Document Outline

• 31200926_A_JLG_G5-18A,2505H,25.5_Service Manual
  • Effectivity Page
  • Read This First
  • Table of Contents
  • 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 Torque Charts
      • 2.2.1 SAE Fastener Torque Chart
      • 2.2.2 Metric Fastener Torque Chart
      • 2.2.3 Hydraulic Hose 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
      • 2.4.1 Fluids
      • 2.4.2 Capacities
    • 2.5 Maintenance Schedule
      • 2.5.1 10,1st 50 & 50 Hour Maintenance Schedule
      • 2.5.2 1st 250, 250 & 500 Hour Maintenance Schedule
      • 2.5.3 1000 & 1500 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 Safety Information
    • 3.3 Two Section Boom System
      • 3.3.1 Boom System Description
    • 3.4 Boom Assembly Maintenance
      • 3.4.1 Complete Boom Removal
      • 3.4.2 Complete Boom Installation
      • 3.4.3 Second Boom Section Removal
      • 3.4.4 Second Boom Section Installation
      • 3.4.5 Extend/Retract Cylinder Removal
      • 3.4.6 Extend/Retract Cylinder Installation
    • 3.5 Boom Wear Pads
      • 3.5.1 Wear Pad Inspection
      • 3.5.2 Wear Pad Installation and Lubrication
      • 3.5.3 Boom Wear Pad Lubrication
    • 3.6 Quick Attach Assembly
      • 3.6.1 Quick Attach Assembly Removal
      • 3.6.2 Quick Attach Assembly Installation
    • 3.7 Forks
    • 3.8 Boom Prop (If Equipped)
      • 3.8.1 Prop Installation
      • 3.8.2 Prop Removal
    • 3.9 Emergency Boom Lowering Procedure
      • 3.9.1 Equipment and Supplies Required
      • 3.9.2 Lowering Procedure
    • 3.10 Troubleshooting
  • Section 4 Cab
    • 4.1 Operator Cab Component Terminology
    • 4.2 Safety Information
    • 4.3 Operator Cab
      • 4.3.1 Operator Cab Description
      • 4.3.2 Serial Number Decal
    • 4.4 Cab Components
      • 4.4.1 Steering Wheel
      • 4.4.2 Steering Column/Valve Replacement
      • 4.4.3 Brake Pedal and Valve
      • 4.4.4 Accelerator Pedal Replacement
      • 4.4.5 Joystick Replacement
      • 4.4.6 Windshield Wiper Assembly (If Equipped)
      • 4.4.7 Windshield Washer Assembly (If Equipped)
      • 4.4.8 Heater/Air Conditioning System (If Equipped)
      • 4.4.9 Air Conditioning (If Equipped)
      • 4.4.10 Air Filter System (If Equipped)
    • 4.5 Cab Removal
    • 4.6 Cab Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology
    • 5.2 Safety Information
    • 5.3 General Information
    • 5.4 Axle Assemblies
      • 5.4.1 Axle Serial Number Plate
      • 5.4.2 Axle Specifications
      • 5.4.3 Axle Internal Service
      • 5.4.4 Axle Maintenance
      • 5.4.5 Axle Removal
      • 5.4.6 Axle Installation
      • 5.4.7 Axle Assembly and Drive Shaft Troubleshooting
    • 5.5 Drive Shafts
      • 5.5.1 Drive Shaft Inspection
      • 5.5.2 Drive Shaft Maintenance
      • 5.5.3 Drive Shaft Removal
      • 5.5.4 Drive Shaft Cleaning and Drying
      • 5.5.5 Drive Shaft Installation
    • 5.6 Wheels and Tires
      • 5.6.1 Removing Wheel and Tire Assembly from Machine
      • 5.6.2 Installing Wheel and Tire Assembly onto Machine
    • 5.7 Steering Angle Adjustment
    • 5.8 Brakes
      • 5.8.1 Brake Disc Inspection
    • 5.9 Towing a Disabled Machine
      • 5.9.1 Equipment and Supplies Required
      • 5.9.2 Towing Procedure
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Safety Information
    • 6.3 Transmission Description
    • 6.4 Transmission Specifications
      • 6.4.1 Transmission Maintenance
    • 6.5 Transmission Replacement
      • 6.5.1 Transmission Removal
      • 6.5.2 Transmission Disassembly
      • 6.5.3 Transmission Installation
  • Section 7 Engine
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Engine Serial Number
      • 7.1.3 Specifications and Maintenance Information
      • 7.1.4 Component Terminology
    • 7.2 Engine Cooling System
      • 7.2.1 Surge Tank Cap
      • 7.2.2 Radiator/Oil Cooler Replacement
    • 7.3 Engine Electrical System
    • 7.4 Fuel System
      • 7.4.1 Diesel Fuel
      • 7.4.2 Fuel/Hydraulic Oil Tank
      • 7.4.3 After Fuel System Service
    • 7.5 Engine Exhaust System
      • 7.5.1 Exhaust System Removal
      • 7.5.2 Exhaust System Installation
    • 7.6 Air Cleaner Assembly
      • 7.6.1 Air Cleaner Assembly Removal
      • 7.6.2 Air Cleaner Assembly Installation
    • 7.7 Engine Replacement
      • 7.7.1 Engine Removal
      • 7.7.2 Engine Disassembly, Inspection and Service
      • 7.7.3 Engine Installation
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 General Information
    • 8.4 Specifications
    • 8.5 Hoses, Tube Lines, Fittings, Etc.
