JLG G5-18A Service Manual
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JLG G5-18A Service Manual

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Service Manual
Models
G5-18A
&
2505
31200361
Revised
January 15, 2018
An Oshkosh Corporation Company

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Summary of Contents for JLG G5-18A

  • Page 1 Service Manual Models G5-18A & 2505 31200361 Revised January 15, 2018 An Oshkosh Corporation Company...
  • Page 3 EFFECTIVITY PAGE February 28, 2008 - A - Original Issue Of Manual January 15, 2018 - B - Revised covers and pages 1-4, 3-14, 8-9, 8-10, 8-11 & 8-22. Added pages 3-8, 3-9. 5-5. 31200361 G5-18A, 2505...
  • Page 4 EFFECTIVITY PAGE G5-18A, 2505 31200361...

  • Page 5: Table Of Contents

    Cab Installation ............G5-18A, 2505...

  • Page 6: Subject

    Hydraulic Cylinders ........... . 8-24 G5-18A, 2505...
  • Page 7 Switches, Solenoids and Senders ......... 9-21 G5-18A, 2505...
  • Page 8 Section Subject Page G5-18A, 2505...
  • Page 9 Safety Decals ............G5-18A,2505...

  • Page 10: Safety Practices

    When additional In the event of an accident, know where to obtain medical information is desired consult the local JLG distributor. assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency...

  • Page 11: Safety Instructions

    Capture fluid in an appropriate container and attempting service. dispose of in accordance with prevailing environmental When removing hydraulic components, plug hose ends and regulations. connections to prevent excess leakage and contamination. G5-18A, 2505...

  • Page 12: Safety Decals

    Allow the battery to thaw before jump-starting or connecting a battery charger. SAFETY DECALS Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information. G5-18A, 2505...

  • Page 13: General Information And Specifications

    O-ring Installation (Replacement) ......... . 2-68 G5-18A, 2505...

  • Page 14: Replacement Parts And Warranty Information

    A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

  • Page 15: Specifications

    Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance, Wet Charged Quantity 1 (100 Ah) (C Reserve Capacity CCA @ -.4° F: 880 EN Group/Series DIN 600,44 Alternator 12V, 75 Amps Starter 12V, 3,0 KW Type EV (Gear Reduction) G5-18A, 2505...

  • Page 16: Engine Performance Specifications

    12 Ply Pneumatic 80 psi (5,5 bar) Approx. 220 lb foam 14 x 17.5 12 Ply Pneumatic 70 psi (4,8 bar) Approx. 220 lb foam Note: Standard wheel lug nut torque is 210-230 lb-ft (285 - 312 Nm). G5-18A, 2505...

  • Page 17: Fluids, Lubricants And Capacities

    424 Tractor Hydraulic Fluid (ISO 46) Hydraulic System System Capacity 23.5 gallons (89 liters) Reservoir Capacity to FULL Mark 16 gallons (60,6 liters) ® Type of Fluid Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) Auxiliary Hydraulic Circuit Max Flow 20 GPM (75,7 LPM) G5-18A, 2505...

  • Page 18: Maintenance Schedules

    Torque Filter EVERY 1000 Check Engine Drain Fuel/ Check Coolant Level Water Air Filter Separator MY2560 Change Change Wheel Change Check Change Axle Oil End Oil Hydraulic Hydraulic Tank Transmission Fluid & Filters Filter Change Engine Coolant MY2570 G5-18A, 2505...

  • Page 19: Lubrication Schedule

    General Information and Specifications LUBRICATION SCHEDULE 2.5.1 250 Hour Lubrication Schedule EVERY MYSTIK TETRIMOLY (NLGI 2 GC-LB) MY2580 G5-18A, 2505...

  • Page 20: Thread Locking Compound

    High Strength (Red) Vibra-TITE ™ ™ 0100071 Medium - High Strength (Red) Vibra-TITE ™ ™ ™ ™ ® ® Loctite can be substituted in place of Loctite . Vibra-TITE 122 can be substituted in place of Vibra-TITE 121. G5-18A, 2505...

  • Page 21: Torque Charts

    2300 3128 1974 2676 NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER G5-18A, 2505...
  • Page 22 4350 2665 3625 NOTES: 5000059K 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 2-10 G5-18A, 2505...
  • Page 23 2385 1645 2237 NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER G5-18A, 2505 2-11...
  • Page 24 3870 2665 3625 NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 2-12 G5-18A, 2505...
  • Page 25 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. G5-18A, 2505 2-13...
  • Page 26 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 2-14 G5-18A, 2505...

  • Page 27: Metric Fastener Torque Chart

    3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. G5-18A, 2505 2-15...
  • Page 28 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 2-16 G5-18A, 2505...
  • Page 29 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. G5-18A, 2505 2-17...
  • Page 30 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 2-18 G5-18A, 2505...
  • Page 31 General Information and Specifications This Page Intentionally Left Blank G5-18A, 2505 2-19...

  • Page 32: Hydraulic Connection Assembly And Torque Specification

    MBTS - Metric flareless bite type fitting, pressure rating S (high) per ISO 8434, DIN 2353 MAE9050 MAE9010 BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types b. Straight Thread Types, Tube and Hose Connections JIC - 37° flare per SAE J514 MAE9060 MAE9020 2-20 G5-18A, 2505...
  • Page 33 2. When making a connection to tubing, compression or flare, inspect the tube in the area of the fitting attachment to ensure that the tube has not been damaged. G5-18A, 2505 2-21...
  • Page 34 Aluminum and Brass - Reduce steel values by 35% Stainless Steel - Use the upper limit for steel. 5. To achieve the specified torque, the torque wrench is to be held perpendicular to the axis of rotation. MAE9100 2-22 G5-18A, 2505...
  • Page 35 General Information and Specifications This Page Intentionally Left Blank G5-18A, 2505 2-23...

