JLG G5-18A Service Manual

Service Manual

Models G5-18A

&

2505

31200361

Original

February 28, 2008

An Oshkosh Truck Corporation Company

EFFECTIVITY PAGE

February 28, 2008 - A - Original Issue Of Manual

31200361

G5-18A/2505

a

EFFECTIVITY PAGE

-b

G5-18A/2505

31200361

SECTION CONTENTS

Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.1
1.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.2	Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.3	Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.4	Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.5	Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
1.6	Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
1.7	Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.1
2.1	Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.2
2.2	Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.3
2.3	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
2.4	Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.8
2.5	Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.9
2.6	Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.10
Section 3
Boom . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.1
3.1	Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.2
3.2	Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
3.3	Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
3.4	Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.10
3.5	Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.11
3.6	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.14
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4.1
4.1	Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . .	4.2
4.2	Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.3
4.3	Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.3
4.4	Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.8
4.5	Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.9
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		5.1
5.1	Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . .	5.2
5.2	General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.3
5.3	Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.3
5.4	Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.9
5.5	Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.10
5.6	Steering Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.11
5.7	Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.11

G5-18A, 2505

i

Section Subject Page

Section 6
Transmission .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.1
6.1	Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.2
6.2	Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.3	Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.4	Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.5	Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.5
6.6	Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.6
Section 7
Engine: Perkins 1104D-44T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		7.1
7.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.2
7.2	Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.4
7.3	Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.4
7.4	Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.4
7.5	Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.5
7.6	Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.5
7.7	Engine Exhaust and Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.7
7.8	Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.7
7.9	Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.9
7.10	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.10
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		8.1
8.1	Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.3
8.2	Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.4
8.3	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.4
8.4	Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.4
8.5	Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.5
8.6	Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.8
8.7	Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.11
8.8	Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.11
8.9	Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.13
8.10	Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.14
8.11	Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.23
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		9.1
9.1	Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.2
9.2	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.3
9.3	Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.3
9.4	Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.6
9.5	Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.11
9.6	Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.15
9.7	Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.16
9.8	Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.17
9.9	Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.19
9.10	Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.20
9.11	Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.21

ii	G5-18A, 2505

Section 1

Safety Practices

Contents

PARAGRAPH		TITLE	PAGE
1.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.2	Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.3	Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.4	Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.5	Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.3
	1.5.1	Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
1.6	Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.3
	1.6.1	Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
	1.6.2	Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
	1.6.3	General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.4
	1.6.4	Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.4
1.7	Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.4

G5-18A/2505

1.1

Safety Practices

1.1INTRODUCTION

This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local JLG distributor.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.

1.2

1.2DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3OPERATION & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Safety Manual is supplied with each machine and must be kept in the cab. In the event that the Operation & Safety Manual is missing, consult the local JLG distributor before proceeding.

1.4DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

G5-18A/2505

Safety Practices

1.5SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

G5-18A/2505

1.6SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before proceeding.

1.6.1Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

1.3

Safety Practices

1.6.3General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

1.6.4Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an

appropriate container and dispose of in accordance with prevailing environmental regulations.

RADIATOR CAP: Always wear steam-resistant, heat protective gloves when opening the radiator cap. Cover the cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

1.4	G5-18A/2505

Section 2

General Information and Specifications

Contents

PARAGRAPH		TITLE	PAGE
2.1	Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.2
2.2	Torques.	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.3
	2.2.1	ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . .	2.3
	2.2.2	ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.4
	2.2.3	Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.5
2.3	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.6
	2.3.1	Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
	2.3.2	Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . .	2.6
	2.3.3	Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
	2.3.4	Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.7
	2.3.5	Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.7
2.4	Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.8
2.5	Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.9
	2.5.1	10,1st 50 & 50 Hour Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . .	2.9
	2.5.2	1st 250, 250, 500 & 1000 Hour Maintenance Schedule . . . . . . . . . . . . . .	2.9
2.6	Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.10
	2.6.1	250 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.10

G5-18A/2505

2.1

General Information and Specifications

2.1REPLACEMENT PARTS AND WARRANTY INFORMATION

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate is located as indicated in the figure.

MY2350

IMPORTANT: The replacement of any part on this machine with any other than a JLG authorized replacement part can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.

