Engine Exhaust And Air Cleaner System; Engine Replacement; Engine Removal - JLG G5-18A Service Manual

7.7 ENGINE EXHAUST AND AIR
CLEANER SYSTEM
WARNING
Avoid breathing exhaust fumes, and prevent engine
operation from becoming a cause of toxic emissions.
Failure to follow the safety practices could result in
death or serious injury.
CAUTION
Exhaust system
temperatures and can cause severe burns. DO NOT
come into contact
components. Failure to follow the safety practices
could result in death or serious injury.
When the exhaust or air cleaner systems are removed be
sure to cover any open ports to prevent dirt and debris
from contaminating engine components.
NOTICE
NEVER run the engine with only the inner safety
element installed. Serious engine damage could occur
if air cleaner elements are not properly installed.
G5-18A, 2505
components reach
with hot exhaust system
7.8

ENGINE REPLACEMENT

7.8.1

Engine Removal

1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
2. Place an Do Not Operate Tag on both the ignition
key switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Thoroughly clean the engine and surrounding area,
high including all hoses and fittings before proceeding.
5. Disconnect the battery negative (-) cable from the
battery negative (-) terminal.
6. Remove the engine cover, radiator cover and engine
bay access cover.
7. Remove front and rear engine cover supports.
8. Drain hydraulic reservoir. Refer to Section 8.7.2,
"Hydraulic Oil Reservoir Draining."
9. Drain radiator and overflow bottle. Refer to Section
7.4.2, "Radiator/Oil Cooler and Coolant Heater
Replacement."
10. Label, disconnect and cap all hydraulic hoses
attached to engine and radiator, cap all fittings and
plug hoses to keep dirt & debris from entering
hydraulic system.
11. Disconnect the fuel inlet (1) and return lines. Install a
plug in the end of each line.
12. Remove hydraulic and fuel filters, and filter bracket
assembly.
13. Unbolt and remove the fan safety shroud.
14. Remove bolts securing the radiator and lift it clear of
engine compartment. Refer to section Section 7.4.2,
"Radiator/Oil Cooler and Coolant Heater
Replacement.".
15. Mark the engine fan orientation. Remove the engine
fan.
Engine: Perkins 1104D-44T
7-7