JLG G6-23A Service Manual

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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

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

Boom

1. Boom will not extend or retract.

2. Boom will not fully extend. 1. Extend/retract hydraulic system

3. Boom shifts to right or left when extending.

4. Excessive pivot pin noise and/or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/Retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder.

not operating properly.

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication.

2. Worn bushing(s).

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

3. Repair cylinder (Refer to Section

8.11.4, “Cylinder Inspection.”)

1. Refer to Section 8, “Hydraulic System.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.4.2, “Boom Wear Pad Replacement.”

1. Lubricate at regular intervals. (Refer to Section 2.6, “Lubrication Schedules.”) Replace worn pins as needed.

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 and/or connection leaks.

2. Lift/lower hydraulic system not operating properly.

3. Faulty Lift cylinders.

4. Seized boom pivot pin bushing.

G5-19A, G6-23A

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

3. Repair cylinder. (Refer to Section 8.11.4, “Cylinder Inspection.”)

4. Replace bushing.

3.9

Boom

Boom Troubleshooting (Continued)

Problem Cause Remedy

6. Rapid boom pad wear. 1. Incorrect wear pad gap.

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

7. Auxiliary hydraulics will not operate.

1. Auxiliary hydraulic system not operating properly.

1. Check wear pad gaps and correct as needed. Refer to Section 3.4.2, “Boom Wear Pad Replacement.”

2. Reduce cycle times.

3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. 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 Terminology. . . . . . . . . . . . . . . . . . . . . 4.2

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

4.2.1 Operator’s Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.2.2 Serial Number Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

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

4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3.2 Steering Column/Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.3.3 Brake Pedal and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.3.4 Inching Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

4.3.5 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

4.3.6 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.3.7 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.3.8 Windshield Washer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.3.9 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

G5-19A, G6-23A

4.1

Cab and Covers

4.1 OPERATOR’S CAB 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.

Transmission

Control and Gear

Selector Lever

Joystick

Brake Fluid

Reservoir

Steering

Column Tilt

Adjustment

Heater Controls

Parking Brake

MAH1101

4.2

G5-19A, G6-23A

Cab and Covers

WARNING: DO NOT service 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 OPERATOR’S CAB

4.2.1 Operator’s Cab Description

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.

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 and appearance. They are relatively simple to remove and replace.

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 (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. 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.

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

MAH0430

b. Steering Wheel Installation

1. 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 wheel.

4. Connect the battery negative (-) cable to the battery negative (-) terminal.

5. Close and secure the engine cover.

4.3

Cab and Covers

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 (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. 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).

b. Steering Column and Valve Installation

1. Install the orbitrol valve onto the steering column. Torque the four capscrews to 13 lb-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.

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

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. Brake Valve Installation

Refer to Section 8.10.2, b. “Service Brake Valve Installation,” for installation information.

c. 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 (N) NEUTRAL, engage the park brake and shut the engine OFF.

G5-19A, G6-23A

Cab and Covers

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 lower dash panel.

MAH0600

4.3.4 Inching Valve

a. Inching Valve 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. Remove the lower dash panel.

6. Remove the nut holding the inching valve adjusting rod (12) to the brake pedal bracket (13).

7. Label and disconnect all hoses attached to the valve, cap all fittings and plug hoses to keep dirt & debris from entering hydraulic system.

8. Remove the two bolts securing the inching valve to the inside of the cab.

6. Remove the two capscrews (10) securing the brake pedal to the inching valve.

7. Remove the circlip (11), flat washer, and the return spring securing the service brake pedal to the cab.

8. Remove the clip/pin from the brake plunger fork link.

9. Remove the service brake pedal from the cab.

d. Service Brake Pedal Installation

1. Position the service brake pedal in its mounting location within the cab.

2. 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.

3. Adjust the brake pedal as needed.

4. Install and secure the lower dash cover.

5. Connect the battery negative (-) cable to the battery negative (-) terminal.

6. Close and secure the engine cover.

b. Inching Valve Installation

1. Install the inching valve with the two bolts inside the cab.

2. Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations.

3. 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.

4. Mount the inching valve lever (15) to the inching valve. The lever should be 135° ±1° to the pin.

5. Install the adjustable rod (12) to the lever. The lever should be set to approximately 5.125 in (130 mm) in length.

)

(

135°

G5-19A, G6-23A

MAH1000

4.5

Cab and Covers

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 (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. 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.

b. Throttle Pedal Installation

1. Install the 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 lb-ft (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).

MA01912

4.6

17 18

IMPORTANT: During the full throttle check:

• DO NOT operate any hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in (N) NEUTRAL.

2. Check the engine rpm at full throttle. If the rpm is not 2370 ±50 rpm, readjust the throttle limit-stop screw at the throttle pedal within the cab.

MS0930

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 (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. 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 lenshead capscrews.

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 (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. Disconnect the battery negative (-) cable at the battery negative (-) terminal.

WARNING: The 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.

G5-19A, G6-23A

Note: 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

MAH1120

10. Remove the button-head capscrews, nuts and lockwashers securing the heater assembly to the cab.

11. Carefully pull out the heater assembly. Label and disconnect the wiring harness connections at the blower.

12. Remove the heater assembly.

b. Heater Assembly Installation

1. Install the heater assembly to its original orientation.

2. Connect the wiring harness connections at the blower.

3. Install the button-head capscrews, nuts and lockwashers to secure the heater assembly to the cab.

4. Reconnect the two heater hoses.

5. 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.

6. Connect the battery negative (-) cable at the battery negative (-) terminal.

7. 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.

8. 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 CAB REMOVAL

IMPORTANT: To 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 operation, 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 (N) 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.

7. Transfer the coolant into a suitable, covered container, and label as "Used Coolant". Dispose of used coolant at an approved recycling facility.

4.8

G5-19A, G6-23A

Bottom of Cab

MAH1140

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.

Cab and Covers

14. 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.

15. When all wiring, hydraulic hoses and fasteners are 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.

16. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab.

17. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

18. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

Note: Record 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.

G5-19A, G6-23A

MAH0710

4.9

Cab and Covers

4.5 CAB 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 lb-ft (150 Nm).

5. Remove the eye bolts from the top of the cab.

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.

Bottom of Cab

MAH1140

6. Connect the 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

G5-19A, G6-23A

Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

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

5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4

5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5.6

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

5.4.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

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

5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.10

5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5.11

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

5.6.1 Steering Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

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

5.7.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

G5-19A, G6-23A

5.1

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

(Front)

Front Axle

Assembly

Steering Cylinder

(Rear)

Drive Shaft

MAH0190

5.2

G5-19A, G6-23A

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 prevent 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 Axle Serial Number Plate

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.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.3.2 Axle Specifications

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.”

5.3.3 Axle Internal Service

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.

Machine Carraro

Model

G5-19A 141154 FRONT 31200119

G5-19A 141155 REAR 31200120

G6-23A 139970 FRONT 31200121

G6-23A 141247 REAR 31200122

Axle JLG

MANUAL

WARNING: DO NOT 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.

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 drivetrain 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 contamination. If the carrier housing was submerged in

G5-19A, G6-23A

5.3

Axles, Drive Shafts, Wheels and Tires

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.

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 (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. 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 lb-ft (12 Nm).

6. If the axle will be disassembled after removal, place a suitable receptacle under the axle (1) and wheel

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

MAH0990

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 removal 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, “Removing 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

5.4

G5-19A, G6-23A

Axles, Drive Shafts, Wheels and Tires

prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand.