  • Page 36: Assembly Instructions For American Standard Pipe Thread Tapered Connections

    1.89 48.05 1.5 to 2.5 2 - 11 1/2 2.37 60.09 1.5 to 2.5 * ØA thread dimension for reference only. NOTE: ** Refer to Section 2.8.15, “FFWR and TFFT Methods. ” , for TFFT procedure requirements. 2-24 G5-18A, 2505...

  • Page 37: Assembly Instructions For British Standard Pipe Thread Tapered Connections

    1 1/2 - 11 1.88 47.80 1.5 to 2.5 2 - 11 2.35 59.61 1.5 to 2.5 * ØA thread dimension for reference only. NOTE: ** Refer to Section 2.8.15, “FFWR and TFFT Methods. ” , for TFFT procedure requirements. G5-18A, 2505 2-25...

  • Page 38: Assembly Instructions For 37° (Jic) Flare Fittings

    3/4 to 1 2 1/2-12 2.42 61.50 2.50 63.50 3/4 to 1 * ØA and ØB thread dimensions for reference only. NOTE: ** Refer to Section 2.8.15, “FFWR and TFFT Methods. ” , for FFWR procedure requirements. 2-26 G5-18A, 2505...
  • Page 39 3/4 to 1 2 1/2-12 2.42 61.50 2.50 63.50 3/4 to 1 * ØA and ØB thread dimensions for reference only. NOTE: ** Refer to Section 2.8.15, “FFWR and TFFT Methods. ” , for FFWR procedure requirements. G5-18A, 2505 2-27...

  • Page 40: Assembly Instructions For 45° Sae Flare Fittings

    ‘Aluminum/brass fittings or aluminum/brass mating components’ indicate either the following material configurations: a. Steel fittings with aluminum or brass mating components b. Aluminum or brass fittings with steel mating components c. Aluminum or brass fittings with aluminum or brass mating components. 2-28 G5-18A, 2505...
  • Page 41 FITTINGS OR 5/8-18 0.56 14.30 0.63 15.90 ALUMINUM/BRASS MATING 3/4-16 0.69 17.50 0.75 19.10 COMPONENTS; 7/8-14 0.81 20.60 0.87 22.20 UN-LUBRICATED THREADS 1 1/16-14 0.98 25.00 1.06 27.00 * ØA and ØB thread dimensions for reference only. NOTE: G5-18A, 2505 2-29...

  • Page 42: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings

    Aluminum/brass fittings or aluminum/brass mating components’ indicate either the following material configurations: a. Steel fittings with aluminum or brass mating components b. Aluminum or brass fittings with steel mating components c. Aluminum or brass fittings with aluminum or brass mating components. 2-30 G5-18A, 2505...
  • Page 43 2 1/2-12 2.43 61.67 2.50 63.50 1/4 to 1/2 1/2 to 3/4 * ØA and ØB thread dimensions for reference only. NOTE: ** Refer to Section 2.8.15, “FFWR and TFFT Methods. ” , for FFWR procedure requirements. G5-18A, 2505 2-31...

  • Page 44: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    5. Slide collet into position and tighten until finger tight. Mark nut and tube in the finger-tight position. Tighten nut to the number of flats listed while using the Double Wrench Method. The tube must not turn with the nut. 2-32 G5-18A, 2505...
  • Page 45 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75 NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only. ** Refer to Section 2.8.15, “FFWR and TFFT Methods. ” , for FFWR procedure requirements. G5-18A, 2505 2-33...

  • Page 46: Assembly Instructions For Bulkhead (Bh) Fittings

    3. Insert the bulkhead side of the fitting into the panel or bulkhead bracket opening. 4. Hand thread the locknut onto the bulkhead end of the fitting body. 5. Torque nut onto fitting while using the Double Wrench Method. 2-34 G5-18A, 2505...
  • Page 47 1 11/16-12 2-12 Torque Thread Size Type Dash Size [Ft-Lb] [Nm] (UNF) STEEL FITTINGS 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 ° FLARE (JLIC) 7/8-14 BULKHEAD 1 1/16-12 FITTING 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 G5-18A, 2505 2-35...
  • Page 48 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 DIN 24° CONE M22 x 1.5 FLARELESS BITE (MBTS) BULKHEAD M24 x 1.5 FITTING M30 x 2 M36 x 2 M42 x 2 M52 x 2 2-36 G5-18A, 2505...
  • Page 49 General Information and Specifications This Page Intentionally Left Blank G5-18A, 2505 2-37...

  • Page 50: Assembly Instructions For O-Ring Boss (Orb) Fittings

    • Aluminum or brass fittings with steel mating components • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-38 G5-18A, 2505...
  • Page 51 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 NOTE: 1. * ØA Thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. G5-18A, 2505 2-39...
  • Page 52 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 NOTE: 1. * ØA Thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 2-40 G5-18A, 2505...
  • Page 53 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 NOTE: 1. * ØA Thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. G5-18A, 2505 2-41...
  • Page 54 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 NOTE: 1. * ØA Thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 2-42 G5-18A, 2505...
  • Page 55 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 NOTE: 1. * ØA Thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. G5-18A, 2505 2-43...
  • Page 56 1.87 47.60 encountered. 2 1/2-12 2.50 63.50 NOTE: 1. * ØA Thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 2-44 G5-18A, 2505...
  • Page 57 General Information and Specifications This Page Intentionally Left Blank G5-18A, 2505 2-45...

