped with a hydraulic drive pump parking brake mechanism and a limited slip feature the rear axle has none of these The following steps outline a typical axle removal procedure suitable for either the front or the rear axle assembly Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components If using a steam cleaner seal all openings before steam cleaning
160. tion 8 6 Hydraulic Schematic 4 Replace rear cover 5 Close and secure the engine cover G5 19A G6 23A 9 12 CONTROLLER If the controller has been replaced the default settings for the Joystick functions must be properly configured 9 12 1 Joystick Functionality Setting 1 Connect the JLG Analyzer P N 2901443 tool to the PCB board on the machine Turn the ignition to the ON position 2 Scroll through the menus to find ACCESS LEVEL 2 3 Press enter and key in the code 38644 to enter ACCESS LEVEL 0 4 Scroll through the menus to find MACHINE SETUP 5 Choose the option that coincides with the joystick decal in the cab Code Function JYSTK ASSIGN Joystick left right fork tilt 1 X K FORK TELE Knurl boom extend retract JYSTK ASSIGN Joystick left right boom 2 X KS TELE FORK extend retract Knurl fork tilt slow JYSTK ASSIGN 3 X KF TELE FORK Joystick left right boom extend retract Knurl fork tilt fast 6 Verify that joystick functions coincide with the joystick decal in the cab 9 13 TROUBLESHOOTING 9 13 1 Help messages can be viewed using the JLG Analyzer P N 2901443 The Help messages can be accessed by pressing the ENTER key while viewing the current Help message The Help message shall be EVERYTHING OK when no fault is present The Analyzer cable plugs into the X26 connector of the PCB board located behind the operator s seat Anal
161. trols The controls are not serviceable Replace controls if found to be defective c Installation and Testing 1 Check that the variable speed fan control is in the OFF position 2 If installing the temperature control attach the cable connector to the back of the control 3 Insert the control shaft through the panel ensuring that the knob is in the VERTICAL position 4 Install the hex locknut on the shaft and tighten 5 Connect the cab harness connector to the variable speed fan control 6 Install the control panel screws 7 Install the setscrew securing the knob to the control 8 Connect the battery negative cable to the battery negative terminal 9 Close and secure the engine cover 9 21 Electrical System 9 11 SWITCHES SOLENOIDS AND SENDERS 9 11 1 Ignition Key Switch a Ignition Switch Removal 1 Open the engine cover Allow the engine to cool 2 Disconnect the battery negative cable from the battery negative terminal 3 Remove lower dash panel 4 Remove the hex nut securing the ignition key switch to the dash 5 Reach up under the dash to work the ignition switch and wiring out of the mounting hole 6 Disconnect the ignition switch connectors from the cab harness connectors and remove the switch from the machine b Disassembly DO NOT disassemble the ignition switch Replace a defective switch with a new part c Inspection and Replacemen
162. ulfur content fuel with a cloud point the temperature at which wax crystals form in diesel fuel at least 10 below the lowest expected fuel temperature The viscosity of the fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication Note When using diesel fuel with a sulfur content below 1 3 percent the filter change interval must be reduced by 75 hours The use of fuel with a sulfur content above 1 3 percent is not recommended 7 6 2 Fuel Hydraulic Oil Tank a Cleaning and Drying If contaminated fuel hydraulic oil or foreign material is in the tank the tank can usually be cleaned b Ifa leak is suspected between the fuel and hydraulic oil tank contact your local JLG distributor To clean the fuel hydraulic oil tank 1 Have dry chemical Class B fire extinguisher near the work area 2 Depending on which side of the tank is contaminated fuel or hydraulic oil remove the fuel or oil tank drain plug and safely drain any fuel or hydraulic oil into a suitable container Dispose of fuel or hydraulic oil properly 3 Clean the fuel hydraulic oil tank with a high pressure washer or flush the tank with hot water for five minutes and drain the water Dispose of contaminated water properly 4 For the fuel tank side add a diesel fuel emulsifying agent to the tank Refer to the manufacturer s instructions for the correct emulsifying agent to 7 6 water mixture ratio Refill the tank wi
163. val before proceeding 9 Raise the machine using a suitable jack or hoist Place suitable supports under both sides of the frame and lower the machine onto the supports Ensure that the machine will remain in place during axle removal 10 Support the axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 11 Mark and remove both wheel and tire assemblies from the axle that is being removed Refer to Section 5 5 1 Hemoving Wheel and Tire Assembly from Machine Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 12 Remove the drive shaft assembly Refer to Section 5 4 3 Drive Shaft Removal 13 Remove the capscrews locknuts and axle plates securing the axle to the frame 14 Remove the axle from the machine using the jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise disturb the machine while removing the axle Balance the axle and G5 19A G6 23A Axles Drive Shafts Wheels and Tires hs 5 3 6 1 prevent it from tipping turning or falling while removing it from beneath the machine Place the axle on a suitable support or holding stand Axle Installation Before proceeding ensure that the machine will remain in place during axle installation Block the front and rear of both tires on the a