5.3.6 Axle Installation

1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine.

2. 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.

3. 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.

4. Position the axle under the frame, and align with the holes in the frame.

5. Install the axle with capscrews, locknuts and the axle plates. Torque the front and rear axles of the G5-19A to 495 lb-ft (671 Nm). Torque the front axle of the G6-23A to 863 lb-ft (1170 Nm) and the rear axle to 495 lb-ft (671 Nm).

6. Install the drive shaft assemblies. (Refer to Section

5.4.5, “Drive Shaft Installation.”)

7. 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 transmission.

8. 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.

9. 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.

10. Install the wheel and tire assemblies. (Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto Machine.”)

11. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.

12. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.

13. Remove the blocks from the front and rear of both tires on the other axle.

14. Uncap and reconnect the steering and brake lines at their axle fittings. Refer to Section 8.10.4, “Brake Test,” for brake bleeding procedures.

15. Check the hydraulic reservoir oil level.

16. Connect the battery negative (-) cable to the battery negative (-) terminal.

17. Close and secure the engine cover.

18. 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.

G5-19A, G6-23A

5.5

Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low.

2. Axle and/or wheel end housings filled with incorrect oil or oil level low.

3. Incorrect alignment of ring and pinion gears.

4. Incorrect pinion (input) shaft bearing preload.

5. Worn or damaged bearings.

6. Worn or broken gear teeth.

7. Contamination in the axle.

8. Axle housing damaged.

1. Fill oil to correct level. (Refer to 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.

6. Replace gears as needed.

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. Replace damaged parts.

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

1. Universal joint(s) worn or damaged.

2. Differential ring and/or pinion gears damaged.

1. Drive shaft universal joint(s) assembly incorrectly tightened.

2. Drive shaft universal joint(s) worn or damaged.

3. Drive shaft damaged/ unbalanced.

1. Repair or replace universal joints as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

2. Repair or replace universal joints as needed.

3. Replace drive shaft as needed.

5.6

G5-19A, G6-23A

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).

5. Oil leaking from wheel end housing (planet carrier).

1. Drain plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose.

5. Housing (planet carrier) damaged.

1. Replace o-rings as needed and tighten plugs 59 lb-ft (80 Nm).

2. Tighten fittings.

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Carraro Repair Manuals.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 236 lb-ft (320 Nm).

7. Replace housing(s) as needed.

1. Replace o-rings as needed and tighten plugs to 59 lb-ft (80 Nm).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

4. Tighten housing capscrews to 41 lb-ft (55 Nm).

5. Replace housing (planet carrier).

6. Oil leaking from steering cylinder.

G5-19A, G6-23A

1. Hose fittings loose.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged.

4. Cylinder tube damaged.

1. Tighten fittings.

2. Replace o-rings and seals.

3. Replace piston rod seal.

4. Replace cylinder tube.

5.7

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.

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

8. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

3. Worn or damaged swivel bearings.

9. Slow steering response. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

1. Fill oil to correct level with Mobilube HDLS 80W-90 fluid. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Drain axle and/or wheel end housing and fill to correct level with Mobilube HDLS 80W-90 Fluid. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

1. Refer to the appropriate Carraro Repair Manual.

2. Correct bearing preload by adding or removing shims as needed.

3. Replace swivel bearings as needed.

1. Refer to the appropriate Carraro Repair Manual.

2. Repair or replace steering cylinder as needed.

10. Excessive noise when brakes are engaged.

11. Brakes will not engage. 1. Brake (hydraulic) system not

12. Brakes will not hold the machine or braking power reduced.

1. Brake discs worn.

2. Brake discs damaged.

operating properly.

2. Brake piston o-rings and seals damaged (leaking).

1. Brake discs worn.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

1. Check brake discs for wear. Refer to appropriate Carraro Repair Manual.

2. Replace brake discs.

1. Refer to the appropriate Carraro Repair Manual.

2. Replace o-rings and seals.

1. Check brake discs for wear. Refer to the appropriate Carraro Repair Manual.

2. Refer to the appropriate Carraro Repair Manual.

3. Replace o-rings and seals.

5.8

G5-19A, G6-23A

5.4 DRIVE SHAFTS

5.4.1 Drive Shaft Inspection

Whenever servicing the machine, conduct a visual inspection of the drive shaft and cross and bearing assembly (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later.

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.

Axles, Drive Shafts, Wheels and Tires

To Rear Axle

To Fro nt

Axle

MAH0450

5.4.2 Drive Shaft Maintenance

Refer to Section 2.6, “Lubrication Schedules,” for information regarding the lubrication of the grease fittings on the drive shafts.

5.4.3 Drive Shaft Removal

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. 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, 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).

5.4.4 Drive Shaft Cleaning and Drying

1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.

2. Remove any burrs or rough spots from all machined surfaces. Re-clean and dry as required.

5.4.5 Drive Shaft Installation

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.

2. Install the four capscrews (1) and four locknuts securing the yoke flange (2) to the front axle.

Loctite 102 lb-ft (139 Nm).

3. Install the four capscrews securing the bearing crosses to the rear axle. Loctite capscrews to 102 lb-ft (139 Nm).

4. Connect the battery negative (-) ground cable at the battery negative (-) terminal.

5. Close and secure the engine cover.

and torque the capscrews to

and torque the

G5-19A, G6-23A

5.9

Axles, Drive Shafts, Wheels and Tires

5.5 WHEELS AND TIRES

WARNING: Risk 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 smaller 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.

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 machine 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.

5.10

G5-19A, G6-23A

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

MAH0460

5.6 STEERING ADJUSTMENT

5.6.1 Steering Angle Adjustment

Steering angle adjustment instructions can be found in the appropriate Carraro Repair Manual.

5.7 BRAKES

5.7.1 Brake Disk Inspection.

Check the brake disks for wear every 1,000 hours of operation or yearly.

The service brakes can only be checked by performing a teardown of the axle. Refer to the appropriate Carraro Repair Manual for complete teardown instructions. The minimum tolerance for the brake disc gap is 0.016 in (4.10 mm).

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 lb-ft (300 Nm).

OAH0990

5. Remove machine from supports.

G5-19A, G6-23A

5.11

Axles, Drive Shafts, Wheels and Tires

This Page Intentionally Left Blank

5.12

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 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

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

6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4.2 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.4.4 After Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

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

G5-19A, G6-23A

6.1

Transmission:

6.1 TRANSMISSION ASSEMBLY 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 transmission. The following illustration identifies the components that are referred to throughout this section.

Hydrostatic

Transmission

MAH0251

Reverse

Relief

Val ve

Directional

Val ve

Forward

Relief

Val ve

6.2

G5-19A, G6-23A

Transmission:

WARNING: DO NOT 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 Transmission Maintenance

The transmission is a hydraulic component and requires the same maintenance as the hydraulic system. Refer to Section 2.5, “Maintenance Schedules.”

Performance 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 .............................................. 6 mph (10 km/hr)

Second gear ...................................... 21 mph (34 km/hr)

G6-23A (with 405/70-24 tires)

First gear ............................................... 4 mph (7 km/hr)

Second gear ...................................... 20 mph (33 km/hr)

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 Transmission 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, turn rear wheels to give easier access to rear of engine compartment, 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 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 & 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

G5-19A, G6-23A

6.3

Transmission:

chain, but DO NOT raise the transmission at this time.

