31200194 G6-23A/G5-19A 3
TABLE OF CONTENTS
31200194 G6-23A/G5-19A 5
SECTION 1 - FRAME AND ATTACHING PARTS................................................................................................................................ 9
FIGURE 1-1. FRAME SHROUDING AND TRIM ............................................................................................................................ 10
FIGURE 1-2. FRAME SHROUDING AND TRIM, FENDER INSTALLATION ................................................................................. 14
FIGURE 1-3. AXLE INSTALLATION G5-19A ................................................................................................................................. 16
FIGURE 1-4. AXLE INSTALLATION G6-23A ................................................................................................................................. 18
SECTION 2 - BOOM .......................................................................................................................................................................... 21
FIGURE 2-1. FIRST BOOM SECTION G5-19A ............................................................................................................................. 22
FIGURE 2-2. FIRST BOOM SECTION G6-23A ............................................................................................................................. 24
FIGURE 2-3. SECOND BOOM SECTION G5-19A......................................................................................................................... 26
FIGURE 2-4. SECOND BOOM SECTION G6-23A......................................................................................................................... 28
FIGURE 2-5. QUICK SWITCH ASSEMBLY ................................................................................................................................... 30
FIGURE 2-6. HYDRAULIC QUICK SWITCH ASSEMBLY.............................................................................................................. 32
SECTION 3 - ATTACHMENTS .......................................................................................................................................................... 35
FIGURE 3-1. CARRIAGE ASSEMBLY ........................................................................................................................................... 36
FIGURE 3-2. CARRIAGE ASSEMBLY ........................................................................................................................................... 38
FIGURE 3-3. BUCKETS ................................................................................................................................................................. 40
FIGURE 3-4. FOUR IN ONE BUCKET ........................................................................................................................................... 42
FIGURE 3-5. FORK MOUNTED HOOK ......................................................................................................................................... 44
FIGURE 3-6. TRUSS BOOM .......................................................................................................................................................... 46
FIGURE 3-7. MANURE BUCKET ................................................................................................................................................... 48
FIGURE 3-8. FORK ........................................................................................................................................................................ 50
FIGURE 3-9. SIDE SHIFT CARRIAGE........................................................................................................................................... 52
FIGURE 3-10. SIDE TILT CARRIAGE............................................................................................................................................ 54
FIGURE 3-11. FORK POSITION/SIDE SHIFT CARRIAGE ............................................................................................................ 56
FIGURE 3-12. FORK MOUNTED PLATFORM............................................................................................................................... 60
FIGURE 3-13. UNIVERSAL HITCH ATTACHMENT ...................................................................................................................... 62
SECTION 4 - ENGINE AND ATTACHING PARTS ............................................................................................................................ 65
FIGURE 4-1. ENGINE ASSEMBLY ................................................................................................................................................ 66
FIGURE 4-2. DEUTZ ENGINE ....................................................................................................................................................... 70
FIGURE 4-3. FUEL TANK AND LINES .......................................................................................................................................... 74
FIGURE 4-4. RADIATOR ASSEMBLY ........................................................................................................................................... 76
FIGURE 4-5. AIR CLEANER INSTALLATION ................................................................................................................................ 78
FIGURE 4-6. EXHAUST INSTALLATION ....................................................................................................................................... 80
SECTION 5 - DRIVE TRAIN .............................................................................................................................................................. 83
FIGURE 5-1. FRONT AXLE ........................................................................................................................................................... 84
FIGURE 5-2. FRONT AXLE - HOUSING G5-19A .......................................................................................................................... 86
FIGURE 5-3. FRONT AXLE - HOUSING G6-23A .......................................................................................................................... 88
