JLG G6-23A Service Manual - Manual (Page 68)

Engine: Deutz BF 4M 2012
7.8 G5-19A, G6-23A
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).
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 steer-
ing wheel.
• Keep the transmission in NEUTRAL (N).
20. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle.
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