13. Remove the two Allen head bolts that attach the transmission to the engine.

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 transmission 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

Transmission disassembly, internal inspection, service, repair and assembly procedures are covered in the Rexroth Repair Manual (P/N 31200124).

10. Close and secure the engine cover.

6.4.4 After Transmission Replacement

1. Install new hydraulic filters.

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. Run the 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. Add oil 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.

6.4.3 Transmission Installation

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

G5-19A, G6-23A

6.5 TOWING A DISABLED MACHINE

Transmission:

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: BLOCK 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 accurately 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.

MAH0770

After the machine has been towed to a secure location, reactivate the parking brake.

1. Block all four wheels.

WARNING: BLOCK ALL FOUR

WHEELS. Failure to do so could result in

death or serious injury from machine roll away.

G5-19A, G6-23A

MAH0780

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

Transmission:

This Page Intentionally Left Blank

6.6

G5-19A, G6-23A

Section 7

Engine: Deutz BF 4M 2012

Contents

PARAGRAPH TITLE PAGE

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

7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

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

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

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

7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4.2 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7.4

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

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

7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.6.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

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

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

7.8.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.8.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7.8

7.8.3 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

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

7.9.1 Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.9.2 Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

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

G5-19A, G6-23A

7.1

Engine: Deutz BF 4M 2012

7.1 INTRODUCTION

7.1.1 Disclaimer and Scope

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.

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 lightload 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 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 engine components. The following illustration identifies the components that are referred to throughout this section.

7.2

G5-19A, G6-23A

Primary Fuel

Filter

Engine: Deutz BF 4M 2012

Air Cleaner

Assembly

Coolant

Overflow

Ta nk

Engine

Mount

Thermostat

Starter

Implement

Pump

Oil Filter

Fan

Shroud

Fan

Radiator/Oil

Cooler

Fuel Filter

Alternator

Hydrostatic

Transmission

G5-19A, G6-23A

MAH0230

7.3

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 engine, 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 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.

• If the engine runs hot, check the temperature of the upper radiator hose.

• If the hose is not hot, the thermostat may be stuck in the closed position.

• If 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 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

7.4

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 & 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 & debris from entering the hydraulic system.

12. Detach the fan safety shroud.

MAH0290

13. Remove the two brackets (1) at the front of the radiator attached to the frame.

14. Remove the locknuts holding the 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.

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.”

G5-19A, G6-23A

7.6 FUEL SYSTEM

7.6.1 Diesel Fuel

Fuel 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.

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 #2 diesel fuel with a 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 may be used, however, fuel economy will be reduced.

WARNING: DO NOT mix gasoline

or alcohol with diesel fuel. The mixture can cause an explosion.

Use a low-sulfur 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

water mixture ratio. Refill the tank with 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: If 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 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated.

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.

If contaminated fuel, hydraulic oil or foreign material is in the tank, the tank can usually be cleaned.

b. If a leak is suspected between the fuel and hydraulic oil

tank, contact your local JLG distributor.

To clean the fuel/hydraulic oil tank:

1. Have a 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

7.7 ENGINE EXHAUST AND AIR CLEANER SYSTEM

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. Exhaust 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.

CAUTION: NEVER run the engine

with only the inner safety element installed.

G5-19A, G6-23A

7.8 ENGINE REPLACEMENT

7.8.1 Engine 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 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. Remove the engine cover.

8. Remove battery from engine compartment, disconnect and remove battery tray.

9. Drain hydraulic reservoir. Refer to Section 8.7.1, “Hydraulic Oil Reservoir Draining.”

10. Drain radiator and overflow bottle. Refer to Section

7.4.2, “Radiator/Oil Cooler and Coolant Heater Replacement.”

11. Label, disconnect and cap all hydraulic hoses attached to engine and radiator, cap all fittings and plug hoses to keep dirt & debris from entering hydraulic system.

12. Disconnect the fuel inlet (1) and return lines. Install a plug in the end of each line.

13. Remove hydraulic and fuel filters, windshield washer fluid reservoir and filter bracket assembly.

14. Remove radiator overflow bottle.

15. Unbolt and remove the fan safety shroud.

16. 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.”.

17. Mark the engine fan orientation. Remove the engine fan.

Engine: Deutz BF 4M 2012

MAH0620

18. Unbolt the relay distribution panel behind the engine. Label any loose wire connections.

19. Unplug the necessary harness plugs that go into the cab.

20. Carefully pull wires through engine compartment wall and place on engine.

21. Mark the location of the throttle cable (2) at the engine throttle lever. Disconnect the throttle cable.

22. Detach exhaust and air cleaner hoses from the engine. Cover air inlets to protect from dirt & debris.

23. Remove air cleaner assembly from engine compartment.

24. Completely disconnect exhaust pipe.

25. Remove the hydraulic reservoir fill tube.

26. Secure the engine with a lifting strap or chain from the appropriate lifting points (3). Use a suitable hoist or overhead crane.

27. Remove the 4 motor mount bolts that attach the engine to the frame.

28. Carefully lift the engine from the machine. Avoid causing damage to the surrounding parts.

29. 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.

G5-19A, G6-23A

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 Engine Installation

Note: Refer to Section 2.2, “Torques,” for specific fastener torque specifications.

1. Position engine in engine compartment being sure to line up the 4 motor mount holes. Replace bolts and torque to 71 lb-ft (97 Nm).

2. Connect the hydraulic reservoir fill tube.

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.

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 & debris.

14. Refill the hydraulic reservoir (Refer to the appropriate Operation & Safety Manual for information concerning the hydraulic oil and filter change).

MAH0620

15. Replace the battery tray and battery and reconnect the 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 hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in NEUTRAL (N).

20. Obtain and connect an appropriate engine analyzer or tachometer. Check the engine rpm at full throttle.

7.8

G5-19A, G6-23A

Engine: Deutz BF 4M 2012

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 COUPLER

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).

7.9.2 Coupler Installation

1. Attach the coupler (5) and flex plate (6) using the necessary bolts. Torque to 155 lb-ft (210 Nm).

2. Bolt on the Flywheel Cover Plate (4) over the coupler and flywheel. Torque bolts to 37 lb-ft (50 Nm).

3. Reattach the hydrostatic transmission (3). Follow all guidelines in Section 6.4.3, “Transmission Installation.”

G5-19A, G6-23A

MAH0630

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 Oil 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, 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, 33, 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, 25, 31, 33, 34, 45, 55

11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59

10, 11, 12

Key to Possible Causes

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

10. Clogged fuel filter

11. Restricted air cleaner

12. Air in fuel system

13. Faulty fuel injection pump

14. Faulty fuel injectors or incorrect type

15. Exhauster or vacuum pipe leak

16. Induction system leaks

17. Broken fuel injection pump drive

18. Incorrect fuel pump timing

19. Incorrect valve timing

20. Poor compression

21. Blocked fuel tank vent

22. Incorrect grade of fuel

23. Sticking throttle or restricted movement

24. Exhaust pipe restriction

25. Leaking cylinder head gasket

26. Overheating

27. Cold running

28. Incorrect tappet adjustment

29. Sticking valves

30. Incorrect high pressure pipes

31. Worn cylinder bores

32. Pitted valves and seats

33. Broken, worn or sticking piston ring(s)

34. Worn valve stems and guides

35. Restricted air cleaner

36. Worn or damaged bearings

37. Insufficient oil in sump

38. Inaccurate gauge

39. Oil pump worn

40. Pressure relief valve sticking open

41. Pressure relief valve sticking closed

42. Broken relief valve spring

43. Faulty suction pipe

44. Restricted oil filter

45. Piston seizure/pick up

46. Incorrect piston height

47. Damaged fan

48. Faulty engine mounting

49. Incorrectly aligned flywheel housing or incorrectly aligned flywheel

50. Faulty thermostat

51. Restriction in water jacket

52. Loose fan belt

53. Restricted radiator

54. Faulty water pump

55. Restricted breather pipe

56. Damaged valve stem oil deflectors (if fitted)

57. Coolant level too low

58. Blocked sump strainer

59. Broken valve spring

7.10

G5-19A, G6-23A

Section 8

Hydraulic System

Contents

PARAGRAPH TITLE PAGE

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

8.4.1 Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.4.2 Hose, Tube, Line and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8.3