  • Page 58: Assembly Instructions For Adjustable Port End Metric Fittings

    • Aluminum or brass fittings with steel mating components • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-46 G5-18A, 2505...
  • Page 59 THREADS M33x2 M42x2 M48x2 Torque Torque Thread Connecting M Size Tube O.D Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] (mm) (metric) M10x1 M12x1.5 M14x1.5 ALUMINUM/BRASS M16x1.5 FITTINGS OR ALUMINUM/BRASS M18x1.5 MATING M22x1.5 COMPONENTS; UN-LUBRICATED M27x2 THREADS M33x2 M42x2 M48x2 G5-18A, 2505 2-47...
  • Page 60 M42x2 M48x2 Torque Torque Thread Connecting M Size Tube O.D Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] (mm) (UNF) M10x1 M12x1.5 ALUMINUM/ M14x1.5 BRASS FITTINGS M16x1.5 OR ALUMINUM/ M18x1.5 BRASS MATING M22x1.5 COMPONENTS; M27x2 UN-LUBRICATED M33x2 THREADS M42x2 M48x2 2-48 G5-18A, 2505...
  • Page 61 173 182 190 235 247 258 108 114 119 146 155 161 THREADS M42x2 259 272 285 351 369 386 173 182 190 235 247 258 M48x2 335 352 369 454 477 500 173 182 190 235 247 258 G5-18A, 2505 2-49...
  • Page 62 Torque Torque Thread Connecting M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] Material (metric) (mm) Nom Max M12x1.5 M14x1.5 ALUMINUM/ M16x1.5 BRASS FITTINGS M18x1.5 OR ALUMINUM/ M20x1.5 BRASS MATING M22x1.5 COMPONENTS; M27x2 UN-LUBRICATED M33x2 THREADS M42x2 M48x2 2-50 G5-18A, 2505...
  • Page 63 Torque Torque Thread Connecting M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] Material (metric) (mm) Nom Max M10x1 M12x1.5 ALUMINUM/ M14x1.5 BRASS FITTINGS M16x1.5 OR ALUMINUM/ M18x1.5 BRASS MATING M22x1.5 COMPONENTS; M27x2 UN-LUBRICATED M33x2 THREADS M42x2 M48x2 G5-18A, 2505 2-51...
  • Page 64 ALUMINUM/ M18x1.5 BRASS M22x1.5 MATING COMPONENTS; M27x2 98 153 161 169 207 218 229 UN-LUBRICATED M33x2 173 182 190 235 247 258 THREADS M42x2 259 272 285 351 369 386 M48x2 335 352 369 454 477 500 2-52 G5-18A, 2505...
  • Page 65 General Information and Specifications This Page Intentionally Left Blank G5-18A, 2505 2-53...

  • Page 66: Assembly Instructions For Metric Iso 6149 Port Assembly Stud Ends

    • Aluminum or brass fittings with steel mating components • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-54 G5-18A, 2505...
  • Page 67 M18 x 1.5 OR ALUMINUM/ M20 x 1.5 BRASS M22 x 1.5 MATING M27 x 2 COMPONENTS; UN-LUBRICATED M30 x 2 THREADS M33 x 2 M38 x 2 M42 x 2 M48 x 2 M60 x 2 G5-18A, 2505 2-55...

  • Page 68: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    • Aluminum or brass fittings with steel mating components • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-56 G5-18A, 2505...
  • Page 69 G 1/4A ALUMINUM/ BRASS FITTINGS G 1/4A OR ALUMINUM/ G 3/8A BRASS G 1/2A MATING G 1/2A COMPONENTS; G 3/4A UN-LUBRICATED THREADS G 1A G 1-1/4A NOTE: ** Non typical for JLG Straight Male Stud Fittings, reference only. G5-18A, 2505 2-57...
  • Page 70 G 1/4A ALUMINUM/ BRASS FITTINGS G 1/4A OR ALUMINUM/ G 3/8A BRASS G 1/2A MATING G 1/2A COMPONENTS; UN-LUBRICATED G 3/4A THREADS G 1A G 1-1/4A NOTE: ** Non typical for JLG Straight Male Stud Fittings, reference only. 2-58 G5-18A, 2505...
  • Page 71 153 161 169 207 218 229 96 101 106 130 137 144 THREADS G 1-1/4A 259 272 285 351 369 386 216 227 237 293 308 321 G 1-1/2A 335 352 369 454 477 500 216 227 237 293 308 321 G5-18A, 2505 2-59...
  • Page 72 G 3/8A BRASS FITTINGS G 3/8A OR ALUMINUM/ G 1/2A BRASS MATING G 1/2A COMPONENTS; G 3/4A UN-LUBRICATED G 1A THREADS G 1-1/4A G 1-1/2A NOTE: ** Non typical for JLG Straight Male Stud Fittings, reference only. 2-60 G5-18A, 2505...
  • Page 73 BRASS FITTINGS G 3/8A OR ALUMINUM/ G 1/2A BRASS MATING G 1/2A COMPONENTS; G 3/4A UN-LUBRICATED G 1A THREADS G 1-1/4A G 1-1/2A NOTE: * Typical for JLG Straight Male Stud Fittings. *** Typical for JLG Adjustable Fittings. G5-18A, 2505 2-61...
  • Page 74 89 111 117 122 150 159 165 specific procedure in UN-LUBRICATED this Service Manual. G 1A 153 161 169 207 218 229 THREADS G 1-1/4A 259 272 285 351 369 386 G 1-1/2A 335 352 368 454 477 499 2-62 G5-18A, 2505...
  • Page 75 General Information and Specifications This Page Intentionally Left Blank G5-18A, 2505 2-63...

