Jlg G5-18A Service Manual Bedienungsanleitung

An Oshkosh Truck Corporation CompanyService ManualModelsG5-18A&250531200361OriginalFebruary 28, 2008

Safety Practices1.4 G5-18A/25051.6.3 General HazardsSOLVENTS: Only use approved solvents that are known to be safe for use.HOUSEKEEPING: Keep the work

Hydraulic System8.26 G5-18A/25058.11.8 Hydraulic Cylinder Torque SpecificationsDescriptionExtend/Retract Cylinder Set Screw 60-69 lb-ft (81-94 Nm)All

9.1G5-18A/2505Section 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . .

Electrical System9.2 G5-18A/25059.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information presented in this sec

9.3G5-18A/2505Electrical System9.2 SPECIFICATIONSElectrical system specifications are listed in Section 2, “General Information and Specifications.”9.

Electrical System9.4 G5-18A/25059.3.3 Power Distribution ModuleFuse/Relay Function Amp RatingF1 Shifter, Steer, Park Brake 15F2 F/R Aux, QC 15F3 Displ

9.5G5-18A/2505Electrical System9.3.4 Cab Fuses / RelaysFuse/Relay Function Amp RatingF21 Hazard 10F22 LSI Over Ride 5F23 Dome Light - Radio 10F24 Spee

Electrical System9.6 G5-18A/25059.4 ELECTRICAL SYSTEM SCHEMATICS9.4.1 Cab Harness Schematic "A"MY2240SHEET 1

9.7G5-18A/2505Electrical System9.4.2 Cab Harness Schematic "B"MY2250CE ONLYSHEET 2

Electrical System9.8 G5-18A/25059.4.3 Cab Roof Schematic SHEET 3MY2260

9.9G5-18A/2505Electrical System9.4.4 Chassis SchematicMY2270SHEET 4

2.1G5-18A/2505Section 2General Information and SpecificationsContentsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Information . . . . . . .

Electrical System9.10 G5-18A/25059.4.5 Options Chassis SchematicMY2280SHEET 5

9.11G5-18A/2505Electrical System9.5 CIRCUIT BREAKDOWNS9.5.1 Charge Circuit BreakdownMY2290CAB HARNESSFRAME HARNESS

Electrical System9.12 G5-18A/25059.5.2 Start Circuit BreakdownMY2310CAB HARNESSFRAME HARNESS

9.13G5-18A/2505Electrical System9.5.3 Constant Power Circuit BreakdownMY2300CAB HARNESSFRAME HARNESS

Electrical System9.14 G5-18A/25059.5.4 Drive Circuit BreakdownMY2320OPTIONAL FRAME HARNESSCAB HARNESS B1234FRAME HARNESSCAB HARNESS A1234(CE ONLY)

9.15G5-18A/2505Electrical System9.6 ENGINE START CIRCUIT9.6.1 StarterThe starter (1) is located on the left side of the engine attached to the bell ho

Electrical System9.16 G5-18A/2505Note: DO NOT disassemble the starter. The starter is not serviceable and must be replaced in its entirety, if defect

9.17G5-18A/2505Electrical System2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounting

Electrical System9.18 G5-18A/25059.8.3 Speedometer (CE)The speedometer (1) is located at the top right corner of the cab A pillar directly below the L

9.19G5-18A/2505Electrical System9.9 WINDOW WIPER/WASHER 9.9.1 Windshield Wiper Motora. RemovalNote: It may be necessary to remove several hydraulic h

General Information and Specifications2.2 G5-18A/25052.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiating service inquiri

Electrical System9.20 G5-18A/2505c. Inspection and ReplacementInspect the motor terminals for continuity. Replace motor if continuity is not found.d.

9.21G5-18A/2505Electrical SystemThe cab heater controls are located to the right of the seat. The control panel consists of a variable speed fan contr

Electrical System9.22 G5-18A/25053. Align the ignition switch so that when it is in the OFF position, the key slot is positioned vertically (straight

9.23G5-18A/2505Electrical SystemIf trouble is suspected, time the hourmeter for six minutes to verify that a tenth of an hour has been recorded.The ho

Electrical System9.24 G5-18A/25055. Start the engine. If the engine starts, the fuel shutoff solenoid is functioning. If the engine fails to start, th

9.25G5-18A/2505Electrical Systema. Load Stability Sensor Removal1. Open engine covers. Allow engine to cool.2. Disconnect the negative (-) battery cab