2.2	G5-18A/2505

18A/2505-G5		40		0.00604															FastenerASTM 1.2.2	TORQUES2.2
					380	8	6		—	—	540	12	9	—	—	—	—	—
						VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY										UNPLATED CAP SCREWS
						SAE GRADE 5 BOLTS &					SAE GRADE 8 BOLTS & GRADE 8 NUTS					UNBRAKO 1960 SERIES
						GRADE 2 NUTS						& SOCKET HEAD CAP SCREWS				SOCKET HEAD
			BOLT	TENSILE	CLAMP		TORQUE				CLAMP		TORQUE			CLAMP	TORQUE
		THDS.				DRY OR			LOCTITE	LOCTITE		DRY OR		LOCTITE	LOCTITE		WITHOUT	WITH
	SIZE	PER	DIA.	STRESS	LOAD	LOCTITE	LUB			242 OR	LOAD	LOCTITE	LUB		242 OR	LOAD	LOC-WEL	LOC-WEL
				AREA					262					262
		INCH				263				271		263			271		PATCH	PATCH
			IN	SQ. IN.	LB.	IN-LB	IN-LB		IN-LB	IN-LB	LB.	IN-LB.	IN-LB	IN-LB	IN-LB	LB.	IN-LB	IN-LB
	4		0.1120
		48		0.00661	420	9	7		—	—	600	13	10	—	—	—	—	—	Torque
	8	32	0.1640	0.00909	580	16	12		—	—	820	23	17	—	—	—	—	—
	6	40	0.1380	0.01015	610	18	13		—	—	920	25	19	—	—	—	—	—
		32		0.01400	900	30	22		—	—	1260	41	31	—	—	—	—	—
		36		0.01474	940	31	23		—	—	1320	43	32	—	—	—	—	—	Chart
		20		0.0318	2020	96	75		—	105	2860	144	108	—	160	3180	160	168
	10	24	0.1900	0.01750	1120	43	32		—	—	1580	60	45	—	—	—	—	—
		32		0.02000	1285	49	36		—	—	1800	68	51	—	—	—	—	—
	1/4		0.2500																(English)
		28		0.0364	2320	120	86		—	135	3280	168	120	—	185	3640	168	178
	5/16	18	0.3125	0.0524	3340	17	13		16	19	4720	25	18	22	30	5240	25	28
		24		0.0580	3700	19	14		17	21	5220	25	20	25	30	5800	27	30
	3/8	16	0.3750	0.0775	4940	30	23		28	35	7000	45	35	40	50	7750	45	50
		24		0.0878	5600	35	25		32	40	7900	50	35	45	55	8780	50	55
	7/16	14	0.4375	0.1063	6800	50	35		45	55	9550	70	55	63	80	10630	70	77				General
		20		0.1187	7550	55	40		50	60	10700	80	60	70	90	11870	75	82
	1/2	13	0.5000	0.1419	9050	75	55		68	85	12750	110	80	96	120	14190	110	120
		20		0.1599	10700	90	65		80	100	14400	120	90	108	130	15990	115	127
	9/16	12	0.5625	0.1820	11600	110	80		98	120	16400	150	110	139	165	18200	155	170
		18		0.2030	12950	120	90		109	135	18250	170	130	154	190	20300	165	182				Information
	5/8	11	0.6250	0.2260	14400	150	110		135	165	20350	220	170	180	240	22600	210	231
		18		0.2560	16300	170	130		153	190	23000	240	180	204	265	25600	220	242
	3/4	10	0.7500	0.3340	21300	260	200		240	285	30100	380	280	301	420	33400	365	400
		16		0.3730	23800	300	220		268	330	33600	420	320	336	465	37300	400	440
	7/8	9	0.8750	0.4620	29400	430	320		386	475	41600	600	460	485	660	46200	585	645
		14		0.5090	32400	470	350		425	520	45800	660	500	534	725	50900	635	700
	1	8	1.0000	0.6060	38600	640	480		579	675	51500	900	680	687	990	60600	865	950				and
		12		0.6630	42200	700	530		633	735	59700	1000	740	796	1100	66300	915	1000
	1-1/8	7	1.1250	0.7630	42300	800	600		714	840	68700	1280	960	1030	1400	76300	1240	1365
		12		0.8560	47500	880	660		802	925	77000	1440	1080	1155	1575	85600	1380	1520				Specifications
	ote:	These torque values		do not apply to cadmium plated			fasteners.		1009	1175	87200	1820	1360	1453	2000	96900	1750	1925
	1-1/4	7	1.2500	0.9690	53800	1120	840
		12		1.0730	59600	1240	920		1118	1300	96600	2000	1500	1610	2200	107300	1880	2070
	1-3/8	6	1.3750	1.1550	64100	1460	1100		1322	1525	104000	2380	1780	1907	2625	115500	2320	2550
		12		1.3150	73000	1680	1260		1506	1750	118100	2720	2040	2165	3000	131500	2440	2685
	1-1/2	6	1.5000	1.4050	78000	1940	1460		1755	2025	126500	3160	2360	2530	3475	140500	3040	3345
		12		1.5800	87700	2200	1640		1974	2300	142200	3560	2660	2844	3925	158000	3270	3600
3.2

4.2

2.2

2.