  • Page 76: Assembly Instructions For Flange Connections (Fl61 And Fl62)

    3. Position flange and clamp halves. 4. Place lock washers on bolt and bolt through clamp halves. 5. Tighten all bolts by hand. 6. Torque bolts in diagonal sequence in two or more increments to the torque listed. 2-64 G5-18A, 2505...
  • Page 77 1.59 40.39 5/16-18 0.75 2.00 50.80 3/8-16 CODE 62 1.00 2.25 57.15 7/16-14 SPLIT 1.25 2.62 66.55 1/2-13 FLANGE 1.25 2.62 66.55 (FL62) 1.50 3.12 79.25 5/8-11 2.00 3.81 96.77 3/4-10 NOTE: * A dimension for reference only. G5-18A, 2505 2-65...
  • Page 78 2.25 57.15 M12 x 1.75 SPLIT 1.25 2.62 66.55 M12 x 1.75 FLANGE 1.25 2.62 66.55 M14 x 2 (FL62) 1.50 3.12 79.25 M16 x 2 2.00 3.81 96.77 M20 x 2.5 NOTE: * A dimension for reference only. 2-66 G5-18A, 2505...

  • Page 79: Double Wrench Method

    For hose connections, the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose is twisted. Double Wrench Method to Prevent Hose Twist MAE9490 G5-18A, 2505 2-67...

  • Page 80: Ffwr And Tfft Methods

    The nut is to be rotated clockwise the number of turns. d. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots, to indicate the connection has been properly tightened. 2-68 G5-18A, 2505...

  • Page 81: Section 3 Boom

    Connecting with a Mechanical JLG Quick Attach ....3-13 3.5.2 Connecting with a Hydraulic JLG Quick Attach..... 3-13 3.5.3 Connecting with a Universal Quick Attach .

  • Page 82: Boom System Component Terminology

    The following illustration identifies the components that are referred to throughout this section. COMPENSATING CYLINDER FIRST BOOM SECTION SECOND BOOM PIVOT PIN SECTION TILT CYLINDER EXTEND/RETRACT CYLINDER AUXILIARY HYDRAULIC QUICK CONNECTS MY1940 QUICK ATTACH G5-18A, 2505...

  • Page 83: Boom System - Two Section Boom

    OFF. 3. Place an Do Not Operate Tag on both the ignition Note: Tag each pad, backing plate, shim and bolts from each location. key switch and the steering wheel, stating that the machine should not be operated. G5-18A, 2505...

  • Page 84: First Boom Section Removal

    17. Set the second boom section on level ground. Set the complete boom on suitable stands to begin tear down. 18. Inspect the boom and welds. Consult your local JLG distributor if structural damage is detected. 19. Inspect hoses, hardware, wear pads, mounting points and other components visible with the first boom section.

  • Page 85: First Boom Section Installation

    Raise the boom to allow access to the lift 7. Make sure boom section is level, then remove sling. cylinder and the comp cylinder pivot pins, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. G5-18A, 2505...

  • Page 86: Second Section Boom Removal

    NEVER weld or drill the boom unless approved in writing by JLG. The structural integrity of the boom 13. Lift the complete boom off machine and set on level will be impaired if subjected to any repair involving ground or supports being careful not to damage the welding or drilling.

  • Page 87: Second Section Boom Installation

    Boom 8. Inspect the boom and welds. Consult your local JLG Section 3.4.1, “Wear Pad Inspection.” distributor if structural damage is detected. 8. Slide the tilt and auxiliary hoses between the boom 9. Inspect hoses, hardware, wear pads, mounting sections.

  • Page 88: Tilt And Auxiliary Hose Removal

    There should be approximately 1/2 in. (12,7 mm) of clearance. 11. If adjustment is needed, loosen the tilt tubes (and if equipped) auxiliary tubes. Move tubes to achieve the proper clearance. G5-18A, 2505...

  • Page 89: Tilt And Auxiliary Hose Installation

    7. Connect the tilt (1) and auxiliary (2) hoses at bottom of first boom section. 8. Reinstall wear pads and shims. 9. Reinstall attachment. 10. Properly connect battery. 11. Check for hydraulic leaks. Check hydraulic fluid level. Add hydraulic fluid if necessary. 12. Close and secure the engine cover. G5-18A, 2505...

  • Page 90: Extend/Retract Cylinder Removal

    4. Uncap and connect the tubes to the previously at the rear of the first boom section. Plug the tube labeled fittings at the extend/retract cylinder. Apply ends to prevent dirt and debris from entering the Loctite 545 to the fittings. ® hydraulic system. 3-10 G5-18A, 2505...

  • Page 91: Boom Wear Pads

    BOOM WEAR PADS auxiliary hoses (4). Attach both sets to their appropriate fittings until wrench-tight. Mark the On the G5-18A a total of 14 wear pads are installed on fitting, then tighten each hose firmly 1 to 1,5 flats. the boom.

  • Page 92: Boom Wear Pad Lubrication

    The gap at the rear of the boom should be no more than 0.12 in (3 mm). Shims are available in four thicknesses, 0.02 in (0,5mm), 0.04 in (1 mm), 0.06 in (1,5mm) and 0.08 in (2,0mm). MU4080 3-12 G5-18A, 2505...

  • Page 93: Quick Attach Assembly

    2. Align attachment pin (2) with recess in attachment (3). Raise boom slightly to engage attachment pin in recess. This machine is equipped with a JLG Quick Attach system for easy attachment changes. An optional 3. Engage quick attach device.

  • Page 94: Connecting With A Universal Quick Attach

    3.5.4 Connecting a Hydraulic Operated Attachment 1. Install the hydraulic Attachment. See Section 3.5.2, “Connecting with a Hydraulic JLG Quick Attach,” Section 3.5.3, “Connecting with a Universal Quick Attach,” or Section 3.5.4, “Connecting a Hydraulic Operated Attachment,” 2. Lower the attachment to the ground and set the park brake.

  • Page 95: Forks

    5. Fork markings should be legible, re-stamp if required. 6. Compare fork tips (11) when mounted on a carriage. Maximum difference in height of fork tips is 3 percent of the length of the blade (13). MH6460 G5-18A, 2505 3-15...