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

8.5.1 Pressure Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

8.5.2 Main Control Valve Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

8.5.3 Charge Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

8.5.4 Drive Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

8.5.5 Steering Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

8.5.6 Brake Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

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

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

8.7.1 Hydraulic Oil Reservoir Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

8.7.2 Hydraulic Oil Reservoir Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

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

8.8.1 Implement Pump Failure Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

8.8.2 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

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

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

8.10.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11

8.10.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

8.10.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

8.10.4 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14

8.10.5 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14

8.10.6 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14

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

8.11.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16

8.11.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16

8.11.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17

8.11.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17

8.11.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17

8.11.6 General Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

8.11.7 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

8.11.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8.19

G5-19A, G6-23A

8.1

Hydraulic System

8.1 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.

Extend/Retract

Cylinder

Tilt Cylinder

Main Control

Val ve

Lift/Lower Cylinder

Main

Pump

Hydraulic

Filter

Compensating

(Slave)

Cylinder

Hydraulic

Reservoir

8.2

MAH0241

Implement

Pump

Steering Cylinder

G5-19A, G6-23A

Hydraulic System

8.2 SAFETY INFORMATION

WARNING: DO NOT 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.

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 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 otherwise 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.

and cautiously loosen the part

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 component.

8.4.1 Replacement Considerations

Conditions including, but not limited to, the following are sufficient for considering component replacement:

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 markings, 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.

G5-19A, G6-23A

8.3

Hydraulic System

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.

8.5 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:

• Gauges for testing high and low pressure circuits

• Fittings, couplers and hoses

• Durable carrying case

Contact your local JLG distributor for ordering information.

Part

Number

80904003 Hydraulic Pressure Test Kit 10 lbs. Consult Factory

Description Approximate

Weight

Price and

Availability

8.5.1 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 that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly.

6. As 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.

8.4

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.

MAH0120

8.5.3 Charge Pressure Checking

Attach a 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.

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.

8.5.5 Steering Pressure Checking

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.

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.

MAH0850

8.5.6 Brake Pressure Checking

Attach a pressure gauge to the test fitting (5) 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.

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.

MAH0780

8.5.4 Drive Pressure Checking

Attach a pressure gauge to the test fitting (3) on the hydrostatic transmission to check the system pressure. Check the drive pressure with the park brake on and the service 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.

G5-19A, G6-23A

MAH0030

8.5

Hydraulic System

8.6 HYDRAULIC SCHEMATIC

LEFT

RIGHT

CYLINDER

REAR STEERING

LEFT

CYLINDER

FRONT STEERING

RIGHT

LS P

PRIORITY

FLOW VALVE

INLET

ITEM DESCRIPTION

PUMP, DRIVE

MOTOR, DRIVE - G5-19A

MOTOR, DRIVE - G6-23A

B3 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

Q VALVE, TRAILER BRAKES - OPTIONAL R VALVE, BRAKE INCHING

MAH1150

8.6

G5-19A, G6-23A

Hydraulic System

LEVAGE LIFT

COMPENSATION

INCLINGISON TILT

OUTILLAGE AUX

TELESCOPAGE CROWD

P2B

250

T2B

280280

T3B

T2 T1

Fa1

T1U

Vg min.

Vg max.

MAH1160

G5-19A, G6-23A

8.7

Hydraulic System

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 filter 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 Hydraulic Oil Reservoir Draining

1. Park the machine on a firm, level surface, fully retract the boom, support 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. 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.

8.7.2 Hydraulic Oil Reservoir Filling

1. Be sure the reservoir is clean and free of all debris.

2. Install new hydraulic oil filters.

3. Fill the reservoir with Mobilfluid oil. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

4. Start the machine. Run engine to normal operating temperature. Operate all hydraulic functions.

424 (ISO Grade 46)

8.8 HYDRAULIC SYSTEM PUMP

8.8.1 Implement Pump Failure Analysis

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.

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 (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. Drain the hydraulic oil reservoir. Refer to Section

8.7.1, “Hydraulic Oil Reservoir Draining.”

5. Remove the belly pan.

8.8

G5-19A, G6-23A

MAH0270

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 & debris from entering the hydraulic system.

8. Remove the engine oil filter (2).

9. Remove the two bolts that hold the pump in place.

Hydraulic System

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 part. 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 hydraulic oil.

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.

e. Implement Pump Assembly

Note: Before assembly, all parts must be perfectly clean and lubricated with hydraulic fluid. Renew all seals using hydraulic fluid as a lubricant.

1. Fit the shaft seal mounting flange with the garter spring facings into the pump and refit the circlip.

2. Fit the 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 original 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.

5. Fit the o-ring into its groove in the mounting flange and apply a small amount of Loctite

to the lower

front face of the body.

G5-19A, G6-23A

8.9

Hydraulic System

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 lb-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 orings.

2. Use the two Allen head bolts to secure the pump into place. Torque to 70 lb-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. All tube and hose 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.

8.9 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).

MAH0520

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 (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. 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 & debris from entering hydraulic system.

6. Support the pump and remove the four bolts attaching the pump to the front axle.

b. Front Drive Pump Installation

1. Install the pump onto the front axle. Torque the four bolts to 178 lb-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.

8.10

G5-19A, G6-23A

Hydraulic System

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

MAH0120

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.

Valve Section

Load Sense

Section

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 (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. Remove the rear panel. Allow the hydraulic fluid to cool.

4. Thoroughly clean the main control valve and surrounding 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 & 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.

MAH0720

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 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.

G5-19A, G6-23A

8.11

Hydraulic System

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 hydraulic 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.

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

functions.

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.”

Assemble the Main Control Valve

1. Place all three tie rods with the washers and nuts through the 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 lb-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.

8.10.2 Service Brake Valve

The service brake valve is at the base of the steering column support, concealed by the lower dash cover.

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 (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. 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 & debris from entering the hydraulic system.

8.12

G5-19A, G6-23A

MAH0030

6. Remove the bolts that mount the service brake valve to the steering column support

Hydraulic System

8.10.3 Parking Brake

The park brake is secured with two capscrews (1) and lockwashers (2) at the left side of the seat base.

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 oil.

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 Te st.”

MAH1260

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 (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. 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.

G5-19A, G6-23A

8.13

Hydraulic System

2. Use new oiled o-rings 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.

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 Steering Orbitrol Valve

Refer to Section 4.3.2, “Steering Column/Valve Replacement,” for details.

8.10.6 Steer Select Valve

The steer select valve is attached to a manifold mounted on a mounting 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.