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

UNPLATED CAP SCREWS

SAE GRADE 5 BOLTS &

SAE GRADE 8 BOLTS & GRADE 8 NUTS

UNBRAKO 1960 SERIES

GRADE 2 NUTS

& SOCKET HEAD CAP SCREWS

SOCKET HEAD

(Metric)ChartTorqueFastenerASTM

SpecificationsandInformationGeneral

TENSILE

TORQUE

TORQUE

TORQUE

THDS.

BOLT

CLAMP

DRY OR

LOCTITE

CLAMP

DRY OR

LOCTITE

CLAMP

WITHOUT

WITH

STRESS

LOCTITE

LOCTITE

SIZE

PER

DIA.

LOAD

LOCTITE

LUB

242 OR

LOAD

LOCTITE

LUB

242 OR

LOAD

LOC-WEL

LOC-WEL

AREA

262

262

INCH

263

271

263

271

PATCH

PATCH

IN

SQ. IN.

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

IN

SQ. IN.

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

Note: These torque values do not apply to cadmium plated fasteners.

18A/2505-G5

General Information and Specifications

2.2.3Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

				CLASS 8.8 METRIC BOLTS &					CLASS 10.9 METRIC BOLTS &
				CLASS 8 METRIC NUTS					CLASS 10 METRIC NUTS
		TENSILE			TORQUE					TORQUE
			CLAMP	DRY OR			LOCTITE	CLAMP	DRY OR				LOCTITE
		STRESS				LOCTITE					LOCTITE
SIZE	PITCH		LOAD					LOAD
		AREA		LOCTITE	LUB		242 OR		LOCTITE	LUB			242 OR
						262					262
				263			271		263				271
		sq. mm	KN	N, m	N, m	N, m	N, m	KN	N, m	N, m	N, m		N, m
3	.5	5.03	2.19	1.3	1.0	1.2	1.4	3.13	1.9	1.4	1.5		2.1
3.5	.6	6.78	2.95	2.1	1.6	1.9	2.3	4.22	3.0	2.2	2.4		3.3
4	.7	8.78	3.82	3.1	2.3	2.8	3.4	5.47	4.4	3.3	3.5		4.8
5	.8	14.2	6.18	6.2	4.6	5.6	6.8	8.85	8.9	6.6	7.1		9.7
6	1	20.1	8.74	11	7.9	9.4	12	12.5	15	11	12		17
7	1	28.9	12.6	18	13	16	19	18	25	19	20		28
8	1.25	36.6	15.9	25	19	23	28	22.8	37	27	29		40
10	1.5	58.0	25.2	50	38	45	55	36.1	72	54	58		79
12	1.75	84.3	36.7	88	66	79	97	52.5	126	95	101		139
14	2	115	50.0	140	105	126	154	71.6	200	150	160		220
16	2	157	68.3	219	164	197	241	97.8	313	235	250		344
18	2.5	192	83.5	301	226	271	331	119.5	430	323	344		473
20	2.5	245	106.5	426	320	383	469	152.5	610	458	488		671
22	2.5	303	132.0	581	436	523	639	189.0	832	624	665		915
24	3	353	153.5	737	553	663	811	220.0	1060	792	845		1170
27	3	459	199.5	1080	810	970	1130	286.0	1540	1160	1240		1690
30	3.5	561	244.0	1460	1100	1320	1530	349.5	2100	1570	1680		2310
33	3.5	694	302.0	1990	1490	1790	2090	432.5	2600	2140	2280		2860
36	4	817	355.0	2560	1920	2300	2690	509.0	3660	2750	2930		4020
42	4.5	1120	487.0	4090	3070	3680	4290	698.0	5860	4400	4690		6440

Note: These torque values do not apply to cadmium plated fasteners.

METRIC CLASS 8.8 METRIC CLASS 10.9

G5-18A/2505

2.5

General Information and Specifications

2.3SPECIFICATIONS

2.3.1	Travel Speed
12 x 16.5 Tires (Standard)		16 mph (26 kmph)
14 x 17.5 Tires		18 mph (29 kmph)

2.3.2Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature.

Function	Approximate Times (sec.)
Boom Extend	6
Boom Retract	4
Boom Lift	6
Boom Lower	4
Attachment Tilt - UP	2
Attachment Tilt - DOWN	2

2.3.3Electrical System

Note: Refer to Section 9.3, “Fuses and Relays,” for more information.