Electrical System9.26 G5-18A/2505This Page Intentionally Left Blank

An Oshkosh Truck Corporation CompanyJLG Worldwide LocationsJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPh

2.3G5-18A/2505General Information and Specifications2.2 TORQUES2.2.1 ASTM Fastener Torque Chart (English)VALUES FOR ZINC PLATED / YELLOW CHROMATE FAST

General Information and Specifications2.4 G5-18A/25052.2.2 ASTM Fastener Torque Chart (Metric) VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS

2.5G5-18A/2505General Information and Specifications2.2.3 Metric Fastener Torque ChartVALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLYCLASS 8.8

General Information and Specifications2.6 G5-18A/25052.3 SPECIFICATIONS2.3.1 Travel Speed 2.3.2 Hydraulic Cylinder Performance SpecificationsNote: Ma

2.7G5-18A/2505General Information and Specifications2.3.4 Engine Performance Specifications2.3.5 TiresNote: Standard wheel lug nut torque is 210-230

General Information and Specifications2.8 G5-18A/25052.4 FLUIDS, LUBRICANTS AND CAPACITIESEngine Crankcase OilCapacity w/Filter Change 9.6 quarts (9,0

2.9G5-18A/2505General Information and Specifications2.5 MAINTENANCE SCHEDULES2.5.1 10,1st 50 & 50 Hour Maintenance Schedule2.5.2 1st 250, 250, 500

General Information and Specifications2.10 G5-18A/25052.6 LUBRICATION SCHEDULE2.6.1 250 Hour Lubrication ScheduleMY2580EVERY250MYSTIK TETRIMOLY(NLGI 2

3.1G5-18A/2505Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.2 G5-18A/25053.1 BOOM SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this section, it

3.3G5-18A/2505Boom3.2 BOOM SYSTEM - TWO SECTION BOOM 3.2.1 Boom System DescriptionThe boom operates via an interchange among the electrical, hydraulic

Boom3.4 G5-18A/250516. Pull the second boom section halfway out of the first boom section, reposition the sling, balancing the second boom section and

3.5G5-18A/2505Boom3.3.3 First Boom Section InstallationNote: Light lubrication of the boom wear surfaces with a factory authorized grease is recommen

Boom3.6 G5-18A/25053. Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be opera

3.7G5-18A/2505Boom8. Inspect the boom and welds. Consult your local JLG distributor if structural damage is detected.9. Inspect hoses, hardware, wear

Boom3.8 G5-18A/25056. With the sling still in place, install the rod end of the lift/lower cylinder, pin and lock bolt. Apply Loctite® #242 and torque

3.9G5-18A/2505Boom10. Loosen and remove both fittings from the bottom of the extend/retract cylinder barrel. Plug the openings in the extend/retract c

EFFECTIVITY PAGE31200361 G5-18A/2505 aFebruary 28, 2008 - A - Original Issue Of Manual

Boom3.10 G5-18A/25053.4 BOOM WEAR PADSOn the G5-18A a total of 14 wear pads are installed on the boom.Twelve of the fourteen wear pads on this boom ar

3.11G5-18A/2505Boom3.4.3 Boom Wear Pad LubricationAfter replacing any wear pad(s), or after prolonged periods of inoperation, light lubrication of the

Boom3.12 G5-18A/25052. Align attachment pin (2) with recess in attachment (3). Raise boom slightly to engage attachment pin in recess.3. Engage quick

3.13G5-18A/2505Boom3.5.5 Quick Attach Removal1. If equipped with a hydraulic quick attach device, remove both hydraulic hoses (13) from the valve body

Boom3.14 G5-18A/25053.6 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during operation of

3.15G5-18A/2505Boom6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.4.2, “Boom Wear

Boom3.16 G5-18A/2505This Page Intentionally Left Blank

4.1G5-18A/2505Section 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . .

Cab and Covers4.2 G5-18A/25054.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presen

4.3G5-18A/2505Cab and Covers4.2 OPERATOR’S CAB4.2.1 Operator’s Cab DescriptionThe welded metal cab features a modular design, allowing for a relativel

EFFECTIVITY PAGEG5-18A/2505 31200361-b

Cab and Covers4.4 G5-18A/25054.3.2 Steering Column/Valve Replacementa. Steering Column and Valve Removal1. Park the machine on a firm, level surface,

4.5G5-18A/2505Cab and Covers2. Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not

Cab and Covers4.6 G5-18A/2505b. Throttle Pedal Installation1. Align the throttle pedal assembly with its mount holes under the cab dash.2. Install thr