MAH1060

2. Remove the plastic cap from the brake bleeder. Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially

8.14

a. Steer Select Manifold 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 (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

6. 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.

b. Steer Select Valve and Manifold Disassembly,

Cleaning, Inspection and Assembly

1. Place the steer select assembly on a suitable work surface.

2. Separate the steer select valve from the manifold by removing the capscrews. Discard the old o-rings.

3. Remove the solenoid valves and cartridges from the steer select housing.

4. Clean all components with a suitable cleaner before inspection.

5. 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.

6. Inspect internal passageways of the steer select manifold and valve for wear, damage, etc. If inner surfaces of the manifold DO NOT display an ultrasmooth, 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 hydraulic oil.

7. Install the solenoid valves and cartridges in the steer select housing.

8. Attach the steer select valve to the manifold using new, oiled o-rings and socket head capscrews.

c. Steer Select Manifold and Valve Installation

Hydraulic System

MAH0020

4. 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.

5. Inspect for leaks and check the level of the hydraulic fluid in 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. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.

7. Close and secure the engine cover.

d. 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.”

2. Check each steering mode for proper function.

1. Attach the steer select manifold and valve to the mounting plate on the frame using the socket head capscrews.

2. Connect the hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the steer select valve and manifold.

3. 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

8.15

Hydraulic System

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 in (N) 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 in, on, near or around the machine.

8.11.2 General Cylinder Disassembly

1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder.

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.

MAH0160

IMPORTANT: DO NOT tamper with or attempt to 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 with 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).

8.16

G5-19A, G6-23A

Hydraulic System

Note: It may 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 orings 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, 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 Cylinder Cleaning Instructions

1. Discard all seals, back-up rings and o-rings. Replace with new items from complete seal kits to help ensure proper cylinder function.

2. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, grooves, threads, etc.

Note: If a 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 Cylinder Inspection

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.

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

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 General Cylinder Assembly

1. Use the proper tools for specific installation tasks. Clean tools are required for assembly.

2. Install new seals, back-up rings and o-rings (2) on the piston (4) and the head gland (6).

Note: 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 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,” for tightening guidelines for the head gland.

8. If applicable, thread the new counterbalance valve into the block on the cylinder barrel.

and install the

G5-19A, G6-23A

8.17

Hydraulic System

8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.

9. Close and secure the engine cover.

MAH0160

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.

2. Align cylinder bushing and install pin, lock bolt or retaining clip.

3. Uncap and connect the hydraulic hoses in relation to the labels or markings made during removal.

4. Before starting the machine, check fluid level of the hydraulic fluid reservoir and if necessary, fill to full mark with Mobilfluid® 424 (ISO Grade 46) Tractor Fluid.

5. 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.

6. Inspect for leaks and check level of hydraulic fluid in reservoir. Add hydraulic fluid if needed.

7. 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.

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.

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

G5-19A, G6-23A

Hydraulic System

8.11.8 Hydraulic Cylinder Torque Specifications

Description G5-19A G6-23A

All Cylinder Set Screws 15-18 lb-ft (20-25 Nm) 15-18 lb-ft (20-25 Nm)

Lift/Lower Cylinder

Head Gland 369-406 lb-ft (500-550 Nm) 516-553 lb-ft (700-750 Nm)

Piston 1593-1630 lb-ft (2160-2210 Nm) 1940-1977 lb-ft (2630-2680 Nm)

Extend/Retract Cylinder

Head Gland 221-258 lb-ft (300-350 Nm) 221-258 lb-ft (300-350 Nm)

Piston 406-443 lb-ft (550-600 Nm) 406-443 lb-ft (550-600 Nm)

Tilt Cylinder

Head Gland 295-332 lb-ft (400-450 Nm) 516-553 lb-ft (700-750 Nm)

Piston 948-985 lb-ft (1285-1335 Nm) 1940-1977 lb-ft (2630-2680 Nm)

Compensating Cylinder

Head Gland 295-332 lb-ft (400-450 Nm) 295-332 lb-ft (400-450 Nm)

Piston 822-859 lb-ft (1115-1165 Nm) 822-859 lb- 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 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

9.4.1 Cab Roof Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

9.4.2 Cab Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

9.4.3 Power Distribution Module Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

9.4.4 Front & Rear Chassis, Battery, Boom Harness Schematic . . . . . . . . . . . . 9.10

9.4.5 Engine Harness Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

9.4.6 Dashboard Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

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

9.5.1 Charge Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13

9.5.2 Start Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14

9.5.3 Drive Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15

9.5.4 Constant Power Circuit Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16

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

9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17

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

9.7.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

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

9.8.1 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19

9.8.2 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19

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

9.9.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

9.9.2 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

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

9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21

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

9.11.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22

9.11.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22

9.11.3 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9.22

9.11.4 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

9.11.5 Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

9.11.6 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24

9.11.7 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24

9.11.8 Main Control Valve Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

G5-19A, G6-23A

9.1

Electrical System

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

9.12.1 Joystick Functionality Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

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

9.13.1 Analyzer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

9.13.2 Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26

9.13.3 Analyzer Diagnostic Help Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28

9.2

G5-19A, G6-23A

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

Electrical System

Battery

Engine

Compartment

Relays

Horn

Power

Distribution

Module

Engine

Harness

Connections

MAH1071

G5-19A, G6-23A

9.3

Electrical System

9.2 SPECIFICATIONS

Electrical system specifications are listed in Section 2, “General Information and Specifications.”

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).

MAH0480

9.4

G5-19A, G6-23A

9.3.2 Power Distribution Module

Electrical System

F10

F11

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

F29

F30

F31

F32

F33

F34

K1 K5 K9

K2 K6 K10

K3 K7 K11

K4 K8 K12

MAH0490

Fuse/Relay Function Amp Rating

G5-19A, G6-23A

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

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 Engine 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

9.6

K9 Work Lights

K10 Boom Lights

K11 Rear Wiper

K12 Heater Fan

G5-19A, G6-23A

9.4 ELECTRICAL SYSTEM SCHEMATICS

9.4.1 Cab Roof Schematic

Note: For more detailed schematics, contact your local JLG distributor.

RT FRT LT FRT

WKLIGHT

Electrical System

RT REAR

LT REAR

WKLIGHT

(OPT)(OPT)

WKLIGHT

BEACON LIGHT (OPT)(OPT)(OPT)

SPEAKERS

(OPT)

RADIO

(OPT)

RIGHT

LEFT

REAR WIPER

MOTOR

DOME

LIGHT

X31 X30

X33

1 2 3

RADIO BAT

4 5 6

RADIO IGN

GND21

X34

1 2

SX-

SX+

DX-

DX+

6 7 8

DX+

DX-

SX+

SX-

X35

R WIPE IGN53A

31 53

31B

X37

GND2

R WIPE

R WIPE PK

BRK LT PWR

GND21

12 21212121

GND9

FRT WKLTS

X29

GND9

FRT WKLTS

RR WKLTS

GND10

X28 X27

GND10

RR WKLTS

BCN LT

GND27

G5-19A, G6-23A

GND21

GND2

R WIPE

R WIPE PK

RADIO IGN

RADIO BAT

R WIPE IGN

PINS 4-7=2.5MM, ALL OTHERS=1.0MM

CAB ROOF HARNESS

TO CAB HARNESS

X43

BRK LT PWR

GND9

FRT WKLTS

RR WKLTS

GND10

BCN LT

EMPTY

GND27

1521436511871091312 14

MAH0060

9.7

Electrical System

9.4.2 Cab Harness Schematic

8042 18991 & After)

ALL DIODES

ALL 1.0² MM WIRES

DEUTSCH DRC16-40S

CONN J2

ALL 1.0² MM WIRES

AMP SOCKETS 350550-1

AMP MATE-N-LOK 1-480706-0

SWITCH (OPT)

S10

F/R AUX HYD SELECT

X23

SPARE

S24

HORN

SWITCH

SWITCH (OPT)

1/2 AUX HYD SELECT

RESERVED

SWITCH (OPT)

BOOM LIGHTS

SWITCH (OPT)

BEACON LIGHT

X26

DIAGNOSTIC

JLG ANALYZER

AMP 350690-1

AMP 350780-1

X43

CAB HARNESS

TO CAB ROOF HARNESS

PINS 4-7=2.5² MM, ALL OTHERS=1.0² MM

SWITCH (OPT)

REAR WORK LIGHTS

S4 S5

SWITCH (OPT)

FRT WORK LIGHTS

X11

CAB HARNESS

TO DASHBOARD

A/C

SWITCH (OPT)

PTO

S22

SWITCH (OPT)

1N5404

3A. 400V.