Battery:

Type, Rating	12V DC, Negative (-) Ground, Limited Maintenance,
	Wet Charged
Quantity	1 (100 Ah) (C20)
Reserve Capacity	CCA @ -.4° F: 880 EN
Group/Series	DIN 600,44
Alternator	12V, 75 Amps
Starter	12V, 3,0 KW Type EV (Gear Reduction)

2.6	G5-18A/2505

		General Information and Specifications
2.3.4	Engine Performance Specifications
	Description
Engine Make/Model		Perkins 1104D-44T
Low Idle		900 ±50 rpm
High Idle		2150 ±50 rpm
Horsepower		84 BHP/ 64,5 kW @ 2200 rpm
Fuel Delivery		Fuel Injection
Air Cleaner		Dry Type, Replaceable Primary and Safety Elements
Average Fuel Consumption (dependant on load/duty)		1.6 gal/hr (6,1 I/hr)

2.3.5Tires

Size	Tire Type	Minimum Ply/	Fill Type	Pressure
		Star Rating
12 x 16.5	NHS	12 Ply	Pneumatic	80 psi (5,5 bar)
			Approx. 220 lb foam
14 x 17.5	NHS	12 Ply	Pneumatic	70 psi (4,8 bar)
			Approx. 220 lb foam
Note: Standard wheel lug nut torque is 210-230 lb-ft (285 - 312 Nm).

G5-18A/2505

2.7

General Information and Specifications

2.4FLUIDS, LUBRICANTS AND CAPACITIES

Engine Crankcase Oil

Capacity w/Filter Change	9.6 quarts (9,0 liters)
Filter Capacity	1.05 quarts (1,0 liter)
Oil Type	15W-40 CE
Fuel Tank
Capacity	24 gallons (90,8 liters)
Type of Fuel	U.S.A. #2 Diesel
Cooling System
System Capacity w/o Heater	14.6 quarts (13,8 liters)
Type of Fluid	50/50 mix of ethylene glycol & water
Axles
Differential Housing Capacity - Front	3.6 quarts (3,4 liters)
Axle Drop Box - Front	21 ounces (0,6 liters)
Differential Housing Capacity - Rear	3.6 quarts (3,4 liters)
Wheel End Capacity	10 ounces (0,3 liters)
Type of Fluid	Mobilfluid® 424 Tractor Hydraulic Fluid (ISO 46)
Brakes
Master Cylinder Capacity	0.7 quarts (0,7 liters)
Type of Fluid	Mobilfluid® 424 Tractor Hydraulic Fluid (ISO 46)
Hydraulic System
System Capacity	23.5 gallons (89 liters)
Reservoir Capacity to FULL Mark	16 gallons (60,6 liters)
Type of Fluid	Mobilfluid® 424 Tractor Hydraulic Fluid (ISO 46)
Auxiliary Hydraulic Circuit Max Flow	20 GPM (75,7 LPM)

2.8	G5-18A/2505

General Information and Specifications

2.5 MAINTENANCE SCHEDULES	2.5.2	1st 250, 250, 500 & 1000 Hour
		Maintenance Schedule

2.5.110,1st 50 & 50 Hour Maintenance Schedule

1st

250

EVERY
10
Check Fuel	Check Tire	Check Engine	Check Hydraulic
Level	Pressure	Oil Level	Oil Level

Change

Axle Oil

Change Wheel

End Oil

EVERY

250

1st

50

LB/FT

(Nm)

Check Wheel

Lug Nut

Torque

EVERY
50
Check Engine	Drain Fuel/	Check
Coolant Level	Water	Air Filter
	Separator

Check Boom

Bearing

Pads

Change Fuel

Filter

MY2560

Change

Axle Oil

Lubrication	Check Axle	Check Wheel
Schedule	Oil Level	End Oil Levels

LB/FT (

Nm)

Check Wheel

Lug Nut

Torque

EVERY
500
Change Engine	Change
Oil and	Air Filter
Filter

Change Wheel

End Oil

EVERY
1000
Change	Check	Change
Hydraulic	Hydraulic Tank	Transmission
Fluid & Filters	Cap	Filter

Change

Engine Coolant

MY2570

G5-18A/2505

2.9

General Information and Specifications

2.6LUBRICATION SCHEDULE

2.6.1250 Hour Lubrication Schedule

EVERY

250

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

MY2580

2.10	G5-18A/2505

Section 3

Boom

Contents

PARAGRAPH		TITLE	PAGE
3.1	Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.2
3.2	Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.3
	3.2.1	Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
3.3	Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.3
	3.3.1	Second Section Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
	3.3.2	First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.4
	3.3.3	First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.5
	3.3.4	Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.5
	3.3.5	Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.5
	3.3.6	Second Section Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.6
	3.3.7	Second Section Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.7
	3.3.8	Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.7
	3.3.9	Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.8
	3.3.10	Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.9
3.4	Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.10
	3.4.1	Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.10
	3.4.2	Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.10
	3.4.3	Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.11
3.5	Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.11
	3.5.1	Connecting with a Mechanical JLG Quick Attach . . . . . . . . . . . . . . . . . . .	3.11
	3.5.2	Connecting with a Hydraulic JLG Quick Attach. . . . . . . . . . . . . . . . . . . . .	3.11
	3.5.3	Connecting with a Universal Quick Attach . . . . . . . . . . . . . . . . . . . . . . . .	3.12
	3.5.4	Connecting a Hydraulic Operated Attachment . . . . . . . . . . . . . . . . . . . . .	3.12
	3.5.5	Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.13
	3.5.6	Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.13
3.6	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.14

G5-18A/2505

3.1

Boom

3.1BOOM SYSTEM COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.

