JLG G5-19A, G6-23A Telehandlers Service Manual (ANSI) - 31200193

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This service manual PDF download for the G5-19A, G6-23A JLG Telescopic Reach Forklift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG G5-19A
JLG G6-23A


TABLE OF CONTENTS :

    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
        1.6 Safety Instructions
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torques
        2.3 Specifications
        2.4 Fluids, Lubricants and Capacities
        2.5 Maintenance Schedules
        2.6 Lubrication Schedules
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System - Two Section Boom
        3.3 Boom Assembly Maintenance
        3.4 Boom Wear Pads
        3.5 Quick Switch Assembly
        3.6 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
        4.3 Cab Components
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
        5.4 Drive Shafts
        5.5 Wheels and Tires
        5.6 Steering Adjustment
        5.7 Brakes
            
    Section 6 Transmission:
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Description
        6.3 Transmission Specifications
        6.4 Transmission Replacement
        6.5 Towing a Disabled Machine
        
    Section 7 Engine: Deutz BF 4M 2012
        7.1 Introduction
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Engine Cooling System
        7.5 Engine Electrical System
        7.6 Fuel System
        7.7 Engine Exhaust and Air Cleaner System
        7.8 Engine Replacement
        7.9 Engine Coupler
        7.10 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Specifications
        8.4 Hoses, Tube Lines, Fittings, Etc.
        8.5 Hydraulic Pressure Diagnosis
        8.6 Hydraulic Schematic
        8.7 Hydraulic Reservoir
        8.8 Hydraulic System Pump
        8.9 Front Drive Pump
        8.10 Valves and Manifolds
        8.11 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Fuses and Relays
        9.4 Electrical System Schematics
        9.5 Circuit Breakdowns
        9.6 Engine Start Circuit
        9.7 Charging Circuit
        9.8 Electrical System Components
        9.9 Window Wiper/Washer
        9.10 Cab Heater and Fan
        9.11 Switches, Solenoids and Senders
        9.12 Controller
        9.13 Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200193
Total Pages : 122


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31200193_B_G5-19A G6-23A_Service
    Effectivity
    Table of Contents
    
    Section 1 Safety Practices
        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
        
    Section 2 General Information and Specifications
        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
            
    Section 3 Boom
        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
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
            4.2.1 Operator’s Cab Description
            4.2.2 Serial Number Decal
        4.3 Cab Components
            4.3.1 Steering Wheel
            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
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        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
            5.4.1 Drive Shaft Inspection
            5.4.2 Drive Shaft Maintenance
            5.4.3 Drive Shaft Removal
            5.4.4 Drive Shaft Cleaning and Drying
            5.4.5 Drive Shaft Installation
        5.5 Wheels and Tires
            5.5.1 Removing Wheel and Tire Assembly from Machine
            5.5.2 Installing Wheel and Tire Assembly onto Machine
        5.6 Steering Adjustment
            5.6.1 Steering Angle Adjustment
        5.7 Brakes
            5.7.1 Brake Disk Inspection.
            
    Section 6 Transmission:
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Description
        6.3 Transmission Specifications
            6.3.1 Transmission Maintenance
        6.4 Transmission Replacement
            6.4.1 Transmission Removal
            6.4.2 Transmission Disassembly
            6.4.3 Transmission Installation
            6.4.4 After Transmission Replacement
        6.5 Towing a Disabled Machine
        
    Section 7 Engine: Deutz BF 4M 2012
        7.1 Introduction
            7.1.1 Disclaimer and Scope
            7.1.2 Component Terminology
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Engine Cooling System
            7.4.1 Radiator Pressure Cap
            7.4.2 Radiator/Oil Cooler and Coolant Heater Replacement
        7.5 Engine Electrical System
        7.6 Fuel System
            7.6.1 Diesel Fuel
            7.6.2 Fuel/Hydraulic Oil Tank
            7.6.3 After Fuel System Service
        7.7 Engine Exhaust and Air Cleaner System
        7.8 Engine Replacement
            7.8.1 Engine Removal
            7.8.2 Engine Disassembly, Inspection and Service
            7.8.3 Engine Installation
        7.9 Engine Coupler
            7.9.1 Coupler Removal
            7.9.2 Coupler Installation
        7.10 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Specifications
        8.4 Hoses, Tube Lines, Fittings, Etc.
            8.4.1 Replacement Considerations
            8.4.2 Hose, Tube, Line and Fitting Replacement
        8.5 Hydraulic Pressure Diagnosis
            8.5.1 Pressure Checks and Adjustments
            8.5.2 Main Control Valve Pressure Checking
            8.5.3 Charge Pressure Checking
            8.5.4 Drive Pressure Checking
            8.5.5 Steering Pressure Checking
            8.5.6 Brake Pressure Checking
        8.6 Hydraulic Schematic
        8.7 Hydraulic Reservoir
            8.7.1 Hydraulic Oil Reservoir Draining
            8.7.2 Hydraulic Oil Reservoir Filling
        8.8 Hydraulic System Pump
            8.8.1 Implement Pump Failure Analysis
            8.8.2 Implement Pump Replacement
        8.9 Front Drive Pump
        8.10 Valves and Manifolds
            8.10.1 Main Control Valve
            8.10.2 Service Brake Valve
            8.10.3 Parking Brake
            8.10.4 Brake Test
            8.10.5 Steering Orbitrol Valve
            8.10.6 Steer Select Valve
        8.11 Hydraulic Cylinders
            8.11.1 General Cylinder Removal Instructions
            8.11.2 General Cylinder Disassembly
            8.11.3 Cylinder Cleaning Instructions
            8.11.4 Cylinder Inspection
            8.11.5 General Cylinder Assembly
            8.11.6 General Cylinder Installation
            8.11.7 Steering Cylinders
            8.11.8 Hydraulic Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Fuses and Relays
            9.3.1 Engine Compartment Relays and Fuses
            9.3.2 Power Distribution Module
        9.4 Electrical System Schematics
            9.4.1 Cab Roof Schematic
            9.4.2 Cab Harness Schematic
            9.4.3 Power Distribution Module Schematic
            9.4.4 Front & Rear Chassis, Battery, Boom Harness Schematic
            9.4.5 Engine Harness Schematic
            9.4.6 Dashboard Schematic
        9.5 Circuit Breakdowns
            9.5.1 Charge Circuit Breakdown
            9.5.2 Start Circuit Breakdown
            9.5.3 Drive Circuit Breakdown
            9.5.4 Constant Power Circuit Breakdown
        9.6 Engine Start Circuit
            9.6.1 Starter
        9.7 Charging Circuit
            9.7.1 Alternator
        9.8 Electrical System Components
            9.8.1 Back-up Alarm
            9.8.2 Instrument Cluster
        9.9 Window Wiper/Washer
            9.9.1 Windshield Wiper Motor
            9.9.2 Windshield Washer Reservoir and Pump
        9.10 Cab Heater and Fan
            9.10.1 Cab Heater Controls
        9.11 Switches, Solenoids and Senders
            9.11.1 Ignition Key Switch
            9.11.2 Dash Switches
            9.11.3 Fuel Level Indicator and Fuel Level Sender
            9.11.4 Hourmeter
            9.11.5 Coolant Temperature Sender
            9.11.6 Fuel Shut-off Solenoid
            9.11.7 Oil Pressure Sender
            9.11.8 Main Control Valve Solenoids
        9.12 Controller
            9.12.1 Joystick Functionality Setting
        9.13 Troubleshooting
            9.13.1 Analyzer Usage
            9.13.2 Fault Codes
            9.13.3 Analyzer Diagnostic Help Messages
            
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