Jlg G5-18A Service Manual Bedienungsanleitung

An Oshkosh Corporation CompanyService ManualModelsG5-18A & 2505HAgrovector25.5S/N 0160053000 & After including0160051045, 0160051047, 01600510

Safety Practices1-2G5-18A, 2505H, 25.51.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair procedures.

Hydraulic System8-10 G5-18A, 2505H, 25.58.8 HYDRAULIC RESERVOIRThe hydraulic reservoir and fuel tank are part of the frame. For this reason, neither t

8-11G5-18A, 2505H, 25.5Hydraulic System8.9 HYDRAULIC SYSTEM PUMP8.9.1 Implement Pump Removal1. Park the machine on a firm, level surface, fully retrac

Hydraulic System8-12 G5-18A, 2505H, 25.58.10 FRONT DRIVE MOTORFor internal service instructions and detailed specifications, contact the local JLG Dea

8-13G5-18A, 2505H, 25.5Hydraulic System8.11 CONTROL VALVES8.11.1 Main Control ValveThe main control valve is mounted on the rear of the machine behind

Hydraulic System8-14 G5-18A, 2505H, 25.5e. Main Control Valve Assembly Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ens

8-15G5-18A, 2505H, 25.5Hydraulic System6. Label, disconnect and cap the hydraulic hoses connected to the service brake valve (1). Cap all fittings and

Hydraulic System8-16 G5-18A, 2505H, 25.53. DO NOT open the brake bleeder without holding the tubing firmly on the bleeder. There is pressure at the br

8-17G5-18A, 2505H, 25.5Hydraulic System4. Properly connect the battery.5. Start the engine and run at approximately one-third to one-half throttle for

Hydraulic System8-18 G5-18A, 2505H, 25.56. Inspect the hand brake valve and connections for leaks, and check the level of the hydraulic fluid in the r

8-19G5-18A, 2505H, 25.5Hydraulic Systemc. Pilot Select Valve Installation1. Attach the pilot select manifold valve to the mounting plate on the frame

1-3G5-18A, 2505H, 25.5Safety Practices1.6 SAFETY INSTRUCTIONSFollowing are general safety statements to consider BEFORE performing maintenance procedu

Hydraulic System8-20 G5-18A, 2505H, 25.54. Inspect the cartridge for proper operation. Check by shifting the spool to ensure that it is functioning pr

8-21G5-18A, 2505H, 25.5Hydraulic System8.11.8 Priority Valve.The priority valve is attached at the engine pod frame directly beside the engine.Verify

Hydraulic System8-22 G5-18A, 2505H, 25.58.11.9 Steer Select ValveThe steer select valve is attached to inside the frame near the front drive motor.Ver

8-23G5-18A, 2505H, 25.5Hydraulic System8. Close and secure the battery and engine covers.9. Remove the Do Not Operate Tags from both the ignition key

Hydraulic System8-24 G5-18A, 2505H, 25.56. Install the solenoid valve and cartridge in the quick attach valve housing.c. Quick Attach Installation1. A

8-25G5-18A, 2505H, 25.5Hydraulic System4. Inspect the solenoid cartridge for proper operation. Check by shifting the spool to ensure that it is functi

Hydraulic System8-26 G5-18A, 2505H, 25.58.12 HYDRAULIC CYLINDERS8.12.1 General Cylinder Removal Instructions1. Park the machine on a firm, level surfa

8-27G5-18A, 2505H, 25.5Hydraulic System6. Carefully pull the rod assembly along with the head gland out of the cylinder barrel.7. Fasten the rod end i

Hydraulic System8-28 G5-18A, 2505H, 25.5Note: The Crowd cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the

8-29G5-18A, 2505H, 25.5Hydraulic System8.12.8 Hydraulic Cylinder Torque Specificationsa. Lift Lower Cylinderb. Extend/Retract Cylinderc. Tilt Cylinder

Safety Practices1-4G5-18A, 2505H, 25.51.6.4 Operational HazardsENGINE: Stop the engine before performing any service unless specifically instructed ot

Hydraulic System8-30 G5-18A, 2505H, 25.5This Page Intentionally Left Blank

9-1G5-18A, 2505H, 25.5Section 9Electrical SystemPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . .

Electrical System9-2 G5-18A, 2505H, 25.59.12 Hand Held Analyzer (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3G5-18A, 2505H, 25.5Electrical System9.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information presented in t

Electrical System9-4 G5-18A, 2505H, 25.59.2 SAFETY INFORMATION9.3 FUSES AND RELAYS9.3.1 Engine Compartment Relays and FusesThere are seven relays and

9-5G5-18A, 2505H, 25.5Electrical System9.3.3 Power Distribution ModuleFuse/Relay Function Amp RatingF1 Drive Cut-Out 15F2 Auxiliary Circuit 15F3 Displ

Electrical System9-6 G5-18A, 2505H, 25.59.3.4 Cab Fuses / RelaysFuse/Relay Function Amp RatingF21 Hazard 10F22 LSI Over Ride 5F23 Dome Light 10F24 An

9-7G5-18A, 2505H, 25.5Electrical System9.4 ELECTRICAL SYSTEM SCHEMATICSa. Cab Schematic "A"ABCD87654321DCAB12345678BSFIHLPGMFRONT REARMMFLAS

Electrical System9-8 G5-18A, 2505H, 25.5b. Cab Schematic "B"ABCD87654321DCAB12345678PWRLOWMED.HIACACFANHIGNDLOWMEDACMNA MACHINES ONLYCE + AU

9-9G5-18A, 2505H, 25.5Electrical Systemc. Cab Roof, AC and Miscellaneous Schematic ABCD87654321DCAB12345678CAN LCAN HSENSOR VE+SENSOR 2 -VESENSOR 1 -V

2-1G5-18A, 2505H, 25.5Section 2General Information and SpecificationsContentsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Information . . .

Electrical System9-10 G5-18A, 2505H, 25.5d. Base Frame Schematic "A"ABCD87654321DCAB12345678873087a8586OUTGNDLEVELFUELPWR873087a8586873087a8

9-11G5-18A, 2505H, 25.5Electrical Systeme. Base Frame Schematic "B"ABCD87654321DCAB12345678VccVoutGND873087a8586IGN PWR (7-33V)IGN PWR (7-33

Electrical System9-12 G5-18A, 2505H, 25.5f. Engine SchematicABCD87654321DCAB12345678COOLANT LEVELCOOLANT LEVELWATER/FUELWATER/FUELDIAGNOSTICMRL148-1 P

9-13G5-18A, 2505H, 25.5Electrical Systemg. Option Frame SchematicABCD87654321DCAB12345678LOWHIGHSIDETURNLOWHIGHSIDETURNSTOPTURNBACKTAI LSTOPTURNBACKTA

Electrical System9-14 G5-18A, 2505H, 25.5h. Cables and Boom SchematicABCD87654321DCAB12345678MEC58 PRE WIRED ON ENGINE TO RL148-2 SHEET 7CASE GROUNDFR

9-15G5-18A, 2505H, 25.5Electrical System9.5 ENGINE START CIRCUIT9.5.1 StarterThe starter (1) is located on the right side of the engine attached to th

Electrical System9-16 G5-18A, 2505H, 25.516. Remove the top bolt securing the starter to the engine.Note: Use a 13mm deep well socket on a 6 in exten

9-17G5-18A, 2505H, 25.5Electrical System9.6 CHARGING CIRCUITBefore using a battery charger, an attempt can be made to recharge the battery by jump-sta

Electrical System9-18 G5-18A, 2505H, 25.59.7 ELECTRICAL SYSTEM COMPONENTS9.7.1 Back-up AlarmThe back-up alarm is located at the rear of the machine.Wh

9-19G5-18A, 2505H, 25.5Electrical System9.8 WINDOW WIPER/WASHER 9.8.1 Windshield Wiper Motora. RemovalNote: It may be necessary to remove several hyd

General Information and Specifications2-2 G5-18A, 2505H, 25.52.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiating service

Electrical System9-20 G5-18A, 2505H, 25.59.8.2 Rear Window or Roof Wiper Motor (if equipped)a. Removal1. Park the machine on a firm, level surface, le

9-21G5-18A, 2505H, 25.5Electrical System7. Rotate the washer reservoir, label and remove the cab harness connectors from the washer reservoir connecto

