User Manuals: JLG G5-18A Compact Telehandler

Manuals and User Guides for JLG G5-18A Compact Telehandler. We have 2 JLG G5-18A Compact Telehandler manuals available for free PDF download: Service Manual, Operation Manual

JLG G5-18A 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 G5-18A Operation Manual (160 pages)

Brand: JLG | Category: Lifting Systems | Size: 12 MB

Read this First

4
- Operator Qualifications
  4
- Modifications
  4
- Other Publications Available
  6
- Machine Configuration
  6
- Table of Contents
  7
Table of Contents

13
Section 1 - General Safety Practices

13
- Hazard Classification System
  13
  - Safety Alert System and Safety Signal Words
    13
- General Precautions
  13
- Operation Safety
  14
  - Electrical Hazards
    14
  - Tip over Hazard
    16
  - Travel Hazard
    19
  - Load Falling Hazard
    20
  - Lifting Personnel
    21
  - Driving Hazards on Slopes
    22
  - Pinch Points and Crush Hazards
    23
  - Fall Hazard
    25
  - Chemical Hazards
    26
- Clearsky (if Equipped)
  27
  - Federal Communications Commission (FCC) Information for Users
    27
Section 2 - Pre-Operation and Inspection

29
- Pre-Operation Check and Inspection
  29
- Safety Decals
  32
  - ANSI (G5-18A, if Equipped)
    32
  - ISO (2505H) (G5-18A, if Equipped)
    35
- Walk-Around Inspection
  38
- Warm-Up and Operational Checks
  40
  - Warm-Up Check
    40
  - Operational Check
    40
- Operator Cab
  41
- Windows
  42
  - Cab Door Window (if Equipped)
    42
  - Rear Window
    43
Table of Contents

45
Section 3 - Controls and Indicators

45
- General
  45
- Controls
  46
  - Park Brake
    48
  - Parking Procedure
    49
  - Ignition
    50
  - Transmission Control Lever
    51
  - Load Stability Indicator - LSI (2505H)
    52
  - LSI Override Switch (2505H)
    54
  - Steering Column Adjuster (if Equipped)
    55
  - Instrument Panel
    56
  - Joystick
    58
  - Right Hand Console
    60
  - Accessory Control Lever (if Equipped)
    62
  - Reversing Fan (if Equipped)
    63
- Steer Modes
  64
  - Steer Mode Change
    64
- Operator Seat
  65
  - Operator Presence (CE & AUS)
    65
  - Adjustments
    66
  - Seat Belt
    67
- Boom Angle and Extension Indicators
  68
- Reverse Sensing System
  69
Section 4 - Operation

71
- Engine
  71
  - Starting the Engine
    71
  - Cold Weather Starting
    72
  - Battery Boosted Starting
    73
  - Normal Engine Operation
    74
  - Shut-Down Procedure
    74
- Operating with a Non-Suspended Load
  75
  - Lift Load Safely
    75
  - Before Picking up a Load
    75
  - Transporting a Load
    76
  - Leveling Procedure
    76
  - Placing a Load
    77
  - Disengaging a Load
    77
- Operating with a Suspended Load (ANSI & CE)
  78
  - Lift Load Safely
    78
  - Picking up a Suspended Load
    78
  - Transporting a Suspended Load
    79
  - Leveling Procedure
    79
  - Placing a Suspended Load
    80
  - Disengaging a Suspended Load
    80
- Road Operation (2505H)
  81
- Loading and Securing for Transport
  82
  - Tiedown
    82
  - Lifting
    83
Section 5 - Attachments and Hitches

85
- Approved Attachments
  85
- Unapproved Attachments
  85
- JLG Supplied Attachments
  86
- Telehandler/Attachment/Fork Capacity
  88
- Use of the Capacity Chart
  89
  - Capacity Indicator Locations
    89
  - Sample Capacity Chart (ANSI & CE)
    90
  - Sample Capacity Chart (AUS)
    91
  - Example
    92
- Attachment Installation
  93
  - Standard Quick Attach
    93
  - Universal Quick Attach (UQC)
    96
- Hydraulic Operated Attachment
  98
- Adjusting/Moving Forks
  99
- Attachment Operation
  100
  - Carriage with Forks
    102
  - Fork Mounted Hook (ANSI & CE)
    103
  - Side Tilt Carriage
    104
  - Side Shift Carriage
    106
  - Bucket
    108
  - Grapple Bucket
    110
  - Coupler Mounted Hook
    112
- 5.10 Hitches
  113
  - Retrieval Hitch
    113
  - Adjustable Auto Hitch
    114
  - Pin Hitch - CUNA C
    115
  - EEC Manual Pin Hitch
    116
Table of Contents

117
Section 6 - Emergency Procedures

117
- Towing a Disabled Product
  117
  - Moving Short Distances
    117
  - Moving Longer Distances
    117
- Emergency Lowering of Boom
  118
- Emergency Exit from Enclosed Cab
  119
  - Inside Cab
    119
  - Outside Cab (if Equipped)
    119
Section 7 - Lubrication and Maintenance

121
- Introduction
  121
  - Clothing and Safety Gear
    121
- General Maintenance Instructions
  122
- Service and Maintenance Schedule
  123
- Lubrication Schedules
  126
  - 250 Hour Lubrication Schedule
    126
- Operator Maintenance Instructions
  128
  - Fuel System
    128
  - Engine Oil
    130
  - Hydraulic Oil
    131
  - Tires
    132
  - Air Intake System
    134
  - Engine Cooling System
    136
  - Battery
    137
  - Brake System
    138
  - Windshield Washer System (if Equipped)
    139
Section 8 - Additional Checks

141
- General
  141
- Load Stability Indicator System (2505H)
  141
- Reverse Sensing System (if Equipped)
  142
Section 9 - Specifications

143
- Product Specifications
  143
  - Fluids
    143
  - Capacities
    146
  - Tires
    147
  - Performance
    148
  - Dimensions
    149
  - Declaration of Vibration (CE)
    150
  - Noise Emission Level (CE)
    150
  - Machine Towing Capacity
    150
Index

151
Inspection, Maintenance and Repair Log

155

JLG Categories

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User Manuals: JLG G5-18A Compact Telehandler

JLG G5-18A 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