COMPENSATING

CYLINDER

FIRST

BOOM

SECTION

	SECOND
	BOOM	PIVOT PIN
	SECTION

TILT

CYLINDER

EXTEND/RETRACT

CYLINDER

AUXILIARY HYDRAULIC

QUICK CONNECTS

MY1940

QUICK

ATTACH

3.2	G5-18A/2505

Boom

3.2BOOM SYSTEM - TWO SECTION BOOM

3.2.1Boom System Description

The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Components involved include the joystick, tilt cylinder, extend/retract cylinder, lift/lower cylinder, compensating cylinder, electronic sensors, various pivots, supporting hardware and other components.

3.3BOOM ASSEMBLY MAINTENANCE

The boom assembly consists of the first and second section booms and supporting hardware.

Note: Before removing the boom or boom section, the carriage or any other attachment must be removed from the quick attach.

Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.

During service of the boom, perform the following:

1.Check wear pads. (Refer to Section 3.4.1, “Wear Pad Inspection.”)

2.Apply grease at all lubrication points (grease fittings). (Refer to Section 2.6, “Lubrication Schedule.”)

3.Check for proper operation by operating all boom functions through their full ranges of motion several times.

Depending on your particular circumstance, the following procedures explain the removal/installation of individual boom sections or removal/installation of the complete boom.

3.3.1Second Section Boom Removal

1.Remove any attachment from the quick switch assembly.

2.Be sure there is enough room in front of the machine to allow the boom sections to be removed. Park the machine on a hard, 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.

3.Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4.Remove the battery negative (-) cable from the battery negative (-) terminal.

5.Open the engine cover. Allow the system fluids to cool.

6.Remove the quick switch assembly. Refer to Section 3.5.5, “Quick Attach Removal.”

7.Label and disconnect the tilt hoses and (if equipped) auxiliary hydraulic hoses attached to the machine at the boom head. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

8.Label and disconnect the extend/retract hydraulic tubes on the extend/retract cylinder at the rear of the boom.

9.Tag or identify each hose to the corresponding fitting it was removed from.

10.Remove the top and side wear pads from the rear of the second boom section.

Note: Tag each pad, backing plate, shim and bolts from each location.

1

2

MY1960

11.Remove the lock bolt and nut (1) from the rear of the extend/retract cylinder.

12.Remove the extend/retract cylinder mounting pin (2).

13.Support the front of the boom by placing a sling behind the boom head. Pull the second boom section out of the first boom section approximately 6 in to 8 in (15 cm to 20 cm).

14.Pull the tilt hoses and (if equipped) auxiliary hydraulic hoses through the rear of the boom.

15.Remove the top, side and bottom wear pads from the front of the first boom section.

Note: Tag each pad, backing plate, shim and bolts from each location.

G5-18A/2505

3.3

Boom

16.Pull the second boom section halfway out of the first boom section, reposition the sling, balancing the second boom section and remove from the first boom section.

17.Set the second boom section on level ground. Set the complete boom on suitable stands to begin tear down.

18.Inspect the boom and welds. Consult your local JLG distributor if structural damage is detected.

19.Inspect hoses, hardware, wear pads, mounting points and other components visible with the first boom section. Replace any item if damaged.

20.Inspect all wear pads for wear. (Refer to Section 3.4.1, “Wear Pad Inspection.”)

3.3.2First Boom Section Removal

1.Temporarily install the battery negative (-) cable to the battery negative (-) terminal.

2.Start the machine and raise the first boom section to gain access to the lift cylinder pin and the comp cylinder pin.

Note: DO NOT activate ANY boom function other than the boom lift function. Activating the extend/retract, tilt or auxiliary function could cause hydraulic oil to spray onto the machine and/or surrounding areas.

3.Remove the battery negative (-) cable from the battery negative (-) terminal.

4.Support the first boom section by placing a sling at the balance point of the section.

1

2

MY1970

3

4

MY1980

6.Remove the lock bolt and pin (3) from the rod end of the compensating cylinder on the first boom section. Rest the cylinder on the machine frame.

7.Remove the lock bolt and pivot pin (4) from rear of first boom section.

8.Lift the first boom section off machine and set on level ground or supports being careful not to damage the tubes on the bottom of the boom.

9.Inspect the boom and welds. Consult your local JLG distributor if structural damage is detected.

