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Lifting Systems
G5-18A
Service manual
JLG G5-18A Service Manual
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Also See for G5-18A
:
Operation manual
(160 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Section
Table of Contents
Subject
Safety Practices
Introduction
Disclaimer
Operation & Safety Manual
Do Not Operate Tags
Safety Information
Safety Alert System and Signal Words
Safety Instructions
Equipment Hazards
General Hazards
Operational Hazards
Personal Hazards
Safety Decals
Section 2 General Information and Specifications
General Information and Specifications
Replacement Parts and Warranty Information
Specifications
Travel Speed
Electrical System
Hydraulic Cylinder Performance Specifications
Engine Performance Specifications
Tires
Fluids, Lubricants and Capacities
Maintenance Schedules
10,1St 50 & 50 Hour Maintenance Schedule
1St 250, 250, 500 & 1000 Hour Maintenance Schedule
Lubrication Schedule
Hour Lubrication Schedule
Thread Locking Compound
Torque Charts
SAE Fastener Torque Chart
Metric Fastener Torque Chart
Hydraulic Connection Assembly and Torque Specification
Definitions
Assembly Instructions for American Standard Pipe Thread Tapered Connections
Assembly Instructions for British Standard Pipe Thread Tapered Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric Fittings
Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
Assembly Instructions for Adjustable Port End (BSPP) Fittings
Assembly Instructions for Flange Connections (FL61 and FL62)
Double Wrench Method
Adjustable Stud End Assembly
FFWR and TFFT Methods
O-Ring Installation (Replacement)
Section 3 Boom
Boom System Component Terminology
Boom System - Two Section Boom
Boom Assembly Maintenance
Boom System Description
Second Section Boom Removal
First Boom Section Removal
Complete Boom Removal
First Boom Section Installation
Second Boom Section Installation
Second Section Boom Removal
Boom Installation
Second Section Boom Installation
Tilt and Auxiliary Hose Removal
Tilt and Auxiliary Hose Installation
Extend/Retract Cylinder Installation
Extend/Retract Cylinder Removal
Boom Wear Pads
Wear Pad Inspection
Boom Wear Pad Replacement
Boom Wear Pad Lubrication
Quick Attach Assembly
Connecting with a Mechanical JLG Quick Attach
Connecting with a Hydraulic JLG Quick Attach
Connecting a Hydraulic Operated Attachment
Connecting with a Universal Quick Attach
Quick Attach Removal
Forks
Quick Attach Installation
Troubleshooting
Section 4 Cab and Covers
Cab and Covers
Operator's Cab and Covers Component Terminology
Cab Components
Operator's Cab Description
Serial Number Decal
Steering Wheel
Brake Pedal and Valve
Steering Column/Valve Replacement
Throttle Pedal Replacement
Heater/Defroster System
Joystick Assembly Replacement
Windshield Washer Assembly
Windshield Wiper Assembly
Operator's Cab
Cab Removal
Cab Installation
Section 5 Axles, Drive Shafts, Wheels and Tires
Axles, Drive Shafts, Wheels and Tires
Axle, Drive Shaft and Wheel Component Terminology
Axle Assemblies
Axle Serial Number Plate
Axle Internal Service
Axle Maintenance
Axle Specifications
Axle Removal
Axle Installation
Axle Assembly and Drive Shaft Troubleshooting
Steering System Purge Procedure
Drive Shafts
Drive Shaft Cleaning and Drying
Drive Shaft Inspection
Drive Shaft Installation
Drive Shaft Maintenance
Drive Shaft Removal
General Information
Wheels and Tires
Removing Wheel and Tire Assembly from Machine
Brakes
Installing Wheel and Tire Assembly Onto Machine
Brake Disk Inspection
Steering Angle Adjustment
Steering Adjustment
Section 6 Transmission
Transmission Assembly Component Terminology
Transmission Replacement
Transmission Maintenance
Transmission Removal
After Transmission Replacement
Transmission Disassembly
Transmission Installation
Transmission Specifications
Transmission Description
Transmission Filter Replacement
Filter Removal
Filter Installation
Towing a Disabled Machine
Section 7 Engine: Perkins 1104D-44T
Engine: Perkins 1104D-44T
Introduction
Disclaimer and Scope
Component Terminology
Engine Serial Number
Specifications and Maintenance Information
Engine Cooling System
Radiator Pressure Cap
Radiator/Oil Cooler and Coolant Heater Replacement
Engine Electrical System
Fuel System
Diesel Fuel
After Fuel System Service
Fuel/Hydraulic Oil Tank
Engine Exhaust and Air Cleaner System
Engine Replacement
Engine Removal
Engine Installation
Engine Coupler
Coupler Removal
Coupler Installation
Troubleshooting
Section 8 Hydraulic System
Hydraulic System
Hydraulic Component Terminology
Hoses, Tube Lines, Fittings, Etc
Replacement Considerations
Safety Information
Specifications
Hydraulic Pressure Diagnosis
Pressure Checks and Adjustments
Boom Function Pressure Checking
Charge Pressure Checking
Main Control Valve Pressure Checking
Steering Pressure Checking
Hydraulic Schematics
G5-18A
Auxiliary Options
Hydraulic System Pump
Pressurized Hydraulic Oil Fill Cap
Hydraulic Oil Reservoir Draining
Hydraulic Oil Reservoir Filling
Implement Pump Failure Analysis
Implement Pump Replacement
Hydraulic Reservoir
Front Drive Motor
Valves and Manifolds
Main Control Valve
Service Brake Valve
Parking Brake Valve
Brake Test
Pilot Select Valve
Steering Orbitrol Valve
Steer Select Valve
Joystick Enable Valve (CE)
Decompression Valve
Load Stability Indicator Valve (CE)
Hydraulic Cylinders
Section 9 Electrical System
Electrical Component Terminology
Electrical System
Specifications
Fuses and Relays
Electrical System Schematics
Cab Harness Schematic "A
Cab Harness Schematic "B
Cab Roof Schematic
Chassis Schematic
Options Chassis Schematic
Circuit Breakdowns
Charge Circuit Breakdown
Start Circuit Breakdown
Constant Power Circuit Breakdown
Drive Circuit Breakdown
Engine Start Circuit
Starter
Charging Circuit
Alternator
Electrical System Components
Back-Up Alarm
Instrument Cluster
Window Wiper/Washer
Windshield Wiper Motor
Rear Window or Roof Wiper Motor (if Equipped)
Cab Heater and Fan
Windshield Washer Reservoir and Pump
Cab Heater Controls
Switches, Solenoids and Senders
Ignition Key Switch
Dash Switches
Fuel Level Indicator and Fuel Level Sender
Hourmeter
Coolant Temperature Sender
Fuel Shut-Off Solenoid
Oil Pressure Sender
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Quick Links
1
Fluids, Lubricants and Capacities
2
Troubleshooting
3
Troubleshooting
4
Fuses and Relays
Download this manual
See also:
Operating Manual
Service Manual
Models
G5-18A
&
2505
31200361
Revised
January 15, 2018
An Oshkosh Corporation Company
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
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Chapters
Section
5
Section 2 General Information and Specifications
13
Section 3 Boom
81
Section 4 Cab and Covers
99
Section 5 Axles, Drive Shafts, Wheels and Tires
109
Section 6 Transmission
121
Section 7 Engine: Perkins 1104D-44T
127
Section 8 Hydraulic System
137
Section 9 Electrical System
165
Table of Contents
Troubleshooting
Troubleshooting
96
Axle Assembly and Drive Shaft Troubleshooting
114
Troubleshooting
136
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