CONN J1

4213

4213 121089 11765 1413 15

30 29 28 27 26 25 24 21 20 19 6 1 12 16 13 14 10 17 4 22 11 9 2 8 7 31 15 23 5 3 18 36 35 34 33 32

DIODE

PCBGND

MODULE 2

GND

EMPTY

621 43 5 879

537

IGN

BAT

383736

EMPTY

PCB IGN

DIODE

JMP

+ A B

JLG

P/C BOARD

(REF 0610164)

DO/PWM

CAN TERM

302726

3231353433

EMPTY

AUX2

EMPTY

120

LIFT UP

REAR AUX HYD

X45

...

MODULE 2

EMPTY EMPTY EMPTY EMPTY EMPTY

EMPTY

21 43 5 6 789 10

EMPTY

GND8

IGN SGN 1 BCN/AUX PWR REAR AUX HYD

GND 24

RESD SW OUT

SHIELD

CAN HI

CAN LO

DI (LMI C)

DI (JL)

DO/PWM

201922

TILT DN

TILT UP

LIFT DN

121110

1514131716

CANL

CANH

EMPTY

TELE IN

PCB IGN

(SHIELD)

PCB IGN

AUX HYD 1/2

TELE OUT

GND8

IGN SGN 1

HORN PWR HORN

GND8

IGN SGN 1

BCN/AUX PWR AUX HYD 1/2

GND8

IGN SGN 1

RESD SW

RESD SW OUT

GND8

IGN SGN 1

BOOM LT PWR

BOOM LTS

GND8

IGN SGN 1

BCN/AUX PWR

BCN LT

ANAL GND ANAL RX ANAL TX

ANAL PWR

EMPTY GND27 BCN LT GND10

RR WKLTS

GND9

FRT WKLTS

BRK LT PWR

EMPTY

GND2

EMPTY EMPTY

RADIO IGN

RADIO BAT

GND21

GND8

IGN SGN 1

RR WKLT PWR

RR WKLTS

GND8

IGN SGN 1

FRT WKLT PWR

FRT WKLTS

EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY ALT D+

GND8

FUEL GA STR CRB

STR AW STR 2W

LEFT HI BEAM

PREHEAT LT EMPTY ALT W

ENG H2O GA

ENG OIL LT STRT INTLK

HYD LT

ENG H2O LT

FLASHER OUT EMPTY

IGN SGN 1

RT PARK LT

R AXLE CNT EMPTY EMPTY EMPTY EMPTY EMPTY

GND7

GND8

H FAN C

AC TEMP SW

3 2 1

AIR SEAT PWR

X38

SEAT

(OPT)

AIR RIDE

BCN/AUX PWR

EMPTY

PTO

DI (LMI O)

PCB IGN

S16

(OPT)

AND TURN

HEAD LIGHTS

HAZARD

MODULE

SWITCH (OPT)

IN CAB

GND8

FLASHER IN

IGN SGN 2

(RED)

CAB HARNESS

ALL 4.O² MM WIRES

FLSH PWR

(RED)

X44 (DEUTSCH

F WASH

(RED)

HD34-18-8PE)

IGN SGN 2

(BLK)

TO BAT POSITIVE

S25

FRONT WIPER

IGN SGN 1

(BLK)

ON ENGINE

AND NEGATIVE

S11

IGN

DO/PWM

AUX1

EMPTY

PCB IGN

ANAL TX

ANAL RX

ANAL GND1

ANAL PWR

RT TURN

IGN SGN 1

LT TURN

FLASHER OUT

EMPTY

ANAL TX

ANAL RX

PCB IGN

ANAL GND

ANAL PWR

AC TEMP SW

GND5

AC TEMP OUT

X32

312

POWER

DISTRIBUTION

A/C

TEMP

(OPT)

SENSOR

(OPT)

SWITCH

BOOM LTS

X09

CAB HARNESS

F WIPE

GND8

GND19

AUX HYD 1/2

TO OPT BOOM LT/

DEUTSCH DT04-4P

FLASH PWRNCHIGH HDNCLOW HD

34567

PLUG

FLSH PWR

HI BEAM SGN

GND20

H FAN HI

H FAN MED

2. AUX HYD

ALL 1.O² MM WIRES

SIDE LT

PLUG

PARK LT SW

LO BEAM SGN

H FAN PWR

SWITCH

HEATER FAN

SEE SHT 2 FOR

SIGNAL LEVER

LIGHT PWR

LEFT

LT TURN

LT BAT 1

H FAN C

S17

(OPT)

TURN PWR

RIGHT

101112

RT TURN

FLASHER OUT

X39

H FAN LO

S15

KEY

SWITCH

012

210

IGN

BAT

STRT

HEAT

EMPTY

50A

3971562

STR 2W

STR CRB

PLUG

EMPTY

KEY BAT 1

PLUG

H FAN HI

BRK LTS

BRK LT PWR

X40

(OPT)

SWITCH

(OPT)

BRAKE LTS

SHFT/STR PWR

EMPTY

KEY STRT

KEY IGN 1

GND5

GND4

EMPTY

F WIPE H

H FAN LO

F WIPE PK

H FAN MED

GND3

X41

S18

PARK BRAKE

FRONT

(OPT)

HEATER

WIPER MOTOR

BLOWER MOTOR

S14

MODE

STEER

SWITCH

910

GND8

IGN SGN 1

SHFT/STR PWR

STRT INTLK

IGN SGN 1

SWITCH

STR AW

S23

SPEED

CONT AUX HYD

UNUSED SWITCH

SWITCH

SELECT

'S' S13

SWITCH (LEFT) (OPT)

(RIGHT)

S12 'T'