  • Page 96: Troubleshooting

    2. Lift/lower hydraulic system not 2. Refer to Section 8, “Hydraulic operating properly. System.” 3. Faulty Lift cylinders. 3. Repair cylinder. (Refer to Section 8.11.4, “Cylinder Inspection.”) 4. Seized boom pivot pin bushing. 4. Replace bushing. 3-16 G5-18A, 2505...
  • Page 97 4. Operating in extremely dusty/ 4. Clean equipment frequently. abrasive conditions. 7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic operate. operating properly. System.” G5-18A, 2505 3-17...
  • Page 98 Boom This Page Intentionally Left Blank 3-18 G5-18A, 2505...

  • Page 99: Cab And Covers

    Cab Installation ........... . G5-18A, 2505...

  • Page 100: Operator's Cab And Covers Component Terminology

    LEVER (IF EQUIPPED) (2505) FRAME LEVEL JOYSTICK INDICATOR HORN BUTTON RIGHT HAND CONSOLE STEERING WHEEL INSTRUMENT PANEL PARK BRAKE SWITCH (G5-18A) LSI OVERRIDE SWITCH (2505) TRANSMISSION CONTROL LEVER QUICK ATTACH SWITCH SERVICE BRAKE PEDAL STEERING COLUMN ADJUSTER (IF EQUIPPED) IGNITION SWITCH...

  • Page 101: Operator's Cab

    2. Secure the steering wheel with the nut (2). 3. Press the center button (1) onto the steering wheel. 4. Connect the battery negative (-) cable to the battery negative (-) terminal. 5. Close and secure the engine covers. G5-18A, 2505...

  • Page 102: Steering Column/Valve Replacement

    The steering orbitrol valve is not serviceable and must transmission control lever in (N) NEUTRAL, engage be replaced in its entirety, if defective. the park brake and shut the engine OFF. G5-18A, 2505...

  • Page 103: Throttle Pedal Replacement

    8. Connect the battery negative (-) cable to the battery negative (-) terminal. Note: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 9. Close and secure the engine covers. G5-18A, 2505...
  • Page 104 3. If there is an adjustment needed, return to the cab and adjust the throttle cable (4) so the lever on the fuel injector pump bottoms against the limit-stop just before the throttle pedal bottoms against the limit- stop (5) in the cab. MY2360 G5-18A, 2505...

  • Page 105: Joystick Assembly Replacement

    7. Test the boom joystick functions: 8. Remove the front cover from the cab to expose the Test the boom joystick functions to ensure they match the heater/defroster element (9). control pattern on the joystick decal located inside cab. G5-18A, 2505...

  • Page 106: Cab Removal

    Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact your local JLG distributor with any questions about the suitability or condition of a cab. MY2430 Note: Remove and label cab components as needed before removing the cab from the machine.

  • Page 107: Cab Installation

    13. Carefully examine all cab components, fasteners, 16. When the cab is completely clear of the machine, etc., one last time before engine start-up. Rectify any carefully lower it to the ground. Block up or support faulty conditions. the cab. G5-18A, 2505...
  • Page 108 15.Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level. 16. Close and secure the engine covers. 4-10 G5-18A, 2505...
  • Page 109 Brake Disk Inspection........5-12 G5-18A, 2505...

  • Page 110: Axles, Drive Shafts, Wheels And Tires

    The following illustration identifies the components that are referred to throughout this section. FRONT AXLE ASSEMBLY STEERING CYLINDER (REAR) DRIVE SHAFT STEERING CYLINDER (FRONT) MY2070 REAR AXLE ASSEMBLY G5-18A, 2505...

  • Page 111: General Information

    For internal axle service instructions and detailed specifications contact your local JLG distributor for a copy Note: Use a suitable puller for bearing removal. Clean, of the Dana-Spicer Repair Manual (P/N 31200419).

  • Page 112: Axle Removal

    Note: The wheel and tire assemblies must be re-installed covered container, and label the container as "Used later with the directional tread pattern “arrows” facing in Oil." Dispose of the used oil at an approved recycling the direction of forward travel. facility. G5-18A, 2505...

  • Page 113: Axle Installation

    If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission. G5-18A, 2505...

  • Page 114: Axle Assembly And Drive Shaft Troubleshooting

    1. Tighten capscrews to correct when traveling. assembly incorrectly tightened. torque. 2. Drive shaft universal joint(s) 2. Repair or replace universal worn or damaged. joints as needed. 3. Drive shaft damaged/ 3. Replace drive shaft as needed. unbalanced. G5-18A, 2505...
  • Page 115 1. Tighten fittings. cylinder. 2. Steering cylinder o-rings and/or 2. Replace o-rings and seals. seals worn or damaged. 3. Piston rod seal worn or 3. Replace piston rod seal. damaged. 4. Cylinder tube damaged. 4. Replace cylinder tube. G5-18A, 2505...
  • Page 116 Refer to the appropriate Dana reduced. Repair Manual. 2. Brake (hydraulic) system not 2. Refer to the appropriate Dana operating properly. Repair Manual. 3. Brake piston o-rings and seals 3. Replace o-rings and seals. damaged (leaking). G5-18A, 2505...

  • Page 117: Steering System Purge Procedure

    14. Repeat steps 3-13 to complete this Steering System Repeat this cycle 2 times. Purge Procedure. Note: The rear wheels should be left, the front wheels Note: Align all four wheels forward before driving should be right. machine. G5-18A, 2505...

  • Page 118: Drive Shafts

    5. Close and secure the engine covers. securing the yoke flange (2) to the front axle flange. Note: 7. Remove the four capscrews securing the flange yoke to the rear axle flange. 8. Remove the drive shaft assembly (3). 5-10 G5-18A, 2505...

  • Page 119: Wheels And Tires

    Failure to follow the safety practices could result in death or serious injury. JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not...

