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G5-18A
JLG G5-18A Service Manual
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An Oshkosh Corporation Company
Ser
vice Manual
Models
G5-18A
&
2505
31200361
Revised
January 15, 2018
2
Table of Contents
Section
5
Default Chapter
5
Table of Contents
5
Subject
6
Safety Practices
10
Introduction
10
Disclaimer
10
Operation & Safety Manual
10
Do Not Operate Tags
10
Safety Information
10
Safety Alert System and Signal Words
10
Safety Instructions
11
Equipment Hazards
11
General Hazards
11
Operational Hazards
11
Personal Hazards
11
Safety Decals
12
Section 2 General Information and Specifications
13
General Information and Specifications
13
Replacement Parts and Warranty Information
14
Specifications
15
Travel Speed
15
Electrical System
15
Hydraulic Cylinder Performance Specifications
15
Engine Performance Specifications
16
Tires
16
Fluids, Lubricants and Capacities
17
Maintenance Schedules
18
10,1St 50 & 50 Hour Maintenance Schedule
18
1St 250, 250, 500 & 1000 Hour Maintenance Schedule
18
Lubrication Schedule
19
Hour Lubrication Schedule
19
Thread Locking Compound
20
Torque Charts
21
SAE Fastener Torque Chart
21
Metric Fastener Torque Chart
27
Hydraulic Connection Assembly and Torque Specification
32
Definitions
32
Assembly Instructions for American Standard Pipe Thread Tapered Connections
36
Assembly Instructions for British Standard Pipe Thread Tapered Connections
37
Assembly Instructions for 37° (JIC) Flare Fittings
38
Assembly Instructions for 45° SAE Flare Fittings
40
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
42
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
44
Assembly Instructions for Bulkhead (BH) Fittings
46
Assembly Instructions for O-Ring Boss (ORB) Fittings
50
Assembly Instructions for Adjustable Port End Metric Fittings
58
Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
66
Assembly Instructions for Adjustable Port End (BSPP) Fittings
68
Assembly Instructions for Flange Connections (FL61 and FL62)
76
Double Wrench Method
79
Adjustable Stud End Assembly
80
FFWR and TFFT Methods
80
O-Ring Installation (Replacement)
80
Section 3 Boom
81
Boom System Component Terminology
82
Boom System - Two Section Boom
83
Boom Assembly Maintenance
83
Boom System Description
83
Second Section Boom Removal
83
First Boom Section Removal
84
Complete Boom Removal
85
First Boom Section Installation
85
Second Boom Section Installation
85
Second Section Boom Removal
86
Boom Installation
87
Second Section Boom Installation
87
Tilt and Auxiliary Hose Removal
88
Tilt and Auxiliary Hose Installation
89
Extend/Retract Cylinder Installation
90
Extend/Retract Cylinder Removal
90
Boom Wear Pads
91
Wear Pad Inspection
91
Boom Wear Pad Replacement
91
Boom Wear Pad Lubrication
92
Quick Attach Assembly
93
Connecting with a Mechanical JLG Quick Attach
93
Connecting with a Hydraulic JLG Quick Attach
93
Connecting a Hydraulic Operated Attachment
94
Connecting with a Universal Quick Attach
94
Quick Attach Removal
94
Forks
95
Quick Attach Installation
95
Troubleshooting
96
Section 4 Cab and Covers
99
Cab and Covers
99
Operator's Cab and Covers Component Terminology
100
Cab Components
101
Operator's Cab Description
101
Serial Number Decal
101
Steering Wheel
101
Brake Pedal and Valve
102
Steering Column/Valve Replacement
102
Throttle Pedal Replacement
103
Heater/Defroster System
105
Joystick Assembly Replacement
105
Windshield Washer Assembly
105
Windshield Wiper Assembly
105
Operator's Cab
101
Cab Removal
106
Cab Installation
107
Section 5 Axles, Drive Shafts, Wheels and Tires
109
Axles, Drive Shafts, Wheels and Tires
110
Axle, Drive Shaft and Wheel Component Terminology
110
Axle Assemblies
111
Axle Serial Number Plate
111
Axle Internal Service
111
Axle Maintenance
111
Axle Specifications
111
Axle Removal
112
Axle Installation
113
