JLG G6-23A Service Manual - Manual (Page 67)

7.7 G5-19A, G6-23A
Engine: Deutz BF 4M 2012
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.
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.
MAH0620
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