4.7G5-18A/2505Cab and Covers4.3.5 Joystick Assembly Replacementa. Joystick Assembly Removal1. Park the machine on a firm, level surface, fully retract

Cab and Covers4.8 G5-18A/25059. Loosen the hose clamps and disconnect the two heater hoses.10. Remove the capscrews, nuts and lockwashers securing the

4.9G5-18A/2505Cab and Covers8. Loosen the hose clamps, and disconnect the heater hoses from the engine. Cap or plug the hoses to prevent debris from e

Cab and Covers4.10 G5-18A/250514.Start the engine and check the operation of all controls. Check for hydraulic fluid leaks. Check the hydraulic fluid

5.1G5-18A/2505Section 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/25055.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the safety, operation and maint

5.3G5-18A/2505Axles, Drive Shafts, Wheels and Tires5.2 GENERAL INFORMATIONBefore performing any inspection, maintenance or service operation, thorough

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

Axles, Drive Shafts, Wheels and Tires5.4 G5-18A/25055.3.5 Axle RemovalThe front and rear axle assemblies differ in that the front axle assembly is equ

5.5G5-18A/2505Axles, Drive Shafts, Wheels and Tires12. Remove the drive shaft assembly. (Refer to Section 5.4.3, “Drive Shaft Removal.”)13. Remove the

Axles, Drive Shafts, Wheels and Tires5.6 G5-18A/25055.3.7 Axle Assembly and Drive Shaft TroubleshootingProblem Cause Remedy1. Excessive axle noise whi

5.7G5-18A/2505Axles, Drive Shafts, Wheels and Tires4. Oil leaking from axle (differential housing and/or axle housings).1. Drain plugs loose and/or o-

Axles, Drive Shafts, Wheels and Tires5.8 G5-18A/25057. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with Mobilfluid® 424 Trac

5.9G5-18A/2505Axles, Drive Shafts, Wheels and Tires5.4 DRIVE SHAFTS5.4.1 Drive Shaft InspectionWhenever servicing the machine, conduct a visual inspec

Axles, Drive Shafts, Wheels and Tires5.10 G5-18A/25055.5 WHEELS AND TIRESJLG recommends a replacement tire to be the same size, ply and brand as origi

5.11G5-18A/2505Axles, Drive Shafts, Wheels and Tires5.5.2 Installing Wheel and Tire Assembly onto MachineNote: The wheel and tire assemblies must be

Axles, Drive Shafts, Wheels and Tires5.12 G5-18A/2505This Page Intentionally Left Blank

6.1G5-18A/2505Section 6Transmission ContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . .

Section Subject PageiiG5-18A, 2505Section 6Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission6.2 G5-18A/25056.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in

6.3G5-18A/2505Transmission6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance info

Transmission6.4 G5-18A/250511. Vertically secure transmission with a lifting strap or chain. Use a suitable hoist or overhead crane. Operate the hoist

6.5G5-18A/2505Transmission6.5 TRANSMISSION FILTER REPLACEMENTThe hydrostatic pump filter is located on the left (inside) of the pump (1). Cleanliness

Transmission6.6 G5-18A/25056.6 TOWING A DISABLED MACHINETowing a disabled machine should only be attempted as a last resort, after exhausting all othe

7.1G5-18A/2505Section 7Engine: Perkins 1104D-44TContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine: Perkins 1104D-44T7.2 G5-18A/25057.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written for worldwide use. In territories

7.3G5-18A/2505Engine: Perkins 1104D-44TMY1900STARTERAIR CLEANER ASSEMBLYALTERNATORFANIMPLEMENT PUMPTHERMOSTATFUEL FILTEROIL FILTERHYDROSTATIC TRANSMIS

Engine: Perkins 1104D-44T7.4 G5-18A/25057.2 ENGINE SERIAL NUMBERThe Perkins 1104D-44T serial number is located on a tag on top of the engine. Infor

7.5G5-18A/2505Engine: Perkins 1104D-44T9. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radia

1.1G5-18A/2505Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine: Perkins 1104D-44T7.6 G5-18A/2505Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 32° F (0

7.7G5-18A/2505Engine: Perkins 1104D-44T7.7 ENGINE EXHAUST AND AIR CLEANER SYSTEMWhen the exhaust or air cleaner systems are removed be sure to cove

Engine: Perkins 1104D-44T7.8 G5-18A/250516. Label and disconnect all wire connections on the engine.17. Mark the location of the throttle cable (2) at