Electrical System9-22 G5-18A, 2505H, 25.5c. Installation and Testing1. Check that the variable speed fan control is in the OFF position.2. If installi

9-23G5-18A, 2505H, 25.5Electrical Systemd. Ignition Switch Installation1. Connect the ignition key switch to the cab harness connectors.2. Reach up an

Electrical System9-24 G5-18A, 2505H, 25.55. Check that the ignition terminal has current and that the fuse in the fuse panel is not blown.6. Check for

9-25G5-18A, 2505H, 25.5Electrical System9.10.6 Oil Pressure SenderThe oil pressure sender (3) is located on the engine near the oil filter.a. Oil Pres

Electrical System9-26 G5-18A, 2505H, 25.59.11 LOAD STABILITY INDICATOR SYSTEM (2505H & 25.5) The LSI (1) provides visual and audible indication of

9-27G5-18A, 2505H, 25.5Electrical Systema. LSI Axle Sensor Removal1. Remove any fork carrier or attachment from the machine.2. Park the machine on a f

Electrical System9-28 G5-18A, 2505H, 25.5b. LSI Sensor Boom Installation1. Mount the LSI sensor to the side of the first boom section with the previou

9-29G5-18A, 2505H, 25.5Electrical System9.11.4 LSI System Calibrationa. Standard CalibrationTo calibrate the LSI, certain conditions must be met:• The

2-3G5-18A, 2505H, 25.5General Information and Specifications2.2 TORQUE CHARTS2.2.1 SAE Fastener Torque ChartREFERENCE JLG ANEROBIC THREAD LOCKING COMP

Electrical System9-30 G5-18A, 2505H, 25.5b. Field CalibrationTo calibrate the LSI, certain conditions must be met:• The sensor must be installed accor

9-31G5-18A, 2505H, 25.5Electrical System8. Press the SYSTEM CHECK button on the LSI display and release. As the calibration point is recorded, buzzer

Electrical System9-32 G5-18A, 2505H, 25.59.11.6 500 Hour - LSI UGM Calibration Check1. The machine must be on a level surface, wheels steered straight

9-33G5-18A, 2505H, 25.5Electrical System9.12.2 Analyzer Software - Version 1.0MENU:HELP : PRESS ENTERHELP :(001)EVERYTHING OKLOG:(xxx)x : xxxxxxxxxxxM

Electrical System9-34 G5-18A, 2505H, 25.59.13 DIAGNOSTIC TROUBLE CODES (DTC) ON GROUND MODULE9.13.1 Gauge Fault Code DisplayFault codes will appear in

9-35G5-18A, 2505H, 25.5Electrical SystemLift Enable Valve - Short to Battery33161The module is detecting short to B+Deactivate Lift Enable OutputLatch

Electrical System9-36 G5-18A, 2505H, 25.5Conflicting Drive Direction Signals462This fault can only be present if the machine is configured for the CE

9-37G5-18A, 2505H, 25.5Electrical SystemLSI Cutout Output - Short to Battery or Open Circuit8518LSI module detects condition and OMD reading is 100%Ma

Electrical System9-38 G5-18A, 2505H, 25.5Seat Switch Disagreement23119This fault can only occur if the machine detects itself to be a Tier 4 configura

9-39G5-18A, 2505H, 25.5Electrical System9.14 ENGINE DIAGNOSTIC TROUBLE CODE EMR49.14.1 Gauge Fault Code DisplayFault CodesSPN CodesFMI CodesDeutz Desc

General Information and Specifications2-4 G5-18A, 2505H, 25.52.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress AreaClamp LoadI

Electrical System9-40 G5-18A, 2505H, 25.575 523913 4Sensor error glow plug control diagnostic line voltage; signal range check low76 523914 5 Glow plu

9-41G5-18A, 2505H, 25.5Electrical System127 3224 2DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream cat; DPF-system downstream cat

Electrical System9-42 G5-18A, 2505H, 25.5292 523777 9 Passive Time out Error of CAN-Receive-Frame TSC1TE; Set point293 523778 9 Active Time out Error

9-43G5-18A, 2505H, 25.5Electrical System457 975 3 Fan actuator (PWM output); short circuit to battery458 975 4 Fan actuator (PWM output); short circui