FIGURE 5-4. FRONT AXLE - HOUSING AND STEERING CYLINDER G5-19A ........................................................................... 90
FIGURE 5-5. FRONT AXLE - HOUSING AND STEERING CYLINDER G6-23A ........................................................................... 92
FIGURE 5-6. FRONT AXLE - BEVEL GEAR SET .......................................................................................................................... 94
FIGURE 5-7. FRONT AXLE - DIFFERENTIAL ............................................................................................................................... 96
FIGURE 5-8. FRONT AXLE - DOUBLE U-JOINT G5-19A ............................................................................................................. 98
FIGURE 5-9. FRONT AXLE - DOUBLE U-JOINT G6-23A ........................................................................................................... 100
FIGURE 5-10. FRONT AXLE - BRAKES G5-19A......................................................................................................................... 102
FIGURE 5-11. FRONT AXLE - BRAKES G6-23A......................................................................................................................... 104
FIGURE 5-12. FRONT AXLE - WHEEL HUB AND FINAL REDUCTION G5-19A ........................................................................ 106
FIGURE 5-13. FRONT AXLE - WHEEL HUB AND FINAL REDUCTION G6-23A ........................................................................ 108
FIGURE 5-14. FRONT AXLE - TRANSMISSION HOUSING ....................................................................................................... 110
FIGURE 5-15. FRONT AXLE - LOWER AND UPPER SHAFT G5-19A ....................................................................................... 112
FIGURE 5-16. FRONT AXLE - LOWER AND UPPER SHAFT G6-23A ....................................................................................... 114
FIGURE 5-17. REAR AXLE .......................................................................................................................................................... 116
FIGURE 5-18. REAR AXLE - HOUSING ...................................................................................................................................... 118
FIGURE 5-19. REAR AXLE - SWIVEL HOUSING AND STEERING CYLINDER G5-19A ........................................................... 120
FIGURE 5-20. REAR AXLE - SWIVEL HOUSING AND STEERING CYLINDER G6-23A ........................................................... 122
FIGURE 5-21. REAR AXLE - BEVEL GEAR SET ........................................................................................................................ 124
FIGURE 5-22. REAR AXLE - DIFFERENTIAL G5-19A ................................................................................................................ 126
TABLE OF CONTENTS
6 G6-23A/G5-19A 31200194
FIGURE 5-23. REAR AXLE - DIFFERENTIAL G6-23A................................................................................................................. 128
FIGURE 5-24. REAR AXLE - DOUBLE U-JOINT G5-19A ............................................................................................................ 130
FIGURE 5-25. REAR AXLE - DOUBLE U-JOINT G6-23A ............................................................................................................ 132
FIGURE 5-26. REAR AXLE - WHEEL HUB AND FINAL REDUCTION G5-19A ........................................................................... 134
FIGURE 5-27. REAR AXLE - WHEEL HUB AND FINAL REDUCTION G6-23A ........................................................................... 136
FIGURE 5-28. DRIVE SHAFT ....................................................................................................................................................... 138
FIGURE 5-29. TIRES AND RIMS ................................................................................................................................................. 140
SECTION 6 - CAB ............................................................................................................................................................................ 143
FIGURE 6-1. CAB ASSEMBLY ..................................................................................................................................................... 144
FIGURE 6-2. CAB INTERIOR ASSEMBLY ................................................................................................................................... 148
FIGURE 6-3. SEAT ASSEMBLY ................................................................................................................................................... 150
FIGURE 6-4. CAB WINDOWS ...................................................................................................................................................... 152
FIGURE 6-5. CAB DOOR ASSEMBLY ......................................................................................................................................... 154
FIGURE 6-6. WIPER ASSEMBLY G6-23A ................................................................................................................................... 156
FIGURE 6-7. AIR CIRCULATION INSTALLATION ....................................................................................................................... 158
FIGURE 6-8. TOOL BOX ASSEMBLY (OPTIONAL)..................................................................................................................... 162
FIGURE 6-9. FIRE EXTINGUISHER INSTALLATION (OPTIONAL) (G6-23A) ............................................................................. 164
SECTION 7 - CONTROLS ................................................................................................................................................................ 167
FIGURE 7-1. BOOM JOYSTICK ................................................................................................................................................... 168
FIGURE 7-2. STEERING COLUMN AND ATTACHING PARTS ................................................................................................... 170
FIGURE 7-3. ACCELERATOR PEDAL ASSEMBLY ..................................................................................................................... 172
