JLG G6-23A Service Manual

Service Manual

Models G5-19A

G6-23A

P/N - 31200193

Revised

November 17, 2006

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 a

EFFECTIVITY PAGE

G5-19A, G6-23A-b

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.4 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3.5 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

3.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.6 Steering Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

G5-19A, G6-23A

Section Subject Page

Section 6

Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

Section 7

Engine: Deutz BF 4M 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5

7.7 Engine Exhaust and Air Cleaner System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.8 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.9 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.4 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

8.6 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

8.8 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

8.9 Front Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10

8.10 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11

8.11 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

9.5 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13

9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17

9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18

9.8 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19

9.9 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21

9.11 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22

9.12 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

9.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25

G5-19A, G6-23A

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

G5-19A, G6-23A

1.1

Safety Practices

1.1 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, for 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 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 & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Safety Manual is supplied with each machine and must be kept in the cab. In the event that the Operation & 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.

1.2

G5-19A, 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

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

1.6 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

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job 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 it is 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.

proceeding.

G5-19A, G6-23A

1.3

Safety Practices

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s 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 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 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

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 component, 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

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 ply 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 & Safety Manual supplied with machine for information.

1.4

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 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2.2 ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.3 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2.6

2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.4 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.6.1 8 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.6.2 50 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11I

G5-19A, G6-23A

2.1

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.

MAH1230

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 registration 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

2.2 TORQUES

2.2.1 ASTM Fastener Torque Chart (English)

WITH

PATCH

LOC-WEL

TORQUE

PATCH

LOC-WEL

WITHOUT

SOCKET HEAD

General Information and Specifications

UNBRAKO 1960 SERIES

SAE GRADE 8 BOLTS & GRADE 8 NUTS

& SOCKET HEAD CAP SCREWS

LOAD

CLAMP

LOCTITE

TORQUE

DRY OR

LOAD

CLAMP

LOCTITE

TORQUE

271

242 OR

262

LUB

263

LOCTITE

271

242 OR

262

LUB

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

SAE GRADE 5 BOLTS &

G5-19A, G6-23A

GRADE 2 NUTS

DRY OR

CLAMP

TENSILE

BOLT

THDS.

263

LOCTITE

LOAD

AREA

STRESS

DIA.

PER

INCH

SIZE

IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB

0.00604 380 8 6 — — 540 12 9 — — — — —

0.1120

48 0.00661 420 9 7 — — 600 13 10 — — — — —632

0.00909 580 16 12 — — 820 23 17 — — — — —

0.1380

40 0.01015 610 18 13 — — 920 25 19 — — — — —832

0.01400 900 30 22 — — 1260 41 31 — — — — —

0.1640

36 0.01474 940 31 23 — — 1320 43 32 — — — — —1024

0.01750 1120 43 32 — — 1580 60 45 — — — — —

0.1900

32 0.02000 1285 49 36 — — 1800 68 51 — — — — —

0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168

0.2500

28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178

1/4

0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950

0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365

0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925

1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550

12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070

1.3750

12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685

1-3/8

1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345

1.5000

1-1/2

12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600

Note: These torque values do not apply to cadmium plated fasteners.

0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28

0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50

0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77

0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120

0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170

0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231

0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400

0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645

IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB

0.3125

0.3750

0.4375

0.5000

0.5625

0.6250

0.7500

24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30

24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55

20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82

20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127

18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182

18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242

16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440

5/16

3/8

7/16

1/2

9/16

5/8

3/4

0.8750

14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700

7/8

1.0000

12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000

1.1250

12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520

1-1/8

1.2500

1-1/4

2.3

General Information and Specifications

2.2.2 ASTM Fastener Torque Chart (Metric)

WITH

PATCH

LOC-WEL

TORQUE

PATCH

LOC-WEL

WITHOUT

SOCKET HEAD

UNBRAKO 1960 SERIES

LOAD

CLAMP

271

242 OR

LOCTITE

262

LOCTITE

TORQUE

LUB

263

DRY OR

LOCTITE

& SOCKET HEAD CAP SCREWS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

LOAD

CLAMP

271

242 OR

LOCTITE

262

LOCTITE

TORQUE

LUB

GRADE 2 NUTS

SAE GRADE 5 BOLTS &

DRY OR

263

LOCTITE

2.4

LOAD

CLAMP

AREA

0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —

0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —

0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —

40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —832

0.1640

36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —1024

0.01750 1120 5 3.6 — — 1580 7 5 — — — — —

0.1900

32 0.02000 1285 6 4 — — 1800 8 6 — — — — —

STRESS

TENSILE

IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m

DIA.

BOLT

PER

THDS.