Electrical System9-44 G5-18A, 2505H, 25.5547 729 12 Cold start aid relay; over temperature error559 523895 13Check of missing injector adjustment valu

9-45G5-18A, 2505H, 25.5Electrical System609 1328 12 Too many recognized misfires in cylinder 6 (in firing order)610 1322 12 Too many recognized misfir

Electrical System9-46 G5-18A, 2505H, 25.5765 523920 0Physical range check high for exhaust gas back pressure burner; shut off regeneration768 523920 1

9-47G5-18A, 2505H, 25.5Electrical System846 523452 2 Multiple Stage Switch engine torque limitation curve; plausibility error849 1176 3 Sensor error p

Electrical System9-48 G5-18A, 2505H, 25.5926 523720 8 Urea supply module heater temperature; duty cycle in invalid range927 523721 11 Urea supply modu

9-49G5-18A, 2505H, 25.5Electrical System995 105 4 Sensor error charged air temperature; signal range check low996 105 0 High charged air cooler temper

2-5G5-18A, 2505H, 25.5General Information and Specifications2.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress AreaClamp LoadSe

Electrical System9-50 G5-18A, 2505H, 25.51068 1180 4Sensor error exhaust gas temperature upstream turbine; signal range check low1069 4360 0 Physical

9-51G5-18A, 2505H, 25.5Electrical System1121 4375 4 Urea pump motor; short circuit to ground1122 4334 0 Physical range check high for Urea Pump Pressu

Electrical System9-52 G5-18A, 2505H, 25.51216 523914 5 Glow plug control release line; short circuit error1217 523914 11 Glow plug control; internal e

9-53G5-18A, 2505H, 25.5Electrical System1265 524017 12 Spark plug control unit (SPCU); electrical fault1266 524017 12 Spark plug control unit (SPCU);

Electrical System9-54 G5-18A, 2505H, 25.51334 524001 3 Injector 8 (in firing order); short circuit1335 524000 4 High side to low side short circuit in

9-55G5-18A, 2505H, 25.5Electrical System1410 3248 1Physical range check low for exhaust gas temperature particulate filter downstream; warning1411 118

Electrical System9-56 G5-18A, 2505H, 25.51462 1180 0 Exhaust gas temperature upstream turbine; warning threshold exceeded1463 1180 1 Exhaust gas tempe

9-57G5-18A, 2505H, 25.5Electrical System1523 2659 2 Exhaust gas recirculation AGS sensor; plausibility error1524 2659 0 Physical range check high for

Electrical System9-58 G5-18A, 2505H, 25.51672 524118 9 Time out error of CAN-Receive-Frame ComRxCMl1673 524119 9 Time out error of CAN-Receive-Frame C

General Information and Specifications2-6 G5-18A, 2505H, 25.52.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress AreaClamp LoadS

JLG Worldwide LocationsAn Oshkosh Corporation Companywww.jlg.com31200926JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-4

2-7G5-18A, 2505H, 25.5General Information and Specifications2.2.2 Metric Fastener Torque ChartSize PITCHTensileStressAreaClampLoadTorque(Dry or Loctit

General Information and Specifications2-8 G5-18A, 2505H, 25.52.2.2 Metric Fastener Torque Chart (Continued)Size PITCHTensileStressAreaClampLoadK = 0.2

2-9G5-18A, 2505H, 25.5General Information and Specifications2.2.2 Metric Fastener Torque Chart (Continued)Size PITCHTensileStressAreaClamp LoadSee Not

General Information and Specifications2-10 G5-18A, 2505H, 25.52.2.3 Hydraulic Hose Torque ChartNote: By definition the “Flats Method” will contain so

2-11G5-18A, 2505H, 25.5General Information and Specifications2.3 SPECIFICATIONS2.3.1 Travel Speed2.3.2 Hydraulic Cylinder Performance SpecificationsNo

General Information and Specifications2-12 G5-18A, 2505H, 25.52.3.4 Engine Performance Specifications2.3.5 TiresNote: Standard wheel lug nut torque i

2-13G5-18A, 2505H, 25.5General Information and Specifications2.4 FLUIDS, LUBRICANTS AND CAPACITIES2.4.1 Fluidsa. If Equipped for ULSNote: Friction Mo