  • Page 120: Steering Adjustment

    3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 221 lb-ft (300 Nm). OAH0990 5. Remove machine from supports. 5-12 G5-18A, 2505...
  • Page 121 Towing a Disabled Machine ......... . G5-18A, 2505...

  • Page 122: Transmission Assembly Component Terminology

    The following illustration identifies the components that are referred to throughout this section. HYDROSTATIC TRANSMISSION DIRECTIONAL CONTROL VALVE HYDROSTATIC FILTER FORWARD RELIEF VALVE REVERSE RELIEF VALVE MY1920 G5-18A, 2505...

  • Page 123: Transmission Description

    For cleaning solution onto or near the transmission shift internal transmission service instructions and detailed solenoids and other electrical components. specifications contact your local JLG distributor for a copy of the Rexroth Repair Manual (P/N 31200124). 6.4.1 Transmission Removal More information can be obtained from the serial number plate directly mounted on the transmission.

  • Page 124: Transmission Disassembly

    (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. G5-18A, 2505...

  • Page 125: Transmission Filter Replacement

    7. Place a container or shop rags below the filter housing to contain any spilled hydraulic oil. 8. Using a 15/16 in. (25 mm) wrench, loosen and remove the filter housing (2), filter (3) and spring (4). G5-18A, 2505...

  • Page 126: Towing A Disabled Machine

    15. The parking brake should now be reactivated and the front wheels locked. 16. Remove the blocks from the four tires. 17. Verify that the parking brake works. Note: If the parking brake does not work, check all activation operations step by step. G5-18A, 2505...

  • Page 127: Engine: Perkins 1104D-44T

    Troubleshooting ........... 7-10 G5-18A, 2505...

  • Page 128: Introduction

    The following of the engine. For assistance with comprehensive illustration identifies the components that are referred to engine diagnosis, repair and component replacement, throughout this section. contact your local Perkins Service partner. G5-18A, 2505...
  • Page 129 Engine: Perkins 1104D-44T THERMOSTAT FUEL FILTER AIR CLEANER ASSEMBLY IMPLEMENT PUMP OIL FILTER STARTER TURBOCHARGER ALTERNATOR HYDROSTATIC TRANSMISSION ENGINE MY1900 MOUNT ENGINE MOUNT G5-18A, 2505...

  • Page 130: Engine Serial Number

    (-) terminal. 6. Remove radiator cover and support (1). 7. Slowly turn the coolant overflow bottle cap and allow any pressure to escape. Remove the overflow bottle cap. 8. Place a suitable container beneath the radiator petcock. G5-18A, 2505...

  • Page 131: Engine Electrical System

    Low cost, inferior fuel can lead to poor performance and expensive engine repair. Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance. G5-18A, 2505...

  • Page 132: Fuel/Hydraulic Oil Tank

    Inspection Note: If a leak is suspected between the fuel and hydraulic WARNING oil tank, contact your local JLG distributor. 1. Inspect the fuel/hydraulic oil tank thoroughly for any DO NOT mix gasoline or alcohol with diesel fuel. The cracks, slices, leaks or other damage.

  • Page 133: Engine Exhaust And Air Cleaner System

    13. Unbolt and remove the fan safety shroud. 14. Remove bolts securing the radiator and lift it clear of engine compartment. Refer to section Section 7.4.2, “Radiator/Oil Cooler and Coolant Heater Replacement.”. 15. Mark the engine fan orientation. Remove the engine fan. G5-18A, 2505...

  • Page 134: Engine Installation

    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. G5-18A, 2505...

  • Page 135: Engine Coupler

    2. Bolt on the Flywheel Cover Plate over the coupler steering wheel. and flywheel. Torque bolts to 37 lb-ft (50 Nm). • Keep the transmission in NEUTRAL (N). 3. Reattach the hydrostatic transmission. Follow all guidelines in Section 6.4.3, “Transmission Installation.” G5-18A, 2505...

  • Page 136: Troubleshooting

    59. Broken valve spring pump drive 39. Oil pump worn 18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 19. Incorrect valve timing 41. Pressure relief valve sticking closed 20. Poor compression 42. Broken relief valve spring 7-10 G5-18A, 2505...

  • Page 137: Hydraulic System

    G5-18A ........
  • Page 138 Steering Cylinders......... . . 8-26 8.11.8 Hydraulic Cylinder Torque Specifications ......8-27 G5-18A, 2505...

  • Page 139: Hydraulic Component Terminology

    COMPENSATING CYLINDER HYDRAULIC RESERVOIR and LIFT/LOWER CYLINDER (UNDER BOOM) MAIN CONTROL VALVE EXTEND/RETRACT CYLINDER IMPLEMENT PUMP HYDRAULIC HYDROSTATIC FILTER DRIVE PUMP TILT CYLINDER FRONT AXLE DRIVE MOTOR MY2530 STEERING CYLINDER G5-18A, 2505/2505...

  • Page 140: Safety Information

    Removal and replacement of hoses, tube lines, fittings, Refer to Section 2.2, “Specifications,” for hydraulic etc. usually involves straightforward procedures. When system specifications. removing a hydraulic hose or other component, be aware that o-rings are used throughout the hydraulic system. G5-18A, 2505...

  • Page 141: Hydraulic Pressure Diagnosis

    10% more pressure JLG Pressure Test Kit. The kit is contained in a durable than that which the circuit being checked operates polyethylene carrying case for demanding field service under.

  • Page 142: Main Control Valve Pressure Checking

    DO NOT adjust the main control valve relief pressure below 3625 ± 50 psi (250 bar). To check individual valve section pressures, install a tee and test port between the cylinder being checked and the corresponding valve section on the main control valve. G5-18A, 2505...