SIZE

0.1120

0.1380

48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —632

INCH

0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19

0.2500

28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20

1/4

IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m

0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38

0.3125

24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41

5/16

0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68

0.3750

24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75

3/8

0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

0.4375

20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111

7/16

0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163

0.5000

20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172

1/2

0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230

0.5625

18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247

9/16

0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313

0.6250

18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328

5/8

0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542

0.7500

16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597

3/4

0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874

0.8750

14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949

7/8

0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288

1.0000

12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356

0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851

1.1250

1-1/8

12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061

0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610

1.2500

1-1/4

12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807

1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457

1.3750

1-3/8

12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640

1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535

1.5000

1-1/2

12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881

Note: These torque values do not apply to cadmium plated fasteners.

G5-19A, G6-23A

General Information and Specifications

2.2.3 Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 METRIC BOLTS &

CLASS 8 METRIC NUTS

TORQUE

LUB

LOCTITE

262

LOCTITE

242 OR

271

CLAMP

SIZE PITCH

TENSILE

STRESS

AREA

CLAMP

LOAD

DRY OR LOCTITE

263

sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m

3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1

3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3

4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8

5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7

6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17

7 1 28.9 12.6 18 13 16 19 18 25 19 20 28

81.2536.615.92519232822.837272940

10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79

12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139

14 2 115 50.0 140 105 126 154 71.6 200 150 160 220

16 2 157 68.3 219 164 197 241 97.8 313 235 250 344

18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473

20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671

22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915

24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170

27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690

30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310

33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860

36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020

42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

CLASS 10.9 METRIC BOLTS &

CLASS 10 METRIC NUTS

LOAD

DRY OR LOCTITE

263

LUB

TORQUE

LOCTITE

262

LOCTITE

242 OR

271

Note: These torque values do not apply to cadmium plated fasteners.

G5-19A, G6-23A

METRIC CLASS 8.8METRIC CLASS 10.

2.5

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) (C

Reserve Capacity CCA @ -.4° F: 880 EN

Group/Series DIN 600,44

Alternator 14V, 70 Amps

Starter 12V, 3,0 KW Type EV (Gear Reduction)

)

2.6

G5-19A, G6-23A

General Information and Specifications

2.3.4 Engine Performance Specifications

Description G5-19A & G6-23A

Engine Make/Model Deutz BF 4M 2012

Low Idle 925 ±50 rpm

High Idle 2370 ±50 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 lb-ft (300 Nm).

G5-19A, G6-23A

2.7

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 & water

Axles

Differential Housing Capacity - Front 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 & 1st 50 Hour Maintenance Schedule

EVERY

Check Fuel

Level

Check Brake

Fluid Level

Change Axle Oil

Check Tire

Pressure

Lubrication

Schedule

Change Wheel

End Oil

Air Filter

Restriction

Indicator

Change Engine

Oil & Filter

Check Engine

Oil Level

/ F

( N

Check Wheel

Lug Nut

Torque

)

Check Hydraulic

Oil Level

2.5.2 50, 250 & 500 Hour Maintenance Schedule

EVERY

Drain Fuel/

Water

Separator

Check Engine Coolant Level

EVERY

Check

Battery

Lubrication

Schedule

250

Change Engine

Oil and

Filter

Check Boom

Bearing

Pads

Check Axle

Oil Level

Check Wheel

End Oil Levels

EVERY

Air Filter Vacuator

Valve

Check

Fan Belt

500

/ F

( N

)

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.

Change Fuel

Filter

Check Wheel

Lug Nut

Torque

OAH00402

2.5.3 1000 & 1500 Hour Maintenance Schedule

EVERY

1000

Change Axle Oil

Change Wheel

End Oil

EVERY

1500

Change

Engine Coolant

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

Change

Brake Fluid

OAH0050

G5-19A, G6-23A

2.9

General Information and Specifications

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule

EVERY

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

2.10

MAH0820

G5-19A, G6-23A

2.6.2 50 Hour Lubrication Schedule

General Information and Specifications

EVERY

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

G5-19A, G6-23A

MAH0830

2.11

General Information and Specifications

This Page Intentionally Left Blank

2.12

G5-19A, G6-23A

Section 3

Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Boom System - Two Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3.2 Second Section Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3.3 Second Section Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

3.3.4 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

3.4 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3.4.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3.4.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3.4.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

3.5 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

3.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

G5-19A, G6-23A

3.1

Boom

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

Access

Panel

Second

Boom

Section

Tilt

Cylinder

Quick

Switch

Pivot

Extend/Retract

Cylinder

MAH0140

3.2

G5-19A, G6-23A

Boom

3.2 BOOM SYSTEM - TWO SECTION BOOM

3.2.1 Boom System Description

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.