10.Inspect hoses, hardware, wear pads, mounting points and other components visible with the first boom section. Replace any item if damaged.

11.Inspect all wear pads for wear. (Refer to Section 3.4.1, “Wear Pad Inspection.”)

5.Support the lift/lower cylinder and remove the lock bolt (1) and then the rod end pin (2). Lower the lift/ lower cylinder onto the frame rails.

3.4	G5-18A/2505

Boom

3.3.3First Boom Section Installation

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

1.Park the machine on a hard, level surface, 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.

Note: Grease the boom pivot bore, compensating cylinder rod ends, lift/lower cylinder rod end and pins before installing.

4.Using suitable slings, balance the first boom section, lift and carefully guide the boom into place. Align the frame pivot bore with the boom assembly pivot bore. Install boom pivot pin (5) and lock bolt. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

5.With the sling still in place, install the compensating cylinder, pin (6) and lock bolt. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

6

5

MY1980

3.3.4Second Boom Section Installation

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

1.If previously removed, install the extend/retract cylinder into the rear of the second boom section. Pin and clip the barrel end of the cylinder in place.

2.Using suitable slings, balance the second boom section, lift and carefully guide the boom into place.

3.Install the wear pads, shims and bolts to their proper location at the front inside of the first boom section. DO NOT tighten the wear pads at this time.

4.Feed the tilt cylinder hoses and if equipped, the auxiliary hoses through the channel above the extend/retract cylinder.

5.Install the wear pads, shims and bolts previously removed from the rear of the second boom section. DO NOT tighten the wear pads at this time.

6.Uncap and reconnect the extend/retract cylinder fittings and plugs from extend/retract cylinder tubes. Attach each tube to the extend/retract cylinder fittings and tighten until wrench-tight. Mark the fitting, then tighten each tube firmly 1 to 1,5 flats.

7.Uncap and reconnect the tilt hoses and (if equipped) auxiliary hoses. Attach both sets to their appropriate fittings until wrench-tight. Mark the fitting, then tighten each hose firmly 1 to 1,5 flats.

8.Adjust and shim each wear pad as needed.

9.Start the engine and operate all boom functions several times to bleed any air out of the hydraulic system. Check for fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

10.Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

11.Close and secure the engine cover.

6.With the sling still in place, install the rod end of the lift/lower cylinder, pin and lock bolt. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

Note: Raising the boom up or down with the sling may be necessary so the boom, compensating and lift/lower cylinder bores can be aligned for easier pin installation.

7. Make sure boom section is level, then remove sling.

3.3.5Complete Boom Removal

1.Remove any attachment from the quick switch assembly.

2.Be sure there is enough room in front of the machine to allow the boom sections to be removed. Park the machine on a hard, level surface, fully retract the boom, Raise the boom to allow access to the lift cylinder and the comp cylinder pivot pins, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

G5-18A/2505

3.5

Boom

3.Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4.Remove the battery negative (-) cable from the battery negative (-) terminal.

5.Open the engine cover. Allow the system fluids to cool.

6.Remove the quick switch assembly. Refer to Section 3.5.5, “Quick Attach Removal.”

7.Support the boom by placing a sling around the boom head. Support the lift/lower cylinder and remove the lock bolt and then the rod end pin. Lower the lift/lower cylinder onto the frame rails.

8.Label and disconnect the tilt and auxiliary hydraulic hoses attached to the machine at the tubes on top of the boom. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

9.Label and disconnect the extend/retract hydraulic hoses at the tubes on the side of the boom.

Note: Tag or identify each hose to the corresponding fitting it was removed from.

10.Remove the lock bolt and pin (1) from the rod end of the compensating cylinder on the first boom section. Rest the cylinder on the machine frame.

3.3.6Second Section Boom Removal

1.At the boom head, attach a sling around the tilt cylinder. Remove both hoses from tilt cylinder. Plug the hose ends and cap the tilt cylinder fittings to prevent dirt and debris from entering the hydraulic system. Remove the clip from barrel end of tilt cylinder pin. Remove the tilt cylinder pin and lower the tilt cylinder out of the boomhead.

2.Remove the extend /retract tubes from the extend / retract cylinder from the rear of the boom.

3.If equipped, unscrew the auxiliary hoses. Plug the hose ends to prevent dirt and debris from entering the hydraulic system.

Note: Tag or identify each hose to the corresponding fitting it was removed from.

MY1990

1

2

MY1980

11.Lower the boom to a level position and place a suitable support under the rear of the boom. Reposition the slings to each end of the boom.

12.Remove the lock bolt and pivot pin (2) from rear of first boom section.

13.Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the bottom of the boom.

3

4.Remove the lock nut, bolt and pin from rod end of the extend/retract cylinder.