164. ve terminal 3 Check for proper fluid level 4 Start the engine and observe the operator s display for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine low oil obstructed or faulty oil pump defective instrument display 5 Close and secure the engine cover G5 19A G6 23A Electrical System 9 11 8 Main Control Valve Solenoids 1080 a Main Control Valve Solenoid Removal 1 Open the engine cover Allow the engine to cool 2 Disconnect the battery negative cable at the battery negative terminal 3 Remove rear panel 4 Disconnect the wiring connector at the valve solenoid lead 5 Loosen and remove the two allenhead mounting Screws 6 Remove the valve solenoid 4 being careful not to lose or damage any o rings Note the location of any orifices check valves and o rings if equipped b Main Control Valve Solenoid Disassembly DO NOT disassemble a valve solenoid Replace a defective valve solenoid with a new solenoid c Main Control Valve Solenoid Installation 1 Install the valve solenoid using new o rings and tighten the allenhead screws Do not over tighten 2 Connect the wire connector to the valve solenoid 3 Start the machine and slowly move joystick to engage function If further troubleshooting is required refer to Section 9 4 Electrical System Schematics or Sec
165. xis Y NEUTRL IN NEUTRAL Indicates whether joystick is in neutral NOT NEUTRAL position for this axis ERROR AR Displays position in percentage for the analog rocker AR NEUTRL IN NEUTRAL Indicates whether analog rocker is in NOT NEUTRAL neutral position ERROR 51 ON OFF Displays status of S1 pushbutton S2 ON OFF Displays status of S2 pushbutton 53 ON OFF Displays status of S3 pushbutton S4 ON OFF Displays status of S4 pushbutton F1 ON OFF Displays status of F1 pushbutton SYSTEM GM XX XV Ground module battery voltage BATTERY G5 19A G6 23A 9 29 Electrical System Diagnostics Submenu Parameter Parameter Value Description Displayed on Analyzer 1st Displayed Displayed on Analyzer Line on Analyzer 2nd Line 2nd Line DATALOG ON XXXXhXXm Displays total controller on power time LIFT XXXXhXXm Displays total controller lift operation time FORK TILT XXXXhXXm Displays total controller fork tilt operation time TELE XXXXhXXm Displays total controller telescope operation time AUX HYD XXXXhXXm Displays total auxiliary hydraulics 1 and 1 2 2 operation time MAX VOLTS XX XV Displays maximum measured battery voltage RENTAL XXXXhXXm Displays total controller operation time NOTE can be reset ERASE Not available at password level 2 RENTAL ENTER resets rental data log time to Zero VERSION GM SW PX X Displays ground module software version GM HW REV XXXX Disp
166. xle that is already installed on the machine If applicable raise the machine using a suitable jack or hoist Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation Using a suitable jack hoist or overhead crane and sling remove the axle from its support or holding stand Balance the axle and prevent it from tipping turning or falling while positioning it beneath the machine DO NOT raise or otherwise disturb the machine while installing the axle Keep the axle supported and balanced on the jack hoist or overhead crane and sling throughout the installation procedure Position the axle under the frame and align with the holes in the frame Install the axle with capscrews locknuts and the axle plates Torque the front and rear axles of the G5 19A to 495 Ib ft 671 Nm Torque the front axle of the G6 23A to 863 Ib ft 1170 Nm and the rear axle to 495 Ib ft 671 Nm Install the drive shaft assemblies Refer to Section 5 4 5 Drive Shaft Installation If reinstalling an axle previously removed from the machine position the driveshaft yoke on the axle according to the alignment marks made earlier If installing a new axle note the position of the driveshaft yoke at the transmission Align the driveshaft yoke on the axle in the same plane as the yoke on the trans
167. y operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the engine components The following illustration identifies the components that are referred to throughout this section Component Terminology G5 19A G6 23A Radiator Oil Engine Deutz BF 4M 2012 Air Cleaner Assembly Hai Filer Implement Pump Filter Primary Fuel Engine Hydrostatic Transmission AOR QN N MATS Alternator V 2 NN W PX fw 4 f VA N 9 K 6252 L3 JA SAS 5 y Thermostat i gt n 7 3 230 2 0 72 G5 19A G6 23A Engine Deutz BF 4M 2012 7 2 ENGINE SERIAL NUMBER The Deutz BF 4M 2012 serial number is located on a tag on top of the engine Information contained in the serial number is required in correspondence with the engine manufacturer Supply the engine serial number and or data tag information when communicating about an engine or engine components 7 3 SPECIFICATIONS AND MAINTENANCE INFORMATION For engi
168. yzer Usage When the analyzer is first connected it defaults to access level 2 Settings may only be viewed in level 2 Settings cannot be changed until a password is entered to advance to one of three lower levels For more information contact your local JLG distributor 9 25 Electrical System 9 13 2 Fault Codes The following Fault codes can be viewed with either the JLG Analyzer or by translating the flash codes on the PCB board The LED on the PCB flashes out all fault codes from highest to lowest priority Help Message Flash Code Fault Condition Action SYSTEM VOLTS LOW 2 1 System voltage at If occurrence lasts for more than 3 2 pin J1 38 10 volts seconds then disable all outputs The fault shall be cleared upon all 3 axes of the joystick being set to neutral X and Y and Knurl and S4 and S1 and S2 becomes open SYSTEM VOLTS HIGH 2 2 System voltage at If occurrence lasts for more than 3 2 pin J1 38 gt 15 volts seconds then disable all outputs The fault shall be cleared upon all 3 axes of the joystick being set to neutral X and Y and Knurl and S4 and S1 and S2 becomes open JOYSTICK FAULT 3 1 Joystick Fault Disable all functions The fault shall be latched and only reset upon power down of the controller SYSTEM LOCKED OUT 3 2 Joystick X Y or Knurl Disable all functions The fault shall be CENTER JOYSTICK axes not in neutral at cleared upon all 3 axes of the joyst

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