      • 8.5.1 Replacement Considerations
      • 8.5.2 Hose, Tube, Line and Fitting Replacement
    • 8.6 Hydraulic Pressure Diagnosis
      • 8.6.1 Pressure Checks and Adjustments
      • 8.6.2 Main Control Valve Pressure Checking
      • 8.6.3 Charge Pressure Checking
      • 8.6.4 Boom Function Pressure Checking
      • 8.6.5 Steering Pressure Checking
      • 8.6.6 Fan Speed Pressure and Direction Checking
    • 8.7 Hydraulic Schematic
    • 8.8 Hydraulic Reservoir
      • 8.8.1 Pressurized Hydraulic Oil Fill Cap
      • 8.8.2 Hydraulic Oil Reservoir Draining
      • 8.8.3 Hydraulic Oil Reservoir Filling
    • 8.9 Hydraulic System Pump
      • 8.9.1 Implement Pump Removal
      • 8.9.2 Implement Pump Installation
      • 8.9.3 Pump Test
    • 8.10 Front Drive Motor
      • 8.10.1 Front Drive Motor Removal
      • 8.10.2 Front Drive Motor Installation
    • 8.11 Control Valves
      • 8.11.1 Main Control Valve
      • 8.11.2 Service Brake Valve
      • 8.11.3 Park Brake Valve (G5-18A)
      • 8.11.4 Hand Brake Valve (2505H & 25.5)
      • 8.11.5 Steering Orbitrol Valve
      • 8.11.6 Pilot Select Valve
      • 8.11.7 Inching Valve
      • 8.11.8 Priority Valve
      • 8.11.9 Steer Select Valve
      • 8.11.10 Quick Attach Valve
      • 8.11.11 Variable Speed Fan Valve
    • 8.12 Hydraulic Cylinders
      • 8.12.1 General Cylinder Removal Instructions
      • 8.12.2 General Cylinder Disassembly
      • 8.12.3 Cylinder Cleaning Instructions
      • 8.12.4 Cylinder Inspection
      • 8.12.5 General Cylinder Assembly
      • 8.12.6 General Cylinder Installation
      • 8.12.7 Steering Cylinders
      • 8.12.8 Hydraulic Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
    • 9.2 Safety Information
    • 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
    • 9.5 Engine Start Circuit
      • 9.5.1 Starter
    • 9.6 Charging Circuit
      • 9.6.1 Alternator
    • 9.7 Electrical System Components
      • 9.7.1 Back-up Alarm
      • 9.7.2 Gauge Cluster
    • 9.8 Window Wiper/Washer
      • 9.8.1 Windshield Wiper Motor
      • 9.8.2 Rear Window or Roof Wiper Motor (if equipped)
      • 9.8.3 Windshield Washer Reservoir and Pump
    • 9.9 Cab Heater/AC and Fan
      • 9.9.1 Cab Heater/AC Controls
    • 9.10 Switches, Solenoids and Senders
      • 9.10.1 Ignition Key Switch
      • 9.10.2 Dash Switches
      • 9.10.3 Fuel Level Indicator and Fuel Level Sender
      • 9.10.4 Hourmeter
      • 9.10.5 Coolant Temperature Sender
      • 9.10.6 Oil Pressure Sender
    • 9.11 Load Stability Indicator System (2505H & 25.5)
      • 9.11.1 LSI Axle Sensor
      • 9.11.2 LSI Boom Sensors
      • 9.11.3 LSI Modules
      • 9.11.4 LSI System Calibration
      • 9.11.5 LSI-CAN Check PT
      • 9.11.6 500 Hour - LSI UGM Calibration Check
    • 9.12 Hand Held Analyzer (2505H & 25.5)
      • 9.12.1 Analyzer Usage
      • 9.12.2 Analyzer Software - Version 1.0
    • 9.13 Diagnostic Trouble Codes (DTC) on Ground Module
      • 9.13.1 Gauge Fault Code Display
      • 9.13.2 Fault Codes
    • 9.14 Engine Diagnostic Trouble Code EMR4
      • 9.14.1 Gauge Fault Code Display