7.9G5-18A/2505Engine: Perkins 1104D-44T13. Refill the hydraulic reservoir (Refer to the appropriate Operation & Safety Manual for information conc

Engine: Perkins 1104D-44T7.10 G5-18A/25057.10 TROUBLESHOOTINGTrouble Possible Causes (see key, below)Low Cranking PowerWill Not StartDifficult Star

8.1G5-18A/2505Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System8.2 G5-18A/25058.11 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3G5-18A/2505Hydraulic System8.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information presented in this section

Hydraulic System8.4 G5-18A/25058.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid inc

8.5G5-18A/2505Hydraulic SystemALWAYS replace a used o-ring with a new part.Check all routing of hoses, wiring and tubing for sharp bends or interferen

Safety Practices1.2 G5-18A/25051.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair procedures. Follow

Hydraulic System8.6 G5-18A/25058.5.2 Main Control Valve Pressure CheckingAttach 5000 psi (345 bar) gauge to the test port (1) at the rear of the imple

8.7G5-18A/2505Hydraulic System8.5.5 Steering Pressure CheckingAttach a pressure gauge to the test fitting (1) at the rear of the implement pump. The p

Hydraulic System8.8 G5-18A/25058.6 HYDRAULIC SCHEMATICS8.6.1 G5-18AMY2130HYDRAULIC RESERVOIRPTYLSPLRT175 bar235 barABTPCFEFPLSabGSABT1RX1X2T2FaPSMHMAM

8.9G5-18A/2505Hydraulic System8.6.2 2505MY2370PTYFRONT AXLEFRONT STEERINGCYLINDERREAR STEERINGCYLINDERLSPLRT175 bar235 barABTPCFEFPLSPTabGSABT1RX1X2T2

Hydraulic System8.10 G5-18A/25058.6.3 Auxiliary OptionsCFEFPLS1B1A3B3A1b1a3a3b4B4A4a4b2B2A2a2bBNPTTRAILER BRAKE CONNECTIONTRAILER BRAKE VALVESERVICE B

8.11G5-18A/2505Hydraulic System8.7 HYDRAULIC RESERVOIRThe hydraulic reservoir and fuel tank are part of the frame. For this reason, neither tank can b

Hydraulic System8.12 G5-18A/25056. Label, disconnect and cap all hydraulic hoses attached to the pump, cap all fittings and plug hoses to keep dirt &a

8.13G5-18A/2505Hydraulic System6. Carefully fit the mounting plate in its original position. The drain hole in the rear face must be to the low pressu

Hydraulic System8.14 G5-18A/25058.10 VALVES AND MANIFOLDS8.10.1 Main Control ValveThe main control valve is mounted on the rear of the machine behind

8.15G5-18A/2505Hydraulic SystemAssemble each Valve Section1. Reassemble any check valves, compensator valves, anti-cavitation valves or shock valves f

1.3G5-18A/2505Safety Practices1.5 SAFETY INFORMATIONTo avoid possible death or injury, carefully read, understand and comply with all safety messages.

Hydraulic System8.16 G5-18A/2505Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in

8.17G5-18A/2505Hydraulic System4. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the ma

Hydraulic System8.18 G5-18A/2505b. Pilot Select Valve Disassembly, Cleaning, Inspection and Assembly1. Place the pilot select assembly on a suitable w

8.19G5-18A/2505Hydraulic System3. Open the engine covers. Allow the system fluids to cool.4. Label or otherwise mark the hydraulic hoses in relation t

Hydraulic System8.20 G5-18A/25054. Label or otherwise mark the hydraulic hoses in relation to the steer select manifold. Disconnect and cap all hoses,

8.21G5-18A/2505Hydraulic System8.10.9 Joystick Enable Valve (CE)The joystick enable valve is located on top of the frame at the left rear corner of th

Hydraulic System8.22 G5-18A/25058.10.10 Load Stability Indicator Valve (CE)The load stability indicator valve is located at the rear of the machine on

8.23G5-18A/2505Hydraulic System8.11 HYDRAULIC CYLINDERS8.11.1 General Cylinder Removal Instructions1. Park the machine on a firm, level surface, fully

Hydraulic System8.24 G5-18A/25056. Carefully pull the rod assembly along with the head gland out of the cylinder barrel.7. Fasten the rod end in a sof

8.25G5-18A/2505Hydraulic System5. Place the cylinder barrel (1) in a soft-jawed vise or other acceptable holding equipment if possible.6. Carefully in