JLG 2505 Telehandler Manuals

Manuals and User Guides for JLG 2505 Telehandler. We have 1 JLG 2505 Telehandler manual available for free PDF download: Service Manual

JLG 2505 Service Manual (192 pages)

Brand: JLG | Category: Lifting Systems | Size: 16 MB

Section

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
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

JLG Categories

Boom Lifts Lifting Systems Scissor Lifts Construction Equipment Work Light

More JLG Manuals

JLG 2505 Telehandler Manuals

JLG 2505 Service Manual (192 pages)

Table of Contents

Section

Subject

Safety Practices

Section 2 General Information and Specifications

General Information and Specifications

Replacement Parts and Warranty Information

Specifications

Fluids, Lubricants and Capacities

Maintenance Schedules

Lubrication Schedule

Thread Locking Compound

Torque Charts

Hydraulic Connection Assembly and Torque Specification

Section 3 Boom

Boom System Component Terminology

Boom System - Two Section Boom

Boom Assembly Maintenance

Boom Wear Pads

Quick Attach Assembly

Forks

Troubleshooting

Section 4 Cab and Covers

Cab and Covers

Operator's Cab and Covers Component Terminology

Cab Components

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

General Information

Wheels and Tires

Brakes

Steering Adjustment

Section 6 Transmission

Transmission Assembly Component Terminology

Transmission Replacement

Transmission Specifications

Transmission Description

Transmission Filter Replacement

Towing a Disabled Machine

Section 7 Engine: Perkins 1104D-44T

Engine: Perkins 1104D-44T

Introduction

Engine Serial Number

Specifications and Maintenance Information

Engine Cooling System

Engine Electrical System

Fuel System

Engine Exhaust and Air Cleaner System

Engine Replacement

Engine Coupler

Troubleshooting

Section 8 Hydraulic System

Hydraulic System

Hydraulic Component Terminology

Hoses, Tube Lines, Fittings, Etc

Safety Information

Specifications

Hydraulic Pressure Diagnosis

Hydraulic Schematics

Hydraulic System Pump

Hydraulic Reservoir

Front Drive Motor

Valves and Manifolds

Section 9 Electrical System

Electrical Component Terminology

Electrical System

Specifications

Fuses and Relays

Electrical System Schematics

Circuit Breakdowns

Engine Start Circuit

Charging Circuit

Electrical System Components