General Information and Specifications2-14 G5-18A, 2505H, 25.5b. If Equipped for LSNote: Friction Modifier required for axle differentials, refer to

2-15G5-18A, 2505H, 25.5General Information and Specifications2.4.2 CapacitiesEngine Crankcase OilCapacity w/Filter Change 9.6 qt (9,1 L)Fuel TankCapac

General Information and Specifications2-16 G5-18A, 2505H, 25.52.5 MAINTENANCE SCHEDULE2.5.1 10,1st 50 & 50 Hour Maintenance ScheduleOAH2341Check W

2-17G5-18A, 2505H, 25.5General Information and Specifications2.5.2 1st 250, 250 & 500 Hour Maintenance ScheduleOAH22112501stChange AxleDifferentia

EFFECTIVITY PAGE31200926 G5-18A, 2505H, 25.5aMay 9, 2013 - A - Original Issue Of Manual

General Information and Specifications2-18 G5-18A, 2505H, 25.52.5.3 1000 & 1500 Hour Maintenance ScheduleOAH22201000EVERYChange AxleDifferential O

2-19G5-18A, 2505H, 25.5General Information and Specifications2.6 LUBRICATION SCHEDULE2.6.1 250 Hour Lubrication ScheduleOAL1980250EVERY

General Information and Specifications2-20 G5-18A, 2505H, 25.5This Page Intentionally Left Blank

3-1G5-18A, 2505H, 25.5Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-2 G5-18A, 2505H, 25.53.1 BOOM SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this sect

3-3G5-18A, 2505H, 25.5Boom3.2 SAFETY INFORMATION3.3 TWO SECTION BOOM SYSTEM3.3.1 Boom System DescriptionBoom operates via an interchange among electri

Boom3-4 G5-18A, 2505H, 25.510. Lower the boom to a position that allows for the removal of rod end pin (3) connecting lift/lower cylinder to boom.11.

3-5G5-18A, 2505H, 25.5Boom10. Uncap and reconnect extend/retract cylinder fittings and plugs to extend/retract cylinder tubes and tighten until wrench

Boom3-6 G5-18A, 2505H, 25.516. Pull second boom section out of first boom section approximately 6 in to 8 in (15 cm to 20 cm).17. Pull tilt hoses and

3-7G5-18A, 2505H, 25.5Boom12. Start engine and operate all boom functions several times to bleed any air out of hydraulic system. Check for fluid leak

READ THIS FIRST G5-18A, 2505H, 25.5 31200926bModificationsModifications to this machine may affect compliance with Industry Standards and/or Governmen

Boom3-8 G5-18A, 2505H, 25.511. Loosen and remove hose clamps and cover plate (14) from rear of boom assembly.12. Remove any miscellaneous parts such a

3-9G5-18A, 2505H, 25.5Boom3.4.6 Extend/Retract Cylinder Installation1. Carefully install the extend/retract cylinder into rear of boom using a suitabl

Boom3-10 G5-18A, 2505H, 25.5• The number of shims can vary at each shim point. • The bottom wear pads must be shimmed equally on each side.• Maintain

3-11G5-18A, 2505H, 25.5Boom3.6.2 Quick Attach Assembly Installation 1. Line up quick attach assembly between mounts on boom head. Quick attach assembl

Boom3-12 G5-18A, 2505H, 25.53.8 BOOM PROP (IF EQUIPPED)3.8.1 Prop Installation 1. Park the machine on a firm, level surface. Place the transmission co

3-13G5-18A, 2505H, 25.5Boom3.9 EMERGENCY BOOM LOWERING PROCEDURE3.9.1 Equipment and Supplies RequiredAuxiliary Hydraulic Power Supply:• Portable hydra

Boom3-14 G5-18A, 2505H, 25.53.9.2 Lowering Procedurea. Retract the boom as follows:1. Place a suitable receptacle under hose connections.2. Locate the

3-15G5-18A, 2505H, 25.5Boom3.10 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during opera

Boom3-16 G5-18A, 2505H, 25.56. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.5.2, “

4-1G5-18A, 2505H, 25.5Section 4CabContentsPARAGRAPH TITLE PAGE4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . .

SECTION CONTENTSSection Subject PageG5-18A, 2505H, 25.5iSection 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab4-2 G5-18A, 2505H, 25.54.1 OPERATOR CAB COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this sect

4-3G5-18A, 2505H, 25.5Cab4.2 SAFETY INFORMATION4.3 OPERATOR CAB4.3.1 Operator Cab DescriptionThe welded metal cab features a modular design, allowing

Cab4-4 G5-18A, 2505H, 25.54.4.2 Steering Column/Valve Replacementa. Steering Column and Valve Removal1. Park machine on a hard, level surface. 2. Full

4-5G5-18A, 2505H, 25.5Cab4.4.3 Brake Pedal and Valvea. Brake Valve RemovalRefer to Section 8.11.2, a. “Service Brake Valve Removal,” for removal infor

Cab4-6 G5-18A, 2505H, 25.54.4.4 Accelerator Pedal Replacementa. Accelerator Pedal Removal1. Park machine on a hard, level surface. 2. Fully retract bo

4-7G5-18A, 2505H, 25.5Cab4.4.5 Joystick Replacementa. Joystick Removal1. Park machine on a hard, level surface. 2. Fully retract boom, lower boom, pla

Cab4-8 G5-18A, 2505H, 25.54.4.8 Heater/Air Conditioning System (If Equipped)a. Removal1. Park machine on a hard, level surface. 2. Fully retract boom,

4-9G5-18A, 2505H, 25.5Cab4.4.10 Air Filter System (If Equipped)1. Park machine on a hard, level surface. 2. Fully retract boom, lower boom, place tran

Cab4-10 G5-18A, 2505H, 25.54.5 CAB REMOVALNote: To help ensure safety and optimum performance, replace cab if it is damaged. Refer to appropriate par

4-11G5-18A, 2505H, 25.5Cab4.6 CAB INSTALLATION1. Block all four wheels to help prevent machine from moving. Assure that there is sufficient overhead a

Section Subject PageiiG5-18A, 2505H, 25.5Section 5Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab4-12 G5-18A, 2505H, 25.5This Page Intentionally Left Blank

5-1G5-18A, 2505H, 25.5Section 5Axles, Drive Shafts, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Component Terminology

Axles, Drive Shafts, Wheels and Tires5-2 G5-18A, 2505H, 25.55.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the safety, operation a

5-3G5-18A, 2505H, 25.5Axles, Drive Shafts, Wheels and Tires5.2 SAFETY INFORMATION5.3 GENERAL INFORMATIONBefore performing any inspection, maintenance

Axles, Drive Shafts, Wheels and Tires5-4 G5-18A, 2505H, 25.55.4.5 Axle RemovalThe front and rear axle assemblies differ in that the front axle assembl

5-5G5-18A, 2505H, 25.5Axles, Drive Shafts, Wheels and Tires5.4.6 Axle Installation1. Before proceeding, ensure that the machine will remain in place d

Axles, Drive Shafts, Wheels and Tires5-6 G5-18A, 2505H, 25.55.4.7 Axle Assembly and Drive Shaft TroubleshootingProblem Possible Causes Remedy1. Excess

5-7G5-18A, 2505H, 25.5Axles, Drive Shafts, Wheels and Tires4. Oil leaking from axle (differential housing and/or axle housings).1. Drain plugs loose a

Axles, Drive Shafts, Wheels and Tires5-8 G5-18A, 2505H, 25.57. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. (Refer to Sectio

5-9G5-18A, 2505H, 25.5Axles, Drive Shafts, Wheels and Tires5.5 DRIVE SHAFTS5.5.1 Drive Shaft InspectionWhenever servicing the machine, conduct a visua

Section Subject PageiiiG5-18A, 2505H, 25.5Section 9Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axles, Drive Shafts, Wheels and Tires5-10 G5-18A, 2505H, 25.55.6 WHEELS AND TIRESIt is recommended that a replacement tire to be the same size, ply an

5-11G5-18A, 2505H, 25.5Axles, Drive Shafts, Wheels and Tires5.6.2 Installing Wheel and Tire Assembly onto MachineNote: The wheel and tire assemblies

Axles, Drive Shafts, Wheels and Tires5-12 G5-18A, 2505H, 25.55.9 TOWING A DISABLED MACHINETowing a disabled machine should only be attempted after exh

5-13G5-18A, 2505H, 25.5Axles, Drive Shafts, Wheels and Tires5.9.2 Towing Procedure1. Securely block all four wheels.2. Loosen shuttle valve (1) on hyd

Axles, Drive Shafts, Wheels and Tires5-14 G5-18A, 2505H, 25.5This Page Intentionally Left Blank

6-1G5-18A, 2505H, 25.5Section 6Transmission ContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . .

Transmission6-2 G5-18A, 2505H, 25.56.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information pres

6-3G5-18A, 2505H, 25.5Transmission6.2 SAFETY INFORMATION6.3 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specificat

Transmission6-4 G5-18A, 2505H, 25.515. Vertically secure transmission and implement pump with a lifting strap or chain. Use a suitable hoist or overhe

7-1G5-18A, 2505H, 25.5Section 7EngineContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section Subject PageivG5-18A, 2505H, 25.5

Engine7-2 G5-18A, 2505H, 25.57.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written for worldwide use. In territories where legal

7-3G5-18A, 2505H, 25.5Engine7.1.4 Component TerminologyTo understand safety, operation and maintenance information presented in this section, it is ne

Engine7-4 G5-18A, 2505H, 25.57.2 ENGINE COOLING SYSTEM7.2.1 Surge Tank CapA 14.5 psi (1,0 Bar) cap is used on the surge tank. An incorrect or malfu

7-5G5-18A, 2505H, 25.5Engine17. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radiator petcoc

Engine7-6 G5-18A, 2505H, 25.5Note: Retain the key located on the fan motor shaft.5. Turn the fan motor/guard over to access the two fan motor mountin

7-7G5-18A, 2505H, 25.5Engine28. Install and secure the battery cover.29. Remove previously installed boom support.30. Remove the Do Not Operate Tags f

Engine7-8 G5-18A, 2505H, 25.51. Have a dry chemical (Class B) fire extinguisher near the work area.2. Depending on which side of the tank is contamina

7-9G5-18A, 2505H, 25.5Engine7.5.2 Exhaust System InstallationNote: Keep all clamps loosened until entire exhaust system is in place.Note: Replace th

Engine7-10 G5-18A, 2505H, 25.57.6 AIR CLEANER ASSEMBLYNote: Refer to the machine Operation & Safety Manual for the correct element change procedu

7-11G5-18A, 2505H, 25.5Engine7.7 ENGINE REPLACEMENT 7.7.1 Engine Removal1. Park the machine on a firm, level surface, fully retract the boom, lower

1-1G5-18A, 2505H, 25.5Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine7-12 G5-18A, 2505H, 25.57.7.2 Engine Disassembly, Inspection and ServiceEngine disassembly, internal inspection, service, repair and assembly pr

8-1G5-18A, 2505H, 25.5Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . .

Hydraulic System8-2 G5-18A, 2505H, 25.58.12 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3G5-18A, 2505H, 25.5Hydraulic System8.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information presented in this

Hydraulic System8-4 G5-18A, 2505H, 25.58.2 SAFETY INFORMATION8.3 GENERAL INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The tem

8-5G5-18A, 2505H, 25.5Hydraulic SystemNEVER replace a hydraulic hose or other component with a part not specifically designed for this machine. Use on

Hydraulic System8-6 G5-18A, 2505H, 25.58.6.3 Charge Pressure Checking1. Attach a pressure gauge to the test port (3) on the hydrostatic transmission (

8-7G5-18A, 2505H, 25.5Hydraulic System8.7 HYDRAULIC SCHEMATICABCDEFGH12345677654321baDRIVEDRIVEDRIVEPUMPPUMPIMPLEMENTMOTORVALVE, PARKVALVE,PARKBRAKE R

Hydraulic System8-8 G5-18A, 2505H, 25.5G5-18AABCDEFGH12345678GHEFCDAB876543213B3A3B3AAUXILIARY OPTIONSAUXILIARY OPTIONS3B 3AREAR AUXREAR AUXFRONTAUXFR

8-9G5-18A, 2505H, 25.5Hydraulic System2505H & 25.5ABCDEFGH12345678GHEFCDAB876543213B3A3B3AAUXILIARY OPTIONSAUXILIARY OPTIONSCFEFPLSTRAILER BRAKE C