JLG G5-18A Service Manual - Manual (Page 89)

7-11 G5-18A, 2505H, 25.5
Engine
7.7 ENGINE REPLACEMENT
7.7.1 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 a 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. Thoroughly clean the engine and surrounding area,
including all hoses and fittings before proceeding.
5. Properly disconnect the battery.
6. Remove the radiator/oil cooler assembly. Refer to
Section 7.2.2, “Radiator/Oil Cooler Replacement.” for
detailed removal instructions.
7. Drain hydraulic reservoir. Refer to Section 8.8.2,
“Hydraulic Oil Reservoir Draining.”
8. Remove the air cleaner assembly. Refer to Section
7.6.1, “Air Cleaner Assembly Removal,” for detailed
removal instructions.
9. Remove the exhaust system. Refer to Section 7.5.1,
“Exhaust System Removal,” for detailed removal
instructions.
10. Loosen and remove the rear fender (1).
11. Label, disconnect and cap all hydraulic hoses
attached to engine and transmission, cap all fittings
and plug hoses to keep dirt & debris from entering
hydraulic system.
12. Label, disconnect and cap all fuel lines. Install a plug
in the end of each line.
13. Remove hydraulic and fuel filters, and radiator/oil
cooler assembly bracket assembly (2).
14. Label and disconnect all wire connections on the
engine and transmission.
15. Secure the engine (3) with a lifting strap or chain
from the appropriate lifting points. Use a suitable
hoist or overhead crane.
16. Remove the four motor mount bolts that attach the
engine to the frame.
17. Carefully lift the engine from the machine. Avoid
causing damage to the surrounding parts.
18. 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.
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