5.Pull the second boom section out 6 in to 8 in

(15 cm to 20 cm) to be able to loosen and remove all the bolts and remove all the wear pads, backing plates and shims from the rear outside of the second section boom and the front inside of the first section boom. Tag each pad, backing plate, shim and bolts from each location.

6.Carefully pull the tilt and auxiliary hydraulic hoses (3) through the rear of the first boom section.

WARNING

NEVER weld or drill the boom unless approved in writing by JLG. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. Failure to comply could result in death or severe personal injury.

7. Pull out the remainder of the second boom section.

3.6	G5-18A/2505

Boom

8.Inspect the boom and welds. Consult your local JLG distributor if structural damage is detected.

9.Inspect hoses, hardware, wear pads, mounting points and other components visible with the first boom section. Replace any item if damaged.

10.Inspect all wear pads for wear. (Refer to Section 3.4.1, “Wear Pad Inspection.”)

3.3.7Second Section Boom Installation

1.If previously removed, insert the extend/retract cylinder through the rear of the second boom section and attach the pin and clip to the barrel end.

2.Install the bottom rear wear pads, washers and bolts into the second boom section. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

Note: Apply Loctite® #242 to all wear pad bolts prior to installing wear pads.

3.Grease the inside of the first boom section on areas where the second boom section wear pads will slide.

4.Using a suitable sling, carefully slide the second boom section 3 ft to 4 ft (1 m to 1.5 m) into the front of the first boom section. Set the second boom section head onto suitable supports and reset sling under the boom head of the second section. Carefully slide the second section into the first section. Leave 6 in to 8 in (15 cm to 20 cm) of the second section out to be able to install wear pads in front of the first boom section.

5.With the sling still under the boom head, install the top wear pads, washers and bolts in the front of the first boom section. Apply Loctite ® #242 and torque to 66 lb-ft (90 Nm). Raise the second boom section and install the bottom wear pads, backing plates, shims and bolts in the front of the first boom section Apply Loctite ® #242 and torque to 66 lb-ft (90 Nm). Install the left and right side front wear pads, backing plates, shims and bolts in the front of the first boom section. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

6.Install the top rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install the left and right side rear wear pads, backing plates and bolts, do not shim or tighten bolts).

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly.

7.Tighten all rear wear pad bolts after ensuring the minimum gap requirements have been met. Refer to Section 3.4.1, “Wear Pad Inspection.”

G5-18A/2505

8.Slide the tilt and auxiliary hoses between the boom sections.

9.Insert the pin and secure the rod end of the extend/ retract cylinder in place with the bolt and locknut.

10.Install both tubes to the rear of the extend/retract cylinder.

11.Lift the tilt cylinder into place and insert the pins and clips to secure the cylinder to the boomhead.

12.Uncap and reconnect the tilt and auxiliary hoses and attach to their appropriate locations.

3.3.8Boom Installation

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

1.Park the machine on a hard, level surface, 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.

Note: Grease the boom pivot bore, compensating cylinder rod ends, lift/lower cylinder rod end and pins before installing.

4.Using suitable slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bore with the boom assembly pivot bore. Install boom pivot pin (4) and lock bolt. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

5.With the sling still in place, install the compensating cylinder, pin (5) and lock bolt. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

4

5

MY1980

3.7

Boom

6.With the sling still in place, install the rod end of the lift/lower cylinder, pin and lock bolt. Apply Loctite® #242 and torque to 66 lb-ft (90 Nm).

Note: Raising the boom up or down with the sling may be necessary so the boom, compensating and lift/lower cylinder bores can be aligned for easier pin installation.

7.Uncap and reconnect the extend/retract cylinder fittings and plugs from extend/retract cylinder tubes. Attach each tube to the extend/retract cylinder fittings and tighten until wrench-tight. Mark the fitting, then tighten each tube firmly 1 to 1,5 flats.

8.Uncap and reconnect the tilt hoses and (if equipped) auxiliary hoses. Attach both sets to their appropriate fittings until wrench-tight. Mark the fitting, then tighten each hose firmly 1 to 1,5 flats.

9.Start the engine and operate all boom functions several times to bleed any air out of the hydraulic system. Check for fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

10.Check clearance (1) between the tilt hoses (and if equipped) auxiliary hoses and the front of the extend/retract cylinder trunnion. There should be approximately 1/2 in. (12,7 mm) of clearance.

11.If adjustment is needed, loosen the tilt tubes (and if equipped) auxiliary tubes. Move tubes to achieve the proper clearance.

3.3.9Extend/Retract Cylinder Removal

1.Remove any attachment from the quick attach assembly. Refer to Section 3.5, “Quick Attach Assembly.”

