Jlg G6-23A Service Manual Manuel d'utilisateur Page 1

Service ManualModelsG5-19A&G6-23AP/N - 31200193RevisedNovember 17, 2006

Safety Practices1.4 G5-19A, G6-23A1.6.3 General HazardsSOLVENTS: Only use approved solvents that are known to be safe for use.HOUSEKEEPING: Keep the w

Electrical System9.10 G5-19A, G6-23A9.4.4 Front & Rear Chassis, Battery, Boom Harness SchematicMAH0081REAR AXLECENTERPROXHORNREVERSEALARMVALVESTEE

9.11G5-19A, G6-23AElectrical System9.4.5 Engine Harness SchematicMAH0090RELAYSTARTERPUMPFRONTW/WASHERENGINE OILSWITCHPRESSUREPOSITIVE CABLETO BATTERY

Electrical System9.12 G5-19A, G6-23A9.4.6 Dashboard SchematicMAH1240FUELFLASHERENG H2OHYD FILTERBRAKEENG OILCRAB STEERALL WHEEL STEER2 WHEEL STEERPREH

9.13G5-19A, G6-23AElectrical System9.5 CIRCUIT BREAKDOWNS9.5.1 Charge Circuit BreakdownKBAFDECHJGSOMNLQRPWUVTXMAH1180POSITIVE CABLETO BATTERY +NEGATIV

Electrical System9.14 G5-19A, G6-23A9.5.2 Start Circuit BreakdownCAB HARNESSALL 1.0 MM WIRES IN THIS CONNECTORPOWER DISTRIBUTION MODULEENGINE HARNESSM

9.15G5-19A, G6-23AElectrical System9.5.3 Drive Circuit BreakdownREAR CHASSIS HARNESSENGINE HARNESSCAB HARNESSPOWER DISTRIBUTION MODULEMAH1210SHIFTERFN

Electrical System9.16 G5-19A, G6-23A9.5.4 Constant Power Circuit BreakdownMAH1200DBCAEFGHBATTERY POSITIVE (+)13254769810111312 1514 13254769810111312

9.17G5-19A, G6-23AElectrical System9.6 ENGINE START CIRCUIT9.6.1 StarterThe starter (1) is located on the left side of the engine (the left side of th

Electrical System9.18 G5-19A, G6-23Af. Starter Installation1. Position the starter in its mounting opening on the flywheel housing. Position the groun

9.19G5-19A, G6-23AElectrical System2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounti

2.1G5-19A, G6-23ASection 2General Information and SpecificationsContentsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Information . . . . . .

Electrical System9.20 G5-19A, G6-23A9.9 WINDOW WIPER/WASHER 9.9.1 Windshield Wiper Motora. RemovalNote: It may be necessary to remove several hydraul

9.21G5-19A, G6-23AElectrical Systemb. DisassemblyDO NOT disassemble the pump. The pump is not serviceable. Replace pump if found to be defective.c. In

Electrical System9.22 G5-19A, G6-23A9.11 SWITCHES, SOLENOIDS AND SENDERS9.11.1 Ignition Key Switcha. Ignition Switch Removal1. Open the engine cover.

9.23G5-19A, G6-23AElectrical Systemstart the engine. Observe the fuel level indicator needle on the operator’s instrument cluster. 3. Turn the ignitio

Electrical System9.24 G5-19A, G6-23Ain a shorted wire, improper-running engine, improper or low coolant, obstructed or faulty radiator, coolant pump,

9.25G5-19A, G6-23AElectrical System9.11.8 Main Control Valve Solenoidsa. Main Control Valve Solenoid Removal1. Open the engine cover. Allow the engine

Electrical System9.26 G5-19A, G6-23A9.13.2 Fault CodesThe following Fault codes can be viewed with either the JLG Analyzer or by translating the flash

9.27G5-19A, G6-23AElectrical SystemAUX HYD 1 OPEN FAULT 4-8 Open on pin J1-8 None. Fault shall be latched and only reset upon power down of the contro

Electrical System9.28 G5-19A, G6-23A9.13.3 Analyzer Diagnostic Help MessagesThe table below lists Diagnostic Help Messages that the Control System com

9.29G5-19A, G6-23AElectrical SystemJOYSTICK: X POSITION ±XXX% Displays position in percentage for this axisX NEUTRL IN NEUTRAL,NOT NEUTRAL,ERRORIndica

General Information and Specifications2.2 G5-19A, G6-23A2.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiating service inqu

Electrical System9.30 G5-19A, G6-23ADATALOG: ON XXXXhXXm Displays total controller on (power) timeLIFT XXXXhXXm Displays total controller lift operati