FIGURE 7-4. BRAKE PEDAL ASSEMBLY ................................................................................................................................... 174
SECTION 8 - HYDRAULIC CIRCUITS ............................................................................................................................................. 177
FIGURE 8-1. SUPPLY CIRCUIT ................................................................................................................................................... 178
FIGURE 8-2. DUMP CIRCUIT ...................................................................................................................................................... 182
FIGURE 8-3. FRONT DRIVE CIRCUIT G5-19A............................................................................................................................ 186
FIGURE 8-4. FRONT DRIVE CIRCUIT G6-23A............................................................................................................................ 188
FIGURE 8-5. STEER SELECT ...................................................................................................................................................... 190
FIGURE 8-6. SERVICE/PARK BRAKE ......................................................................................................................................... 192
FIGURE 8-7. LIFT CYLINDER ...................................................................................................................................................... 194
FIGURE 8-8. EXTEND/RETRACT CYLINDER G5-19A ................................................................................................................ 196
FIGURE 8-9. EXTEND/RETRACT CYLINDER G6-23A ................................................................................................................ 198
FIGURE 8-10. TILT AND TILT COMPENSATING CYLINDER G5-19A ........................................................................................ 200
FIGURE 8-11. TILT AND TILT COMPENSATING CYLINDER G6-23A ........................................................................................ 202
FIGURE 8-12. AUXILIARY FUNCTION ........................................................................................................................................ 204
FIGURE 8-13. REAR HYDRAULIC OUTLET ................................................................................................................................ 206
SECTION 9 - HYDRAULIC COMPONENTS .................................................................................................................................... 209
FIGURE 9-1. LIFT CYLINDER G5-19A ......................................................................................................................................... 210
FIGURE 9-2. LIFT CYLINDER G6-23A ......................................................................................................................................... 212
FIGURE 9-3. EXTEND/RETRACT CYLINDER G5-19A ................................................................................................................ 214
FIGURE 9-4. EXTEND/RETRACT CYLINDER G6-23A ................................................................................................................ 216
FIGURE 9-5. TILT CYLINDER G5-19A ......................................................................................................................................... 218
FIGURE 9-6. TILT CYLINDER G6-23A ......................................................................................................................................... 220
FIGURE 9-7. COMPENSATING CYLINDER G5-19A ................................................................................................................... 222
FIGURE 9-8. COMPENSATING CYLINDER G6-23A ................................................................................................................... 224
FIGURE 9-9. FORK LOCKING CYLINDER .................................................................................................................................. 226
FIGURE 9-10. FORK LOCKING CYLINDER ASSAMBLY ............................................................................................................ 228
FIGURE 9-11. MAIN CONTROL VALVE (G5-19A Prior to SN 1160003034; G6-23A Prior to SN 1160003516) .......................... 230
FIGURE 9-12. MAIN CONTROL VALVE (G5-19A SN 1160003034 to Present; G6-23A SN 1160003516 to Present) ................ 232
FIGURE 9-13. FRONT DRIVE MOTOR G5-19A ........................................................................................................................... 234
FIGURE 9-14. FRONT DRIVE MOTOR G6-23A ........................................................................................................................... 236
FIGURE 9-15. HYDROSTATIC TRANSMISSION PUMP ............................................................................................................. 238
FIGURE 9-16. HYDRAULIC TANK ASSEMBLY ........................................................................................................................... 240
FIGURE 9-17. IMPLEMENT PUMP .............................................................................................................................................. 242
FIGURE 9-18. AUXILIARY DIVERTER VALVE ............................................................................................................................ 244
SECTION 10 - ELECTRICAL............................................................................................................................................................ 247
TABLE OF CONTENTS
31200194 G6-23A/G5-19A 7
FIGURE 10-1. ELECTRICAL INSTALLATION ............................................................................................................................. 248
FIGURE 10-2. ENGINE HARNESS (G5-19A Prior to SN 1160002222; G6-23A Prior to SN 1160002234) ................................. 252
FIGURE 10-3. ENGINE HARNESS (G5-19A SN 1160002222 to Present; G6-23A SN 1160002234 to Present) ........................ 254
FIGURE 10-4. REAR CHASSIS HARNESS (G5-19A Prior to SN 1160001709; G6-23A Prior to SN 1160001708) .................... 256
FIGURE 10-5. REAR CHASSIS HARNESS (G5-19A SN 1160001709 to Present; G6-23A SN 1160001708 to Present) ........... 258
