Document Outline

• 31200361_A_G5-18A 2505_JLG_Service
  • Effectivity
  • TOC
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operation & Safety Manual
    • 1.4 Do Not Operate Tags
    • 1.5 Safety Information
      • 1.5.1 Safety Alert System and Signal Words
    • 1.6 Safety Instructions
      • 1.6.1 Personal Hazards
      • 1.6.2 Equipment Hazards
      • 1.6.3 General Hazards
      • 1.6.4 Operational Hazards
    • 1.7 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Torques
      • 2.2.1 ASTM Fastener Torque Chart (English)
      • 2.2.2 ASTM Fastener Torque Chart (Metric)
      • 2.2.3 Metric Fastener Torque Chart
    • 2.3 Specifications
      • 2.3.1 Travel Speed
      • 2.3.2 Hydraulic Cylinder Performance Specifications
      • 2.3.3 Electrical System
      • 2.3.4 Engine Performance Specifications
      • 2.3.5 Tires
    • 2.4 Fluids, Lubricants and Capacities
    • 2.5 Maintenance Schedules
      • 2.5.1 10,1st 50 & 50 Hour Maintenance Schedule
      • 2.5.2 1st 250, 250, 500 & 1000 Hour Maintenance Schedule
    • 2.6 Lubrication Schedule
      • 2.6.1 250 Hour Lubrication Schedule
  • Section 3 Boom
    • 3.1 Boom System Component Terminology
    • 3.2 Boom System - Two Section Boom
      • 3.2.1 Boom System Description
    • 3.3 Boom Assembly Maintenance
      • 3.3.1 Second Section Boom Removal
      • 3.3.2 First Boom Section Removal
      • 3.3.3 First Boom Section Installation
      • 3.3.4 Second Boom Section Installation
      • 3.3.5 Complete Boom Removal
      • 3.3.6 Second Section Boom Removal
      • 3.3.7 Second Section Boom Installation
      • 3.3.8 Boom Installation
      • 3.3.9 Extend/Retract Cylinder Removal
      • 3.3.10 Extend/Retract Cylinder Installation
    • 3.4 Boom Wear Pads
      • 3.4.1 Wear Pad Inspection
      • 3.4.2 Boom Wear Pad Replacement
      • 3.4.3 Boom Wear Pad Lubrication
    • 3.5 Quick Attach Assembly
      • 3.5.1 Connecting with a Mechanical JLG Quick Attach
      • 3.5.2 Connecting with a Hydraulic JLG Quick Attach
      • 3.5.3 Connecting with a Universal Quick Attach
      • 3.5.4 Connecting a Hydraulic Operated Attachment
      • 3.5.5 Quick Attach Removal
      • 3.5.6 Quick Attach Installation
    • 3.6 Troubleshooting
  • Section 4 Cab and Covers
    • 4.1 Operator’s Cab and Covers Component Terminology
    • 4.2 Operator’s Cab
      • 4.2.1 Operator’s Cab Description
      • 4.2.2 Serial Number Decal
    • 4.3 Cab Components
      • 4.3.1 Steering Wheel
      • 4.3.2 Steering Column/Valve Replacement
      • 4.3.3 Brake Pedal and Valve
      • 4.3.4 Throttle Pedal Replacement
      • 4.3.5 Joystick Assembly Replacement
      • 4.3.6 Windshield Wiper Assembly
      • 4.3.7 Windshield Washer Assembly
      • 4.3.8 Heater/Defroster System
    • 4.4 Cab Removal
    • 4.5 Cab Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology
    • 5.2 General Information
    • 5.3 Axle Assemblies
      • 5.3.1 Axle Serial Number Plate
      • 5.3.2 Axle Specifications
      • 5.3.3 Axle Internal Service
      • 5.3.4 Axle Maintenance
      • 5.3.5 Axle Removal
      • 5.3.6 Axle Installation
      • 5.3.7 Axle Assembly and Drive Shaft Troubleshooting
    • 5.4 Drive Shafts
      • 5.4.1 Drive Shaft Inspection
      • 5.4.2 Drive Shaft Maintenance
      • 5.4.3 Drive Shaft Removal
      • 5.4.4 Drive Shaft Cleaning and Drying
      • 5.4.5 Drive Shaft Installation
    • 5.5 Wheels and Tires
      • 5.5.1 Removing Wheel and Tire Assembly from Machine
      • 5.5.2 Installing Wheel and Tire Assembly onto Machine
    • 5.6 Steering Adjustment
      • 5.6.1 Steering Angle Adjustment
    • 5.7 Brakes
      • 5.7.1 Brake Disk Inspection.
