JLG G5-18A Service Manual - Manual (Page 62)

Transmission
6.4 G5-18A/2505
11. Vertically secure transmission with a lifting strap or
chain. Use a suitable hoist or overhead crane.
Operate the hoist or crane to remove slack from the
chain, but DO NOT raise the transmission at this
time.
12. Remove the two Allen head bolts that attach the
transmission to the engine.
13. Carefully remove the transmission from the machine.
Avoid causing damage to the transmission or
surrounding parts.
14. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
6.4.2 Transmission Disassembly
Transmission disassembly, internal inspection, service,
repair and assembly procedures are covered in the
Rexroth Repair Manual (P/N 31200124).
6.4.3 Transmission Installation
1. Use a lifting strap or chain attached to a hoist or
overhead crane to position the transmission within
the chassis.
2. Insert the two Allen head bolts that attach the
transmission to the engine. Torque to 154 lb-ft
(210 Nm).
3. Remove the hoist or overhead crane and sling.
4. Uncap and reconnect the previously labeled hoses
and electrical connections to their appropriate
locations.
5. Fill hydraulic reservoir and bleed the system.
6. Reinstall the hood support.
7. Reinstall the air cleaner assembly.
8. Reconnect battery cables to terminals, starting with
the positive (+) terminal.
9. Close and secure the engine covers.
6.4.4 After Transmission Replacement
1. Install new hydraulic filters.
2. Check the hydraulic oil level and add oil as required.
3. Reassemble all components and fill the hydraulic
reservoir with clean, fresh oil. DO NOT overfill.
4. Run the engine for two minutes at idle to help bleed any
air from the hydraulic system.
5. Operate all boom functions to ensure any air is
removed from the hydraulic system.
6. Retract and level the boom, recheck the level of the
fluid in the reservoir.
7. Add oil as necessary to bring the fluid level up until it
reaches the FULL mark on the reservoir. Recheck
the oil level when it reaches operating temperature
(180-200° F or 83-94° C).
8. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
WARNING
The transmission may move while hoisting it out of
the chassis. Carefully move the transmission and
adjust the sling as needed. Keep fingers, hands, legs
and other body parts clear of the transmission.
Failure to follow the safety practices could result in
death or serious injury.
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling. Failure to follow the safety practices
could result in death or serious injury.
NOTICE
DO NOT use flushing compounds for cleaning
purposes.