JLG G5-18A Service Manual - Manual (Page 72)

Engine: Perkins 1104D-44T
7.8 G5-18A/2505
16. Label and disconnect all wire connections on the
engine.
17. Mark the location of the throttle cable (2) at the
engine throttle lever. Disconnect the throttle cable.
18. Detach exhaust and air cleaner hoses from the
engine. Cover air inlets to protect from dirt & debris.
19. Remove air cleaner assembly from engine
compartment.
20. Completely disconnect exhaust pipe.
21. Remove the hydraulic reservoir fill tube.
22. Secure the engine with a lifting strap or chain from
the appropriate lifting points (3). Use a suitable hoist
or overhead crane.
23. Remove the 4 motor mount bolts that attach the
engine to the frame.
24. Carefully lift the engine from the machine. Avoid
causing damage to the surrounding parts.
25. 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.
7.8.2 Engine Disassembly, Inspection and
Service
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Perkins
1104D-44T service manual. Several special engine service
tools are required to properly service the Perkins engine.
Contact your local Perkins 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 Perkins 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. Reattach any previously labeled wire connections on
the engine.
7. Attach the engine fan.
8. Reinstall the front and rear engine cover supports.
9. 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.
10. Install the filter bracket assembly. Secure the
hydraulic and fuel filters.
11. Connect the fuel inlet line to the fuel filter (1) and
reconnect the return fuel line to the engine.
12. Uncap and reconnect all hydraulic hoses and fittings
to the engine and necessary hydraulic elements.
Keep hoses free of dirt & debris.
MY1890
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