Axle Assembly and Drive Shaft Troubleshooting
114
Steering System Purge Procedure
117
Drive Shafts
118
Drive Shaft Cleaning and Drying
118
Drive Shaft Inspection
118
Drive Shaft Installation
118
Drive Shaft Maintenance
118
Drive Shaft Removal
118
General Information
111
Wheels and Tires
119
Removing Wheel and Tire Assembly from Machine
119
Brakes
120
Installing Wheel and Tire Assembly Onto Machine
120
Brake Disk Inspection
120
Steering Angle Adjustment
120
Steering Adjustment
120
Section 6 Transmission
121
Transmission Assembly Component Terminology
122
Transmission Replacement
123
Transmission Maintenance
123
Transmission Removal
123
After Transmission Replacement
124
Transmission Disassembly
124
Transmission Installation
124
Transmission Specifications
123
Transmission Description
123
Transmission Filter Replacement
125
Filter Removal
125
Filter Installation
125
Towing a Disabled Machine
126
Section 7 Engine: Perkins 1104D-44T
127
Engine: Perkins 1104D-44T
127
Introduction
128
Disclaimer and Scope
128
Component Terminology
128
Engine Serial Number
130
Specifications and Maintenance Information
130
Engine Cooling System
130
Radiator Pressure Cap
130
Radiator/Oil Cooler and Coolant Heater Replacement
130
Engine Electrical System
131
Fuel System
131
Diesel Fuel
131
After Fuel System Service
132
Fuel/Hydraulic Oil Tank
132
Engine Exhaust and Air Cleaner System
133
Engine Replacement
133
Engine Removal
133
Engine Installation
134
Engine Coupler
135
Coupler Removal
135
Coupler Installation
135
Troubleshooting
136
Section 8 Hydraulic System
137
Hydraulic System
137
Hydraulic Component Terminology
139
Hoses, Tube Lines, Fittings, Etc
140
Replacement Considerations
140
Safety Information
140
Specifications
140
Hydraulic Pressure Diagnosis
141
Pressure Checks and Adjustments
141
Boom Function Pressure Checking
142
Charge Pressure Checking
142
Main Control Valve Pressure Checking
142
Steering Pressure Checking
143
Hydraulic Schematics
144
G5-18A
144
Auxiliary Options
146
Hydraulic System Pump
147
Pressurized Hydraulic Oil Fill Cap
147
Hydraulic Oil Reservoir Draining
147
Hydraulic Oil Reservoir Filling
147
Implement Pump Failure Analysis
147
Implement Pump Replacement
147
Hydraulic Reservoir
147
Front Drive Motor
149
Valves and Manifolds
150
Main Control Valve
150
Service Brake Valve
151
Parking Brake Valve
152
Brake Test
153
Pilot Select Valve
153
Steering Orbitrol Valve
153
Steer Select Valve
155
Joystick Enable Valve (CE)
157
Decompression Valve
158
Load Stability Indicator Valve (CE)
159
Hydraulic Cylinders
160
Section 9 Electrical System
165
Electrical Component Terminology
166
Electrical System
166
Specifications
167
Fuses and Relays
167
Electrical System Schematics
170
Cab Harness Schematic "A
170
Cab Harness Schematic "B
171
Cab Roof Schematic
172
Chassis Schematic
173
Options Chassis Schematic
174
Circuit Breakdowns
175
Charge Circuit Breakdown
175
Start Circuit Breakdown
176
Constant Power Circuit Breakdown
177
Drive Circuit Breakdown
178
Engine Start Circuit
179
Starter
179
Charging Circuit
180
Alternator
180
Electrical System Components
181
Back-Up Alarm
181
Instrument Cluster
181
Window Wiper/Washer
183
Windshield Wiper Motor
183
Rear Window or Roof Wiper Motor (if Equipped)
183
Cab Heater and Fan
184
Windshield Washer Reservoir and Pump
184
Cab Heater Controls
184
Switches, Solenoids and Senders
185
Ignition Key Switch
185
Dash Switches
186
Fuel Level Indicator and Fuel Level Sender
186
Hourmeter
186
Coolant Temperature Sender
187
Fuel Shut-Off Solenoid
187
Oil Pressure Sender
188
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JLG G5-18A Specifications
General
Maximum Lift Capacity
5, 500 lbs
Maximum Lift Height
18 ft
Engine Manufacturer
Deutz
Engine Model
TD 2.9 L4
Horsepower
74 hp
Tire Type
Pneumatic
Weight
2, 900 lbs
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