  • Page 143: Steering Pressure Checking

    Do NOT adjust any relief settings. The unit is preset at the factory and should not be tampered with. If the proper pressure is not read, the unit may be defective. G5-18A, 2505/2505...

  • Page 144: Hydraulic Schematics

    Hydraulic System HYDRAULIC SCHEMATICS 8.6.1 G5-18A REAR STEERING FRONT AXLE CYLINDER FRONT STEERING CYLINDER IMPLEMENT PUMP SUCTION DRIVE MOTOR RETURN PILOT CONTROLLER RETURN DRIVE PUMP SUCTION FILTER RETURN INCH/STEER VALVE RETURN FILTER RETURN MY2130 G5-18A, 2505...
  • Page 145 Hydraulic System 8.6.2 2505 MY2370 G5-18A, 2505/2505...

  • Page 146: Auxiliary Options

    Hydraulic System 8.6.3 Auxiliary Options TRAILER BRAKE CONNECTION FROM SERVICE BRAKE TO IMPLEMENT VALVE STEERING OPTIONAL TRAILER BRAKE FRONT AUX FROM ITEM #23 (DECOMP VALVE) OPTIONAL SECOND FRONT AUXILIARY -ELECTRIC- MY2140 8-10 G5-18A, 2505...

  • Page 147: Hydraulic Reservoir

    Pump failure usually indicates another problem in the If these conditions cannot be met, the reservoir must be hydraulic system. replaced in its entirety. Contact your local JLG distributor According to pump manufacturer statistics, 90-95 percent should reservoir welding be required.
  • Page 148 Be sure the small holes are to the low pressure side, fit the channel seal and back-up ring. 5. Fit the o-ring into its groove in the mounting flange ® and apply a small amount of Loctite to the lower front face of the body. 8-12 G5-18A, 2505...

  • Page 149: Front Drive Motor

    DO NOT DAMAGE THE SEAL ON For internal service instructions and detailed THE SHAFT. specifications, contact your local JLG distributor. 7. Fit washers and nuts to studs and torque to 65-70 lb-ft (88-95 Nm). 8. Pour a small amount of clean hydraulic fluid into the inlet port and check that the shaft can be turned without undue force.

  • Page 150: Valves And Manifolds

    Lubricate seals and o-rings with clean 8. Remove the four bolts securing the main control hydraulic oil. valve to the frame bracket. 8-14 G5-18A, 2505...

  • Page 151: Service Brake Valve

    7. Inspect for leaks and check the level of the hydraulic MY2160 fluid in the reservoir. Shut the engine OFF. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. G5-18A, 2505/2505 8-15...

  • Page 152: Parking Brake Valve

    2. Use new oiled o-rings as required. Uncap, reattach and secure the three hoses. 3. Check the routing of all hoses for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. 8-16 G5-18A, 2505...

  • Page 153: Brake Test

    The end of the tubing must frame. be below the oil level in the container. 6. Remove the pilot select valve from the machine. Wipe up any hydraulic fluid spillage in, on, near and around the machine. G5-18A, 2505/2505 8-17...
  • Page 154 (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 8-18 G5-18A, 2505...

  • Page 155: Steer Select Valve

    3. Open the engine cover. Allow the system fluids to conduit as required. Tighten all tube and hose clamps. cool. G5-18A, 2505/2505 8-19...
  • Page 156 Refer 8. Attach the steer select valve to the manifold using to Section 8.5.5, “Steering Pressure Checking.” new, oiled o-rings and socket head capscrews. 2. Check each steering mode for proper function. 8-20 G5-18A, 2505...

  • Page 157: Joystick Enable Valve (Ce)

    2. Check joystick enable valve for proper function. replace the manifold or appropriate part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit G5-18A, 2505/2505 8-21...

  • Page 158: Decompression Valve

    TBS00627,” or Section 8.6, “Hydraulic Schematics.” replace the manifold or appropriate part. Often, dirty 2. Check decompression valve for proper function. hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit 8-22 G5-18A, 2505...

  • Page 159: Load Stability Indicator Valve (Ce)

    Often, dirty 2. Check LSI valve for proper function. hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit G5-18A, 2505/2505 8-23...

  • Page 160: Hydraulic Cylinders

    Carefully slide the head gland down along the rod 3. If applicable, remove the counterbalance valve from toward the rod eye end, away from the cylinder the side of the cylinder barrel. barrel. 8-24 G5-18A, 2505...
  • Page 161 8.11.3 Cylinder Cleaning Instructions for tightening guidelines for the piston head and the set screw. 1. Discard all seals, back-up rings and o-rings. Replace with new items from complete seal kits to help ensure proper cylinder function. G5-18A, 2505/2505 8-25...
  • Page 162 9. Close and secure the engine covers. 8.11.7 Steering Cylinders The steering cylinders are attached to each axle center housing. The steer cylinders are covered in the appropriate Dana axle literature. MAH0160 8-26 G5-18A, 2505...
  • Page 163 1400-1500 lb-ft (1898-2034 Nm) Compensating Cylinder Head Gland 300-400 lb-ft (406-542 Nm) Piston 1400-1500 lb-ft (1898-2034 Nm) ® Use Loctite 271 or Equivalent on all Piston Applications ® Use Loctite 243 or Equivalent on all Set Screws G5-18A, 2505/2505 8-27...
  • Page 164 Hydraulic System This Page Intentionally Left Blank 8-28 G5-18A, 2505...
  • Page 165 Oil Pressure Sender ......... 9-24 G5-18A, 2505...

  • Page 166: Electrical System

    The following illustration identifies the components that are referred to throughout this section. BACK-UP ALARM CAB WIRE HARNESS RELAYS FRAME HARNESS FUSE BOX MY2190 BATTERY ENGINE HARNESS CONNECTIONS HORN G5-18A, 2505...