FIGURE 10-6. FRONT CHASSIS HARNESS ............................................................................................................................... 260
FIGURE 10-7. PWM VALVE CONTROLLER ASSEMBLY ........................................................................................................... 262
FIGURE 10-8. ROOF HARNESS ................................................................................................................................................. 264
FIGURE 10-9. MAIN HARNESS ................................................................................................................................................... 266
FIGURE 10-10. GROUND HARNESS .......................................................................................................................................... 270
FIGURE 10-11. BUCKET SHAKE SWITCH (OPTIONAL) ............................................................................................................ 272
FIGURE 10-12. OIL TEMPERATURE GAUGE INSTALLATION G6-23A (OPTIONAL) ............................................................... 274
SECTION 11 - DECALS ................................................................................................................................................................... 277
FIGURE 11-1. FRAME AND BOOM DECALS .............................................................................................................................. 278
FIGURE 11-2. CAB DECALS ....................................................................................................................................................... 282
FIGURE 11-3. MACHINE DECALS, G5-19A ................................................................................................................................ 284
FIGURE 11-4. MACHINE DECALS, G6-23A ................................................................................................................................ 286
SECTION 12 - OPTIONS ................................................................................................................................................................. 289
FIGURE 12-1. CAB WORKLIGHT INSTALLATIONS ................................................................................................................... 290
FIGURE 12-2. BOOM WORKLIGHT INSTALLATION .................................................................................................................. 292
FIGURE 12-3. ROTATING BEACON INSTALLATION ................................................................................................................. 294
FIGURE 12-4. AIR CONDITIONER INSTALLATION (G5-19A Prior to SN 1160004784; G6-23A Prior to SN 1160004665) ....... 296
FIGURE 12-5. AIR CONDITIONER INSTALLATION (G5-19A SN 1160004784 to Present; G6-23A SN 1160004665 to Present)
...................................................................................................................................................................................................... 298
FIGURE 12-6. DRAW BAR COUPLING INSTALLATION ............................................................................................................. 300
FIGURE 12-7. DUAL BOOM AUX HYDRAULIC, MANUAL .......................................................................................................... 302
FIGURE 12-8. DUAL BOOM AUX HYDRAULIC, ELECTRICAL .................................................................................................. 304
FIGURE 12-9. OPTION HARNESS .............................................................................................................................................. 306
FIGURE 12-10. UPPER CAB ELECTRICAL INSTALLATION (G5-19A Prior to SN 1160003034; G6-23A Prior to SN 1160003240)
...................................................................................................................................................................................................... 308
FIGURE 12-11. UPPER CAB ELECTRICAL INSTALLATION (G5-19A SN 1160003034 to Present; G6-23A SN 1160003240 to
Present) ........................................................................................................................................................................................ 310
FIGURE 12-12. PINTLE HITCH INSTALLATION ......................................................................................................................... 312
FIGURE 12-13. DUMP VALVE INSTALLATION........................................................................................................................... 314
FIGURE 12-14. BOOM AUXILIARY ELECTRIC ........................................................................................................................... 316
SECTION 13 - RECOMMENDED SPARE PARTS .......................................................................................................................... 319
FIGURE 13-1. RECOMMENDED SPARE PARTS ....................................................................................................................... 320
PART NUMBER INDEX ................................................................................................................................................................... 323
SECTION 1 - FRAME AND ATTACHING PARTS
31200194 G6-23A/G5-19A 9
SECTION 1 - FRAME AND ATTACHING PARTS
SECTION 1 - FRAME AND ATTACHING PARTS
31200194 G6-23A/G5-19A 10
FIGURE 1-1. FRAME SHROUDING AND TRIM
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JLG Telehandlers G5-19A & G6-23A ANSI Illustrated Master Parts List Manual ! (P/N 31200194)
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Description
This comprehensive parts manual is specifically for the JLG Telehandlers G5-19A & G6-23A ANSI. It provides detailed instructions and includes highly detailed exploded diagrams and pictures, covering all parts such as:
- Frame & Attaching Parts
- Boom
- Attachments
- Engine & Attaching Parts
- Drive Train
- Cab
- Controls
- Hydraulic Circuits
- Hydraulic Components
- Electrical
- Decals
- Options
With instant access, there are no shipping costs or waiting for a physical manual. The manual is compatible with all versions of Windows and Mac, and it is available in English. It can be viewed on a PC or Laptop and is printable. The file format is PDF, and it requires Adobe Reader and Win to access.