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

2.3G5-19A, G6-23AGeneral Information and Specifications2.2 TORQUES2.2.1 ASTM Fastener Torque Chart (English)VALUES FOR ZINC PLATED / YELLOW CHROMATE F

General Information and Specifications2.4 G5-19A, G6-23A2.2.2 ASTM Fastener Torque Chart (Metric) VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTEN

2.5G5-19A, G6-23AGeneral Information and Specifications2.2.3 Metric Fastener Torque ChartVALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLYCLASS

General Information and Specifications2.6 G5-19A, G6-23A2.3 SPECIFICATIONS2.3.1 Travel Speeds2.3.2 Hydraulic Cylinder Performance SpecificationsNote:

2.7G5-19A, G6-23AGeneral Information and Specifications2.3.4 Engine Performance Specifications2.3.5 TiresNote: Standard wheel lug nut torque is 221 l

General Information and Specifications2.8 G5-19A, G6-23A2.4 FLUIDS, LUBRICANTS AND CAPACITIESEngine Crankcase OilCapacity w/Filter Change 9.6 quarts (

2.9G5-19A, G6-23AGeneral Information and Specifications2.5 MAINTENANCE SCHEDULES2.5.1 8 & 1st 50 Hour Maintenance ScheduleNote: In order to gain

General Information and Specifications2.10 G5-19A, G6-23A2.6 LUBRICATION SCHEDULES2.6.1 8 Hour Lubrication ScheduleMAH08208EVERYMYSTIK TETRIMOLY(NLGI

2.11G5-19A, G6-23AGeneral Information and Specifications2.6.2 50 Hour Lubrication ScheduleMAH083050EVERYMYSTIK TETRIMOLY(NLGI 2 GC-LB)

General Information and Specifications2.12 G5-19A, G6-23AThis Page Intentionally Left Blank

3.1G5-19A, G6-23ASection 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.2 G5-19A, G6-23A3.1 BOOM SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this section,

3.3G5-19A, G6-23ABoom3.2 BOOM SYSTEM - TWO SECTION BOOM 3.2.1 Boom System DescriptionThe boom operates via an interchange among the electrical, hydrau

Boom3.4 G5-19A, G6-23A3.3.1 Boom Removal1. Remove any attachment from the quick switch assembly. 2. Be sure there is enough room in front of the machi

3.5G5-19A, G6-23ABoom6. 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 th

Boom3.6 G5-19A, G6-23AInstall 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, i

3.7G5-19A, G6-23ABoomUse 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

EFFECTIVITY PAGE31200193 G5-19A, G6-23A aMarch 24, 2006 - A - Original Issue Of ManualNovember 17, 2006 - B - Added Controller procedure in Section 9.

Boom3.8 G5-19A, G6-23A3.5.2 Connecting with a Hydraulic Quick Switch Device1. Retract quick switch device to provide clearance. Check to be sure lock

3.9G5-19A, G6-23ABoom3.6 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during operation of

Boom3.10 G5-19A, G6-23A6. Rapid boom pad wear. 1. Incorrect wear pad gap.2. Rapid cycle times with heavy loads.3. Contaminated, corroded or rusted wea

4.1G5-19A, G6-23ASection 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . .

Cab and Covers4.2 G5-19A, G6-23A4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information pre

4.3G5-19A, G6-23ACab and Covers4.2 OPERATOR’S CAB4.2.1 Operator’s Cab DescriptionThe welded metal cab features a modular design, allowing for a relati

Cab and Covers4.4 G5-19A, G6-23A4.3.2 Steering Column/Valve Replacementa. Steering Column and Valve Removal1. Park the machine on a firm, level surfac

4.5G5-19A, G6-23ACab and Covers2. Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should

Cab and Covers4.6 G5-19A, G6-23ANote: The dimensional values given for inching valve adjustment are to be used as a starting point. More thorough adj

4.7G5-19A, G6-23ACab and Covers4.3.6 Joystick Assembly Replacementa. Joystick Assembly Removal1. Park the machine on a firm, level surface, fully retr

EFFECTIVITY PAGEG5-19A, G6-23A-b

Cab and Covers4.8 G5-19A, G6-23A10. Remove the button-head capscrews, nuts and lockwashers securing the heater assembly to the cab.11. Carefully pull

4.9G5-19A, G6-23ACab and CoversNote: Label all hoses to ensure correct installation.8. Loosen the hose clamps, and disconnect the heater hoses from t

Cab and Covers4.10 G5-19A, G6-23A4.5 CAB INSTALLATION1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient

5.1G5-19A, G6-23ASection 5Axles, Drive Shafts, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Component Terminology. . .