2.Park the machine on a hard, level surface, extend the boom to gain access to the extend/retract cylinder pin in the second boom section (approximately 3 ft (1 m), level the boom assembly, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

Note: The boom must be properly aligned (level) with the access hole at the rear of the frame to allow removal of the extend/retract cylinder barrel mounting pin.

3.Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4.Open the engine cover. Allow the system fluids to cool.

1

MY2000

12.Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

13.Close and secure the engine cover.

2

MY2680

5.Remove the battery negative (-) cable from the battery negative (-) terminal.

6.Remove the cylinder rod eye retaining clips and mounting pin (2) at the side of the second boom section.

7.Loosen and remove the hose clamps and cover plate (3) from the rear of the boom assembly.

8.Label and disconnect the tilt and auxiliary hydraulic hoses attached to the machine at the tubes on top of the boom (4). Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

9.Loosen and remove the extend/retract cylinder tubes at the rear of the first boom section. Plug the tube ends to prevent dirt and debris from entering the hydraulic system.

3.8	G5-18A/2505

Boom

10.Loosen and remove both fittings from the bottom of the extend/retract cylinder barrel. Plug the openings in the extend/retract cylinder barrel.

11.Loosen and remove the locking bolt on the cylinder barrel mounting pin.

12.Remove the cylinder barrel pin (5). Note the location of the spacers and washers.

13.Attach a sling or other suitable lifting device to the extend/retract cylinder and carefully pull the extend/ retract cylinder free of the machine through the rear of the boom/chassis assembly.

Note: The tilt hoses and if equipped, the auxiliary hoses may need to be moved during removal of the extend/ retract cylinder.

14.Place the extend/retract cylinder in a designated area for the next operation.

3.3.10Extend/Retract Cylinder Installation

1.Carefully install the extend/retract cylinder into the rear of the boom and line up the barrel end of the cylinder with the pin bores on the first boom section.

Note: The tilt hoses and if equipped, the auxiliary hoses may need to be moved during installation of the extend/ retract cylinder.

2.Install the mounting pin (5), spacers and washers through the frame access hole on the chassis and the first boom section bore and cylinder barrel.

Secure with retaining clips.

4

3

5

MY2670

3.Remove the plugs in the bottom of the extend/retract cylinder and install the previously removed fittings.

4.Uncap and connect the tubes to the previously labeled fittings at the extend/retract cylinder. Apply Loctite 545® to the fittings.

G5-18A/2505

5.Uncap and reconnect the tilt hoses and (if equipped) auxiliary hoses (4). Attach both sets to their appropriate fittings until wrench-tight. Mark the fitting, then tighten each hose firmly 1 to 1,5 flats.

6.Install the cover plate and hose clamps (3) at the rear of the boom assembly.

7.Install the battery negative (-) cable to the battery negative (-) terminal.

8.Start the machine and extend the extend/retract cylinder until the rod eye of the cylinder aligns with the pin bore in the second boom section.

9.Shut the engine OFF.

10.Install the mounting pin through the side of the second boom section (2) and secure with the retaining clips.

11.Start the machine and cycle the extend/retract cylinder checking for leaks or any alignment problems.

3.9

Boom

3.4BOOM WEAR PADS

On the G5-18A a total of 14 wear pads are installed on the boom.

Twelve of the fourteen wear pads on this boom are flat rectangular wear pads with metal inserts. Two wear pads on the bottom of the second section boom are channeled for tilt hose and auxiliary hose clearance.

3.4.1Wear Pad Inspection

Inspect all wear pads (2) for wear. If the angle indicators (3) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

3	3

2

MA2070

3.4.2Boom Wear Pad Replacement

When replacing a wear pad on the boom, replace both wear pads on that side of the boom; e.g.: replace top front left and top front right wear pads at the same time.

Usually, shimming will remain the same when installing new wear pads. All wear pads are secured to the boom using different capscrews and washers. When installing new wear pads, apply Loctite® #242 to all wear pad mounting capscrews M10 x 1,5 and torque to 23 lb-ft (31Nm). On 5/16 x 18 capscrews, apply Loctite® #242 to and torque to 17 lb-ft (23 Nm). Grease the new pads and surrounding area.

The boom wear pads are mounted on the inside of the first boom section (4) and the outside of the second boom section (5).

3.10

4

MY2010

5

MY2020

Use shims under the wear pads as required to maintain a maximum gap of 0.06 in (1,5 mm) (6) between the wear pad on the front and sides of the boom. The gap at the rear of the boom should be no more than 0.12 in (3 mm).

Shims are available in four thicknesses, 0.02 in (0,5mm), 0.04 in (1 mm), 0.06 in (1,5mm) and 0.08 in (2,0mm).

6

MU4080

G5-18A/2505