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 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 undertaken. 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.

, as described in

G5-19A, G6-23A

3.3

Boom

3.3.1 Boom Removal

1. Remove any attachment from the quick switch assembly.

2. Be sure 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 (N) 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 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.

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 Second Section Boom Removal

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.

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. At the 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 the 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. At the 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.

MAH0140

11. Lower the boom to a level position and place a suitable support under the rear of the boom. Reposition the slings to each end of the boom.

3.4

MAH0660

5. Remove the two snap rings and pin from barrel end of the extend/retract cylinder.

G5-19A, G6-23A

Boom

6. 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.

7. Remove the clip and pin from the rod end of the extend/retract cylinder and pull through the rear of the second boom section.

8. Pull out the remainder of the second boom section.

9. Inspect the boom and welds. Consult your local JLG distributor if structural damage is detected.

10. Inspect hoses, hardware, wear pads, mounting points and other components visible with the first boom section. Replace any item if damaged.

11. Inspect all wear pads for wear. (Refer to Section

3.4.1, “Wear Pad Inspection.”)

first boom section. Apply Loctite

#242 and torque to 66 lb-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 lb-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 lb-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. Tighten all rear wear pad bolts after ensuring the minimum gap requirements have been met. Refer to Section 3.4.1, “Wear Pad Inspection.”

7. Insert the pin and clip into the barrel end of the extend/retract cylinder.

8. Lift the tilt cylinder into place and insert the pins and clips to secure the cylinder to the boomhead.

9. Slide the tilt and auxiliary hoses between the boom sections.

10. Uncap and reconnect the tilt and auxiliary hoses and attach to their appropriate locations.

3.3.3 Second Section Boom Installation

1. Insert the extend/retract cylinder through the rear of the second boom section and attach the pin and clip to the rod end.

2. Install the bottom rear wear pads, washers and bolts into the first boom section. Apply Loctite torque to 66 lb-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).

3. Grease the inside of the first boom section on areas where the second boom section wear pads will slide.

4. 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 second section out to be able to install wear pads in front of the first boom section.

5. With the sling still under the boom head, install the top wear pads, washers and bolts in the front of the

#242 and

3.3.4 Boom Installation

IMPORTANT: 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.

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.

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. 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.

G5-19A, G6-23A

3.5

Boom

Install boom pivot pin (1) and lock bolt. Apply

Loctite

#242 and torque to 66 lb-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 lb-ft (90 Nm).

MAH0140

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 lb-ft (90 Nm).

Note: Raising the boom up or down with the sling may be necessary so the boom, compensating and lift/lower cylinder bores can be aligned for easier pin installation.

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.

3.4 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear pads with metal inserts.

On the G5-19A and G6-23A a total of 16 wear pads are installed on the outer boom.

3.4.1 Wear Pad Inspection

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.

3.4.2 Boom Wear Pad Replacement

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 time.

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 mounting capscrews M10 and torque to 36 lb-ft (50 Nm). Rear upper pads on G6-23A, apply Loctite wear pad mounting capscrews M10 and torque to 66 lb-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.

#242 to all wear pad

MA2070

#242 to all

3.6

G5-19A, G6-23A

Boom

3.4.3 Boom Wear Pad Lubrication

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.

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

MAH0300

easy attachment changes.

MAH0870

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 (0,5mm),

0.04 in (1 mm), 0.06 in (1,5mm) and 0.08 in (2,0mm).

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.”

G5-19A, G6-23A

MU4080

3.7

Boom

MAH1250

3.5.2 Connecting with a Hydraulic Quick Switch Device

1. Retract quick switch device to provide clearance. Check to be sure lock pin is disengaged.

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. Press the button (12) and at the same time, move the joystick to engage or to disengage the quick switch device.

MAH0980

5. Raise the boom to eye level and visually check that the quick switch pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.5.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”

MAH1270

3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment

1. Lower attachment to ground and set parking brake.

2. Quickly depress and release button (14) to relieve pressure at the male auxiliary fitting.

3. Connect to the male auxiliary fitting (13).

4. Quickly depress and release button (15) to relieve pressure at the female auxiliary fitting.

5. Connect to the female auxiliary fitting (13).

3.5.4 Quick Switch Removal

1. Remove the lock bolt (11) holding the tilt cylinder rod end pin 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. If damaged or if it cannot be repaired the pin must be replaced.

3.5.5 Quick Switch Installation

1. Assemble the quick switch to the boom head. Line up the quick switch between the mounts on the 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 and insert the tilt cylinder pin. Align the tilt cylinder pin and screw in the lock bolt (11). Torque to 72 lb-ft (97 Nm).

3.8

G5-19A, G6-23A

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