Axles, Drive Shafts, Wheels and Tires5.2 G5-19A, G6-23A5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the safety, operation and ma

5.3G5-19A, G6-23AAxles, Drive Shafts, Wheels and Tires5.2 GENERAL INFORMATIONBefore performing any inspection, maintenance or service operation, thoro

Axles, Drive Shafts, Wheels and Tires5.4 G5-19A, G6-23Awater, especially if the water level was above the vent tube (breather), drain the axle and ins

5.5G5-19A, G6-23AAxles, Drive Shafts, Wheels and Tiresprevent it from tipping, turning or falling while removing it from beneath the machine. Place th

Axles, Drive Shafts, Wheels and Tires5.6 G5-19A, G6-23A5.3.7 Axle Assembly and Drive Shaft TroubleshootingProblem Cause Remedy1. Excessive axle noise

5.7G5-19A, G6-23AAxles, Drive Shafts, Wheels and Tires4. Oil leaking from axle (differential housing and/or axle housings).1. Drain plugs loose and/or

SECTION CONTENTSSection Subject PageG5-19A, G6-23AiSection 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axles, Drive Shafts, Wheels and Tires5.8 G5-19A, G6-23A7. Axle overheating. 1. Oil level too high.2. Axle and/or wheel end housings filled with incorr

5.9G5-19A, G6-23AAxles, Drive Shafts, Wheels and Tires5.4 DRIVE SHAFTS5.4.1 Drive Shaft InspectionWhenever servicing the machine, conduct a visual ins

Axles, Drive Shafts, Wheels and Tires5.10 G5-19A, G6-23A5.5 WHEELS AND TIRESJLG recommends a replacement tire to be the same size, ply and brand as or

5.11G5-19A, G6-23AAxles, Drive Shafts, Wheels and Tires5.5.2 Installing Wheel and Tire Assembly onto MachineIMPORTANT: The wheel and tire assemblies

Axles, Drive Shafts, Wheels and Tires5.12 G5-19A, G6-23AThis Page Intentionally Left Blank

6.1G5-19A, G6-23ASection 6Transmission: ContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . .

Transmission:6.2 G5-19A, G6-23A6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presente

6.3G5-19A, G6-23ATransmission:6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance

Transmission:6.4 G5-19A, G6-23Achain, but DO NOT raise the transmission at this time.13. Remove the two Allen head bolts that attach the transmission

6.5G5-19A, G6-23ATransmission:6.5 TOWING A DISABLED MACHINETowing a disabled machine should only be attempted as a last resort, after exhausting all o

Section Subject PageiiG5-19A, G6-23ASection 6Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission:6.6 G5-19A, G6-23AThis Page Intentionally Left Blank

7.1G5-19A, G6-23ASection 7Engine: Deutz BF 4M 2012ContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine: Deutz BF 4M 20127.2 G5-19A, G6-23A7.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written for worldwide use. In territorie

7.3G5-19A, G6-23AEngine: Deutz BF 4M 2012MAH0230Coolant Overflow Ta nk StarterAir Cleaner AssemblyRadiator/Oil CoolerAlternatorFan ShroudPrimary FuelF

Engine: Deutz BF 4M 20127.4 G5-19A, G6-23A7.2 ENGINE SERIAL NUMBERThe Deutz BF 4M 2012 serial number is located on a tag on top of the engine. Info

7.5G5-19A, G6-23AEngine: Deutz BF 4M 2012container. Dispose of properly if coolant needs to be replaced. Close the radiator petcock.10. Label, disconn

Engine: Deutz BF 4M 20127.6 G5-19A, G6-23Abest economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may b

7.7G5-19A, G6-23AEngine: Deutz BF 4M 20127.8 ENGINE REPLACEMENT 7.8.1 Engine Removal1. Park the machine on a firm, level surface, fully retract the

Engine: Deutz BF 4M 20127.8 G5-19A, G6-23A7.8.2 Engine Disassembly, Inspection and ServiceEngine disassembly, internal inspection, service, repair and

7.9G5-19A, G6-23AEngine: Deutz BF 4M 2012If the rpm is not 2370 ±50 rpm, readjust the throttle limit-stop screw at the throttle pedal within the cab.2

1.1G5-19A, G6-23ASection 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine: Deutz BF 4M 20127.10 G5-19A, G6-23A7.10 TROUBLESHOOTINGTrouble Possible Causes (see key, below)Low Cranking PowerWill Not StartDifficult St

8.1G5-19A, G6-23ASection 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System8.2 G5-19A, G6-23A8.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information presented in this sec

8.3G5-19A, G6-23AHydraulic System8.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid i

