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JLG 2505 User Manual

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

Table of Contents

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JLG 2505 Specifications

General IconGeneral
WeightI don't know
Drive TypeElectric
Max Working Height8.00 m
Maximum Lift Height6.00 m
Maximum Platform Height6.00 m
Platform Length1.2 m
Platform Width0.8 m

Summary

Safety Practices

1.4 Do Not Operate Tags

Instructs to place tags on ignition and steering wheel before service/maintenance.

1.5 Safety Information

Highlights the importance of complying with safety messages to avoid death or injury.

1.6 Safety Instructions

Provides general safety statements to consider before performing maintenance procedures.

General Information and Specifications

2.3 Fluids, Lubricants and Capacities

Lists capacities and types of fluids for engine, axles, brakes, and hydraulic systems.

2.4 Maintenance Schedules

Outlines scheduled maintenance tasks for various hour intervals.

2.5 Lubrication Schedule

Provides a diagram for 250-hour lubrication points.

2.7 Torque Charts

Presents torque values for SAE and metric fasteners based on grade, lubrication, and coating.

Hydraulic Connection Assembly and Torque Specification

2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections

Provides instructions for assembling NPTF pipe threads, including torque and turns from finger tight.

2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections

Details assembly instructions for BSPT pipe threads, including torque and turns from finger tight.

2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings

Explains assembly for JIC flare fittings, including torque and flats from wrench resistance.

2.8.5 Assembly Instructions for 45° SAE Flare Fittings

Provides instructions for assembling 45° SAE flare fittings, including torque specifications.

2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings

Details assembly procedures for ORFS fittings, including torque and lubrication.

2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)

Explains assembly for DIN 24° flare bite type fittings, including torque and flats from wrench resistance.

2.8.8 Assembly Instructions for Bulkhead (BH) Fittings

Covers assembly instructions for bulkhead fittings, including torque values.

2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings

Provides assembly instructions for ORB fittings, including torque values for various types.

2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings

Details assembly instructions for adjustable port end metric fittings, including torque values.

2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends

Explains assembly for metric ISO 6149 port assembly stud ends, including torque values.

2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings

Provides assembly instructions for adjustable port end BSPP fittings, including torque values.

2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)

Outlines assembly instructions for flange connections FL61 and FL62, including torque values for inch fasteners.

Boom

3.3 Boom Assembly Maintenance

Details general maintenance procedures for the boom assembly.

3.3.1 Second Section Boom Removal

Provides step-by-step instructions for removing the second boom section.

3.3.2 First Boom Section Removal

Details the procedure for removing the first boom section from the machine.

3.7 Troubleshooting

Offers solutions for common boom-related problems, causes, and remedies.

Cab and Covers

4.4 Cab Removal

Provides instructions for removing the operator's cab, including disconnecting hoses and wiring.

4.5 Cab Installation

Guides through the process of installing the operator's cab, including alignment and torque specifications.

Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Addresses common problems with axle assemblies and drive shafts, their causes, and remedies.

Transmission

Engine: Perkins 1104D-44T

7.8 Engine Replacement

Details engine removal procedures, including disconnecting systems and fluid drainage.

7.10 Troubleshooting

Offers solutions for common engine problems, their causes, and remedies.

Hydraulic System

8.5 Hydraulic Pressure Diagnosis

Provides general steps for conducting pressure checks and adjustments in hydraulic circuits.

8.5.2 Main Control Valve Pressure Checking

Details how to check and adjust main control valve pressure.

8.5.3 Charge Pressure Checking

Explains how to check charge pressure on the hydrostatic transmission.

8.5.4 Boom Function Pressure Checking

Guides on checking pressure for individual boom function circuits.

8.5.5 Steering Pressure Checking

Details how to check steering system pressure and individual valve section pressures.

8.8 Hydraulic System Pump

Covers analysis of implement pump failure and replacement procedures.

8.10 Valves and Manifolds

Covers removal, disassembly, cleaning, inspection, assembly, installation, and testing of various valves.

8.10.1 Main Control Valve

Covers main control valve removal, disassembly, cleaning, inspection, assembly, installation, and testing.

8.10.11 Load Stability Indicator Valve (CE)

Covers removal, installation, and calibration of the Load Stability Indicator (LSI).

8.11.8 Hydraulic Cylinder Torque Specifications

Lists torque specifications for various hydraulic cylinder components.

Electrical System

9.6 Engine Start Circuit

Covers testing, removal, cleaning, and installation of the starter motor.

9.7 Charging Circuit

Discusses charging the battery and checking the alternator.

9.11.8 Load Stability Indicator (CE)

Explains the function of the LSI and notes it is not serviceable.

c. Load Stability Indicator Calibration (CE)

Provides detailed steps for calibrating the Load Stability Indicator (LSI).

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