REV

GND8

1ST GEAR

SHFT/STR PWR

X20

ITT AJ3

JOYSTICK

FWD

BCD

FNR

SHFT/STR PWR

PWR

SHIFTER

1939 CAN

CAN L

CAN H

VCC

120

GND

PWR

680

1300

Y AXIS-LIFT UP/DN

X AXIS-TILT UP/DN

KNURL-TELE IN/OUT

BUTTON 1-UNUSED

BUTTON 2-UNUSED

BUTTON 3-UNUSED

BUTTON 4-AUX HYD ENABLE

ITT (STD) JOYSTICK

FUNCTIONS

LMI/JOY PWR GND1 CANH CANL

KEY & PLUG

GND27 PLUG PLUG

GND24

PCBGND

GND23

GND22

X01

GND21

GND20

CAB HARNESS

GND19

TO POWER DIST. MODULE

GND18

GND17

AMP MATE-N-LOK PLUG W/ PINS

GND16

ALL 1.0² MM WIRES IN THIS CONNECTOR

GND15

GND14

15 21 4365 87109 131211 14

KEY & PLUG

1413

GND13

GND12

GND11

GND10 GND9 GND8

X02

GND7 PLUG

CAB HARNESS

GND5

TO POWER DIST. MODULE

GND4 GND3

AMP MATE-N-LOK PLUG W/ PINS

GND2 GND1

PLUG PLUG PLUG PLUG PLUG

NEUT

PLUG PLUG

F WIPE

PLUG

PCB IGN

PLUG

STRT INTLK

SHFT/STR PWR KEY STRT KEY IGN 1

KEY & PLUG

KEY BAT 1

FLASHER IN

IGN SGN 1

FLASHER OUT

HI BEAM SGN

LO BEAM SGN IGN SGN 2 FLSH PWR

KEY & PLUG

LMI/JOY PWR

FUEL SOL HTR CNTRL

PINS 1,3,6-10,11-15=1.0² MM. PINS 2,4-5=2.5² MM.ALL 1.0² MM WIRES IN THIS CONNECTOR

ALL 1.0² MM WIRES IN THIS CONNECTOR

2143 6587 11109121514 1 3254 7698 10 11 1312 621514 1 435 10879 1211 1 3

X00

CAB HARNESS

TO POWER DIST. MODULE

AMP MATE-N-LOK PLUG W/ PINS

X03

CAB HARNESS

TO POWER DIST. MODULE

AMP MATE-N-LOK PLUG W/ PINS

RESD SW

BCN/AUX PWR BOOM LT PWR RR WKLT PWR

FRT WKLT PWR PARK LT SW BRK LT PWR

PLUG

LT BAT 1

PLUG

RT PARK LT LT PARK LT

KEY & PLUG

AIR SEAT PWR

HORN PWR

AC TEMP OUT

H FAN PWR F WIPE PK F WIPE H AC PSI SW

RIGHT HI BEAM RADIO BAT RADIO IGN STRT RLY

LEFT LO BEAM

LEFT HI BEAM

REV OUT

REV

KEY & PLUG

REAR AUX HYD

FUEL GA GND23 TILT DN TILT UP

LIFT DN

LIFT UP GND18 GND17 GND16

AUX1 AUX2 PLUG

RT PARK LT

LT PARK LT LT TURN RT TURN

TELE OUT

TELE IN PLUG PLUG

BRK LTS REV OUT

ENG H2O LT PREHEAT LT

HTR CNTRL

AC PSI SW

FWD

REV OUT

FUEL SOL

STRT RLY GND15 GND14

ENG H2O GA

ENG OIL LT PLUG PLUG PLUG PLUG PLUG PLUG

ALT D+ ALT W

F WASH

PLUG

HYD LT

RIGHT HI BEAM

GND22

STR CRB

STR AW

PLUG

GND13 GND12 GND11

LEFT HI BEAM

PLUG PLUG

RT PARK LT

LT PARK LT

1ST GEAR

HORN

LT TURN RT TURN

IGN SGN 1 PLUG PLUG PLUG

PLUG PLUG PLUG

R AXLE CNT

IGN SGN 1 PLUG

AUX HYD 1/2

PTO

NOTE: S12 AND S13 WIRING AND CONNECTORS ARE PROVIDED WITH ITT JOYSTICK

RIGHT LO BEAM

LEFT LO BEAM

1241213 14 15 213 8657 10911 1413 15

X04

CAB HARNESS

PIN 7 & 10=2.5² MM.

TO POWER DIST. MODULE

PINS 1-6, 9, 11-15=1.0² MM.

AMP MATE-N-LOK PLUG W/ PINS

CAB HARNESS

TO POWER DIST. MODULE

AMP MATE-N-LOK PLUG W/ PINS

PINS 1-11,15=1.0² MM. PINS 12-14=2.5² MM.

X06 X05

CAB HARNESS

DEUTSCH HD34-24-31PE

TO REAR CHASSIS HARNESS

ALL 1.0² MM WIRES IN THIS CONNECTOR

WUTVX12 1911345678910 151312 14 1716 18 232120 22 1234567891011

Q PR

X07

KBSTUVWX A FDCE HGJ SOMLN

CAB HARNESS

TO ENGINE HARNESS

DEUTSCH HD34-24-23PE

ALL 1.0² MM WIRES IN THIS CONNECTOR

R Q

X08

CAB HARNESS

DEUTSCH HD34-24-23SE

TO FRONT CHASSIS HARNESS

ALL 1.0² MM WIRES IN THIS CONNECTOR

A BC ED FGHJKLMNOP

X06

DEUTSCH

HARNESS

CAB HARNESS

HD34-24-31PE

THIS CONNECTOR

TO REAR CHASSIS

ALL 1.0² MM WIRES IN

2425 26 27 28 2930 31

537

NEUT

S19

MAH1170

9.8

G5-19A, G6-23A

9.4.3 Power Distribution Module Schematic

Electrical System

X01

TO CAB HARNESS

X02

TO CAB HARNESS

POWER DISTRIBUTION MODULE POWER DISTRIBUTION MODULE

X00

TO CAB HARNESS

POWER DISTRIBUTION MODULE

X03

TO CAB HARNESS

POWER DISTRIBUTION MODULE

X04

TO CAB HARNESS

POWER DISTRIBUTION MODULE

1511 1312 14 84213 657 1210911 1413 15 1 325476981110 1312 1514 10216435 879 141211 13 15 10216435 879 11141211 13 15 1 2 3 4 5 6 7 8 9 10 151312 14

X05

TO CAB HARNESS

POWER DISTRIBUTION MODULE

24311098756

GND9 GND8 GND7 GND6 GND5 GND4 GND3 GND2 GND1

NEUT

REV

KEY PLUG GND27 GND26 GND25 GND24 PCBGND GND23 GND22 GND21 GND20 GND19 GND18 GND17 GND16 GND15

GND14

KEY PLUG GND13 GND12 GND11 GND10

EMPTY EMPTY EMPTY EMPTY EMPTY

KEY STRT

KEY PLUG

RESD IGN

RESD BAT

FLSH PWR

PCB IGN

KEY PLUG

PCB BAT

FUEL SOL

EMPTY

RESD SW

LT BAT 2

LT BAT 1

TRAILER

KEY PLUG

F WIPE H

STRT RLY

REV OUT

KEY PLUG

STRT INTLK

SHFT/STR PWR

KEY IGN 1

KEY BAT 1

FLASHER IN

IGN SGN 1

FLASHER OUT

F WIPE HS

HI BEAM SGN LO BEAM SGN

IGN SGN 2

R WIPE IGN

LMI/JOY PWR

HTR CNTRL

BCN/AUX PWR BOOM LT PWR RR WKLT PWR

FRT WKLT PWR PARK LT SW BRK LT PWR

RT PARK LT LT PARK LT

AIR SEAT PWR AUX OUT PWR

AC TEMP OUT

H FAN PWR F WIPE PK

AC PSI SW

RIGHT LO BEAM

RIGHT HI BEAM RADIO BAT RADIO IGN

LEFT LO BEAM LEFT HI BEAM

RADIO

RADIO BAT

HEATER FAN

IGNITION 1

FRONT WIPER

7.5

F5F3F4

10520

AUX PWR SOCKET

F8F6F7

AIR SUSPENSION SEAT

F10

RT HEADLIGHT LOW

LT HEADLIGHT LOW

RT HEADLIGHT HIGH

LT HEADLIGHT HIGH

7.5

1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm

1mm

1mm 1mm 1mm

2.5mm 1mm 1mm 1mm 1mm

2.5mm

2.5mm 1mm

1mm 1mm 1mm 1mm 1mm

1mm 1mm 1mm 1mm

1mm 1mm 1mm 1mm 1mm 1mm 1mm

2.5mm 1mm

1mm 1mm 1mm 1mm 1mm

1mm 1mm 1mm 1mm 1mm 1mm 1mm

2.5mm

2.5mm 1mm 1mm 1mm

1mm 1mm

1mm

2.5mm

2.5mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm 1mm

LEFT PARK/SIDE LIGHTS

F11

F12

7.5

FRONT WORKLIGHTS

RIGHT PARK/SIDE LIGHTS

F14

F13

151515

7.5

BOOM LIGHTS

REAR WORKLIGHTS

F15

BEACON/AUX1.2.