  • Page 167: Specifications

    The relays control the starter (1), ignition (2) and engine preheat (3). MY2230 9.3.2 Cab Compartment Fuses and Relays The cab fuse block (4) is located behind an access panel at the right side of the dash. MY2480 G5-18A, 2505...
  • Page 168 Shifter, Steer, Park Brake F/R Aux, QC Display Joystick Fuel Valve, Cold Start Advance Fuel Pump Back-Up Alarm, Reverse Light Beacon Spare Spare Horn Spare Front Worklights Boom Worklights Rear Worklights Worklights 35 N.O. Back-Up Alarm, Reverse Light 36 N. O. G5-18A, 2505...
  • Page 169 Right Headlight - Low Beam Left Headlight - Low Beam Right Marker Lights - Trailer Light Connection Left Marker Lights - License Light - Trailer Connection Turn Signal Switch Brake Pedal Switch Radio HVAC Switch - AC Flasher Park Brake Switch G5-18A, 2505...

  • Page 170: Electrical System Schematics

    Electrical System ELECTRICAL SYSTEM SCHEMATICS 9.4.1 Cab Harness Schematic "A" SHEET 1 MY2240 G5-18A, 2505...

  • Page 171: Cab Harness Schematic "B

    Electrical System 9.4.2 Cab Harness Schematic "B" SHEET 2 MY2250 G5-18A, 2505...

  • Page 172: Cab Roof Schematic

    Electrical System 9.4.3 Cab Roof Schematic SHEET 3 MY2260 G5-18A, 2505...

  • Page 173: Chassis Schematic

    Electrical System 9.4.4 Chassis Schematic SHEET 4 MY2270 G5-18A, 2505...

  • Page 174: Options Chassis Schematic

    Electrical System 9.4.5 Options Chassis Schematic SHEET 5 MY2280 9-10 G5-18A, 2505...

  • Page 175: Circuit Breakdowns

    Electrical System CIRCUIT BREAKDOWNS 9.5.1 Charge Circuit Breakdown FRAME HARNESS CAB HARNESS MY2290 G5-18A, 2505 9-11...

  • Page 176: Start Circuit Breakdown

    Electrical System 9.5.2 Start Circuit Breakdown FRAME HARNESS CAB HARNESS MY2310 9-12 G5-18A, 2505...

  • Page 177: Constant Power Circuit Breakdown

    Electrical System 9.5.3 Constant Power Circuit Breakdown FRAME HARNESS CAB HARNESS MY2300 G5-18A, 2505 9-13...

  • Page 178: Drive Circuit Breakdown

    Electrical System 9.5.4 Drive Circuit Breakdown CAB HARNESS “A” FRAME HARNESS OPTIONAL FRAME HARNESS CAB HARNESS “B” MY2320 (CE ONLY) 9-14 G5-18A, 2505...

  • Page 179: Engine Start Circuit

    2. If a “whirring” noise is heard but the engine does not turn over, the starter is spinning but not engaging the flywheel. The starter drive or solenoid that pushes G5-18A, 2505 9-15...

  • Page 180: Charging Circuit

    Remove the alternator from the machine. b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper mounting hardware through the alternator mount. DO NOT tighten completely at this time. 9-16 G5-18A, 2505...

  • Page 181: Electrical System Components

    REVERSE position. 4. Connect the battery negative (-) cable at the battery The alarm should sound. negative (-) terminal. Replace a defective or faulty alarm with a new part. 5. Close and secure the battery cover. G5-18A, 2505 9-17...
  • Page 182 Dip Switch Position b. Disassembly DO NOT disassemble the speedometer. The speedometer is not serviceable. Replace speedometer if found to be defective. c. Inspection and Replacement Inspect the speedometer terminals for continuity. Replace speedometer if continuity is not found. 9-18 G5-18A, 2505...

  • Page 183: Window Wiper/Washer

    Replace motor if found to be defective. b. Disassembly DO NOT disassemble the motor. The motor is not c. Inspection and Replacement serviceable. Replace motor if found to be defective. Inspect the motor terminals for continuity. Replace motor if continuity is not found. G5-18A, 2505 9-19...

  • Page 184: Cab Heater And Fan

    Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. For additional information on the removal and installation of the heater box, refer to Section 4.3.8, a. “Heater Assembly Removal.” 9-20 G5-18A, 2505...

  • Page 185: Switches, Solenoids And Senders

    8. Connect the battery negative (-) cable to the battery connectors. negative (-) terminal. 2. Reach up and under the dash to work the ignition 9. Close and secure the battery cover. switch into the ignition switch-mounting hole on the lower right side of the dash. G5-18A, 2505 9-21...

  • Page 186: Dash Switches

    Disconnect odometer, and will display 99,999.9 hours before the fuel level sender wiring harness leads. With the resetting to zero. help of an assistant, touch both harness leads together. 9-22 G5-18A, 2505...

  • Page 187: Coolant Temperature Sender

    1. Thread the coolant temperature sender into the negative (-) terminal. engine housing snugly, then connect the sender connector to the wiring harness connector. 2. Connect the battery negative (-) cable to the battery negative (-) terminal. G5-18A, 2505 9-23...

  • Page 188: Oil Pressure Sender

    Note: The Load Stability Indicator is NOT a serviceable sender lead. item. The Load Stability Indicator must be inspected and/ 4. The oil pressure sender is threaded into the engine. or replaced by a qualified dealer or JLG technician Remove the sender. 9.11.9 Load Stability Sensor b.
  • Page 189 6. Plug the electrical connector into the sensor beginning with step 1. assembly. 7. Connect the negative (-) battery cable to the negative (-) battery terminal. 8. Close and secure engine covers. G5-18A, 2505 9-25...
  • Page 190 Electrical System This Page Intentionally Left Blank 9-26 G5-18A, 2505...
  • Page 192 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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