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Transmission Description
    • 6.3 Transmission Specifications
      • 6.3.1 Transmission Maintenance
    • 6.4 Transmission Replacement
      • 6.4.1 Transmission Removal
      • 6.4.2 Transmission Disassembly
      • 6.4.3 Transmission Installation
      • 6.4.4 After Transmission Replacement
    • 6.5 Transmission Filter Replacement
      • 6.5.1 Filter Removal
      • 6.5.2 Filter Installation
    • 6.6 Towing a Disabled Machine
  • Section 7 Engine: Perkins 1104D-44T
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
    • 7.2 Engine Serial Number
    • 7.3 Specifications and Maintenance Information
    • 7.4 Engine Cooling System
      • 7.4.1 Radiator Pressure Cap
      • 7.4.2 Radiator/Oil Cooler and Coolant Heater Replacement
    • 7.5 Engine Electrical System
    • 7.6 Fuel System
      • 7.6.1 Diesel Fuel
      • 7.6.2 Fuel/Hydraulic Oil Tank
      • 7.6.3 After Fuel System Service
    • 7.7 Engine Exhaust and Air Cleaner System
    • 7.8 Engine Replacement
      • 7.8.1 Engine Removal
      • 7.8.2 Engine Disassembly, Inspection and Service
      • 7.8.3 Engine Installation
    • 7.9 Engine Coupler
      • 7.9.1 Coupler Removal
      • 7.9.2 Coupler Installation
    • 7.10 Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Specifications
    • 8.4 Hoses, Tube Lines, Fittings, Etc.
      • 8.4.1 Replacement Considerations
      • 8.4.2 Hose, Tube, Line and Fitting Replacement
    • 8.5 Hydraulic Pressure Diagnosis
      • 8.5.1 Pressure Checks and Adjustments
      • 8.5.2 Main Control Valve Pressure Checking
      • 8.5.3 Charge Pressure Checking
      • 8.5.4 Boom Function Pressure Checking
      • 8.5.5 Steering Pressure Checking
    • 8.6 Hydraulic Schematics
      • 8.6.1 G5-18A
      • 8.6.2 2505
      • 8.6.3 Auxiliary Options
    • 8.7 Hydraulic Reservoir
      • 8.7.1 Pressurized Hydraulic Oil Fill Cap
      • 8.7.2 Hydraulic Oil Reservoir Draining
      • 8.7.3 Hydraulic Oil Reservoir Filling
    • 8.8 Hydraulic System Pump
      • 8.8.1 Implement Pump Failure Analysis
      • 8.8.2 Implement Pump Replacement
    • 8.9 Front Drive Motor
    • 8.10 Valves and Manifolds
      • 8.10.1 Main Control Valve
      • 8.10.2 Service Brake Valve
      • 8.10.3 Parking Brake Valve
      • 8.10.4 Brake Test
      • 8.10.5 Steering Orbitrol Valve
      • 8.10.6 Pilot Select Valve
      • 8.10.7 Inching Valve
      • 8.10.8 Steer Select Valve
      • 8.10.9 Joystick Enable Valve (CE)
      • 8.10.10 Load Stability Indicator Valve (CE)
    • 8.11 Hydraulic Cylinders
      • 8.11.1 General Cylinder Removal Instructions
      • 8.11.2 General Cylinder Disassembly
      • 8.11.3 Cylinder Cleaning Instructions
      • 8.11.4 Cylinder Inspection
      • 8.11.5 General Cylinder Assembly
      • 8.11.6 General Cylinder Installation
      • 8.11.7 Steering Cylinders
      • 8.11.8 Hydraulic Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
    • 9.2 Specifications
    • 9.3 Fuses and Relays
      • 9.3.1 Engine Compartment Relays and Fuses
      • 9.3.2 Cab Compartment Fuses and Relays
      • 9.3.3 Power Distribution Module
      • 9.3.4 Cab Fuses / Relays
    • 9.4 Electrical System Schematics
      • 9.4.1 Cab Harness Schematic "A"
      • 9.4.2 Cab Harness Schematic "B"
      • 9.4.3 Cab Roof Schematic
      • 9.4.4 Chassis Schematic
      • 9.4.5 Options Chassis Schematic
    • 9.5 Circuit Breakdowns
      • 9.5.1 Charge Circuit Breakdown
      • 9.5.2 Start Circuit Breakdown
      • 9.5.3 Constant Power Circuit Breakdown
      • 9.5.4 Drive Circuit Breakdown
    • 9.6 Engine Start Circuit
      • 9.6.1 Starter
    • 9.7 Charging Circuit
      • 9.7.1 Alternator
    • 9.8 Electrical System Components
      • 9.8.1 Back-up Alarm
      • 9.8.2 Instrument Cluster
      • 9.8.3 Speedometer (CE)
    • 9.9 Window Wiper/Washer
      • 9.9.1 Windshield Wiper Motor
      • 9.9.2 Rear Window or Roof Wiper Motor (if equipped)
      • 9.9.3 Windshield Washer Reservoir and Pump
    • 9.10 Cab Heater and Fan
      • 9.10.1 Cab Heater Controls
    • 9.11 Switches, Solenoids and Senders
      • 9.11.1 Ignition Key Switch
      • 9.11.2 Dash Switches
      • 9.11.3 Fuel Level Indicator and Fuel Level Sender
      • 9.11.4 Hourmeter
      • 9.11.5 Coolant Temperature Sender
      • 9.11.6 Fuel Shut-off Solenoid
      • 9.11.7 Oil Pressure Sender
      • 9.11.8 Load Stability Indicator (CE)
      • 9.11.9 Load Stability Sensor