RESERVED SWITCH

F17

F16

1515151010

PCB BAT

IGNITION 2

RESERVED IGN

RESERVED BAT

F21

F19

F20

F18

F22

PCB IGN

LMI/JOYSTICK

F23

F24

REAR WIPER

F25

KEY BAT

FLASHER PWR

F27

F26

151515

BRAKE LIGHTS

A/C COMPRESSOR

F29

F28

7.5

SHIFT/STEER

ENG HEATER CONTROL

FUEL SOL/COLD START

DRIVING LIGHTS BAT 2

DRIVING LIGHTS BAT 1

F34

F33

F32

F30

F31

7.5

BATTERY NEGATIVE (-)

1mm 1mm

1mm

4mm

1mm

2.5mm

DESIGN LOAD: 80 AMPS CONTINUOUS

BATTERY POSITIVE (+)

G5-19A, G6-23A

4mm

BATTERY

POSITIVE

BATTERY

NEGATIVE

308685

308786

4mm

4mm-RED

87a

IGN

PWR 4

RELAY

TRAVEL

REVERSE

4mm

6A/400V

858687

87a

FRONT

RELAY

WIPER

INTLK

RELAY

START

4mm

858687

308686

878585

308686

878585

308686

87a

49a

IGN

RELAY

PWR 1

RELAY

FLASHER

PWR 2

87a

IGN

WORK

RELAY

PWR 3

BOOM

RELAY

LIGHTS

K10

87a

FAN

REAR

RELAY

WIPER

RELAY

HEATER

K12

K11

MAH0070

9.9

Electrical System

9.4.4 Front & Rear Chassis, Battery, Boom Harness Schematic

L E

L L A

N R O H

K L B

m m 5 2

I B

T H

T LO

R O

I B

M M ² 0

. 1 L L A

R O

6 0

I T

² 0

. 1 L L A

D Y H

A N O

I T P O

² 0

. 1 = 1 3

6 1 , 4 1

1 S N

I P

LT P

T G

LT T

T T

2 1

1 1

0 1

LTS

T T

LT T

1/2

LTS

1 3

0 3

L B

9 2

8 2

7 2

L B

6 2

1/2

5 2

4 2

3 2

L G

2 2

1 2

TILT D

0 2

ILT

9 1

LIF

T D

8 1

LIF

7 1

6 1

5 1

4 1

3 1

2 1

1 1

T PA

0 1

LT PA

LT TU

T TU

I C

LL2

I C

LL1

LTS

D O H

T L

N R U T

T R

T G

1/2

ILT

LIF

T D

LIFT U

E E

W T

P S

)

(

)

(

R A E

)

(

S R F

)

(

U A

T L

I T

T L

I T

E L

E T

I L

E K

)

(

A R

V L A

V L

O R T N O C

R A B 2 1

1 T L

K R

S B

N L

R T

L B

E V L

2 1

)

( L

I A R T

9.10

B U A

U F

E S

N E

I L

P O T S

T H G

I V

I R

B E R T H

I G

S T H G

N L

I V

I R

K D

A E R T

I E

A L

L G

T PA

LTS

T TU

T PA

LT T

LT P

Y T P M E

) N

R G

(

X U A D N 2

)

(

)

(

O T

K L B

m m 0 5

T C E

)

( S

H D

I R

T T A

E R

K L

m 0

m 0 5

16 G

IG R

D N U O R G S

I S S A H C

(-)

(+)

C E R

MAH0081

G5-19A, G6-23A

JLG G6-23A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 INTRODUCTION

1.2 DISCLAIMER

1.3 OPERATION & SAFETY MANUAL

1.4 DO NOT OPERATE TAGS

1.5 SAFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.6 SAFETY INSTRUCTIONS

1.6.1 Personal Hazards

1.6.2 Equipment Hazards

1.6.3 General Hazards

1.6.4 Operational Hazards

1.7 SAFETY DECALS

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

2.2 TORQUES

2.2.1 ASTM Fastener Torque Chart (English)

2.2.2 ASTM Fastener Torque Chart (Metric)

2.2.3 Metric Fastener Torque Chart

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

2.3.2 Hydraulic Cylinder Performance Specifications

2.3.3 Electrical System

2.3.4 Engine Performance Specifications

2.3.5 Tires

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

2.5 MAINTENANCE SCHEDULES

2.5.1 8 & 1st 50 Hour Maintenance Schedule

2.5.2 50, 250 & 500 Hour Maintenance Schedule

2.5.3 1000 & 1500 Hour Maintenance Schedule

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule

2.6.2 50 Hour Lubrication Schedule

3.1 BOOM SYSTEM COMPONENT TERMINOLOGY

3.2 BOOM SYSTEM - TWO SECTION BOOM

3.2.1 Boom System Description

3.3 BOOM ASSEMBLY MAINTENANCE

3.3.1 Boom Removal

3.3.2 Second Section Boom Removal

3.3.3 Second Section Boom Installation

3.3.4 Boom Installation

3.4 BOOM WEAR PADS

3.4.1 Wear Pad Inspection

3.4.2 Boom Wear Pad Replacement

3.4.3 Boom Wear Pad Lubrication

3.5 QUICK SWITCH ASSEMBLY

3.5.1 Connecting with a Mechanical Quick Switch Device

3.5.2 Connecting with a Hydraulic Quick Switch Device

3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment

3.5.4 Quick Switch Removal

3.5.5 Quick Switch Installation

3.6 TROUBLESHOOTING

4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY

4.2 OPERATOR’S CAB

4.2.1 Operator’s Cab Description

4.3 CAB COMPONENTS

4.3.1 Steering Wheel

4.2.2 Serial Number Decal

4.3.2 Steering Column/Valve Replacement

4.3.3 Brake Pedal and Valve

4.3.4 Inching Valve

4.3.5 Throttle Pedal Replacement

4.3.6 Joystick Assembly Replacement

4.3.7 Windshield Wiper Assembly

4.3.8 Windshield Washer Assembly

4.3.9 Heater/Defroster System

4.4 CAB REMOVAL

4.5 CAB INSTALLATION

5.2 GENERAL INFORMATION

5.3 AXLE ASSEMBLIES

5.3.1 Axle Serial Number Plate

5.3.2 Axle Specifications

5.3.3 Axle Internal Service

5.3.4 Axle Maintenance

5.3.5 Axle Removal

5.3.6 Axle Installation

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

5.4 DRIVE SHAFTS