Hydraulic System8.4 G5-19A, G6-23AALWAYS replace a used o-ring with a new part.Check all routing of hoses, wiring and tubing for sharp bends or interf

8.5G5-19A, G6-23AHydraulic System8.5.2 Main Control Valve Pressure CheckingAttach 5000 psi (345 bar) gauge to the test port (1) on the main control va

Hydraulic System8.6 G5-19A, G6-23A8.6 HYDRAULIC SCHEMATICMAH1150ITEM DESCRIPTIONAPUMP, DRIVEB1MOTOR, DRIVE - G5-19AB2MOTOR, DRIVE - G6-23AB3 MOT

8.7G5-19A, G6-23AHydraulic SystemMAH1160LEVAGELIFTINCLINGISONTILTCROWDTELESCOPAGEOUTILLAGEAUXABDFCOMPENSATIONGUL250T2BP1P2BABAB280280AB280280ABT1T3BPS

Hydraulic System8.8 G5-19A, G6-23A8.7 HYDRAULIC RESERVOIRThe hydraulic reservoir and fuel tank are part of the frame. For this reason, neither tank ca

8.9G5-19A, G6-23AHydraulic System6. Thoroughly clean the pump (1) and surrounding area, including all hoses and fittings before proceeding.7. Label, d

Safety Practices1.2 G5-19A, G6-23A1.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair procedures. Fol

Hydraulic System8.10 G5-19A, G6-23A6. Carefully fit the mounting plate in its original position. The drain hole in the rear face must be to the low pr

8.11G5-19A, G6-23AHydraulic System8.10 VALVES AND MANIFOLDS8.10.1 Main Control ValveThe main control valve is mounted on the rear of the machine behin

Hydraulic System8.12 G5-19A, G6-23Ad. Main Control Valve Parts InspectionInspect all parts and internal passageways for wear, damage, etc. If inner su

8.13G5-19A, G6-23AHydraulic System6. Remove the bolts that mount the service brake valve to the steering column supportNote: DO NOT disassemble the s

Hydraulic System8.14 G5-19A, G6-23A2. Use new oiled o-rings as required. Uncap, reattach and secure the three hoses.3. Check the routing of all hoses

8.15G5-19A, G6-23AHydraulic System6. Remove the steer select manifold with attached steer select valve from the machine. Wipe up any hydraulic fluid s

Hydraulic System8.16 G5-19A, G6-23A8.11 HYDRAULIC CYLINDERS8.11.1 General Cylinder Removal Instructions1. Park the machine on a firm, level surface, f

8.17G5-19A, G6-23AHydraulic SystemNote: It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the

Hydraulic System8.18 G5-19A, G6-23A8.11.6 General Cylinder Installation1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropri

8.19G5-19A, G6-23AHydraulic System8.11.8 Hydraulic Cylinder Torque SpecificationsDescription G5-19A G6-23AAll Cylinder Set Screws 15-18 lb-ft (20-25 N

1.3G5-19A, G6-23ASafety Practices1.5 SAFETY INFORMATIONTo avoid possible death or injury, carefully read, understand and comply with all safety messag

Hydraulic System8.20 G5-19A, G6-23AThis Page Intentionally Left Blank

9.1G5-19A, G6-23ASection 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . .

Electrical System9.2 G5-19A, G6-23A9.12 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3G5-19A, G6-23AElectrical System9.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information presented in this s

Electrical System9.4 G5-19A, G6-23A9.2 SPECIFICATIONSElectrical system specifications are listed in Section 2, “General Information and Specifications

9.5G5-19A, G6-23AElectrical System9.3.2 Power Distribution ModuleMAH0490F1F2F3F4F5F6F7F8F9F10F11F12F13F14F22F23F24F25F26F27F28F15F16F17F18F19F20F21F29

Electrical System9.6 G5-19A, G6-23AF13 Right Park/Side Lights 7.5F14 Front Worklights 15F15 Rear Worklights 15F16 Boom Lights 15F17 Beacon/Aux 15F18 R

9.7G5-19A, G6-23AElectrical System9.4 ELECTRICAL SYSTEM SCHEMATICS9.4.1 Cab Roof SchematicNote: For more detailed schematics, contact your local JLG

Electrical System9.8 G5-19A, G6-23A9.4.2 Cab Harness Schematic8042 18991 & After)MAH1170HA BC ED FGH JKLMNOPQR54M2431M1234CBLHMB32A1EDCGFKBSTUVWX

9.9G5-19A, G6-23AElectrical System9.4.3 Power Distribution Module SchematicMAH007024311098756878586873087a8586873087a87a8586873087a3086854949a31C28587