Jlg 2505 Parts Manual- Manuals

Page 3 - EFFECTIVITY PAGE

EFFECTIVITY PAGE 31200360 G5-18A/2505 i February 22, 2008 - A - Original Issue Of Manual April 30, 2008 - B - Revised Manual October 23, 2008 - C - Revised Manual June 12, 2009 - D - Revised Manual November 18, 2011 - E - Revised Manual August 6, 2012 - F - Revised Manual February 25, 2013 - G - Rev...

Page 4 - ii

Page 5 - TABLE OF CONTENTS; iii

TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. 31200360 G5-18A/2505 iii SECTION 1 – FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 Frame Shrouding & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 6 - TITLE; iv; SECTION 6 –

TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. G5-18A/2505 31200360 iv 5-3 Front Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-4 Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 10 - FRAME & ATTACHING PARTS; Figure 1-1 Frame Shrouding & Attaching Parts

G5-18A/2505 31200360 1-2 FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Attaching Parts PAP17320 301 304 305 306 308 313 314 313 314 401 402 403 404 405 4 322 320 320 323 326 320323 321 318 319 327 328 324 325 310317 309315 316 302

Page 12 - Item

G5-18A/2505 31200360 1-4 FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Attaching Parts Item Part Number Qty. Description Rev. 1001098514 Ref ENGINE POD INSTALLATION, (not available to order, see items 1 thru 4 for service) D 1 0682220 4 HEX HD CAPSCREW, 3/4-10X2-1/2, GR8 2 4892200 4 W...

Page 19 - BAR; ENGINE COVER REPLACEMENT KIT,

31200360 G5-18A/2505 1-11 FRAME & ATTACHING PARTS 902 88501012 2 HEX NUT, 3/4-10 903 1001008436 1 MIRROR, (includes items 954 thru 956) B 904 1001080241 1 BAR 1001111700 1 BAR, (2505 - AUS) 954 1001008475 2 LOCKWASHER, #12 955 1001009062 2 WASHER 956 1001010838 2 HEX HD BOLT 1001 0100071 AR ADHE...

Page 20 - Figure 1-3 Engine Pod Insulation

G5-18A/2505 31200360 1-12 FRAME & ATTACHING PARTS Figure 1-3 Engine Pod Insulation PAP17470 317 318319320 403404405 207 208 315 310 304 302 308 309 303 314 316 311 301 305 306 401 402 1 2 3 101 102 104 103 105 206 2505

Page 28 - Figure 1-6 License Plate Holder Installation

G5-18A/2505 31200360 1-20 FRAME & ATTACHING PARTS Figure 1-6 License Plate Holder Installation PAL5070 102 111 111 107 1 2 5 151 152 3 4 Before S/N 0160037440

Page 29 - LICENSE PLATE HOLDER INSTALLATION,

31200360 G5-18A/2505 1-21 FRAME & ATTACHING PARTS Figure 1-6 License Plate Holder Installation Item Part Number Qty. Description Rev. 1001081394 1 LICENSE PLATE HOLDER INSTALLATION, (UK & Ireland) , (not available for service, see items 1 thru 5 for service) B 1 10700730 2 HEX HD CAPSCREW, 3...

Page 32 - Figure 1-7 Rear Engine Cover

G5-18A/2505 31200360 1-24 FRAME & ATTACHING PARTS Figure 1-7 Rear Engine Cover 107108 103110 104 3 4 15 4 3 PAL5311 105 15

Page 34 - This Page Intentionally Left Blank

G5-18A/2505 31200360 1-26 FRAME & ATTACHING PARTS This Page Intentionally Left Blank

Page 36 - BOOM

G5-18A/2505 31200360 2-2 BOOM Figure 2-1 Boom Assembly - Components PAP17460 4 8 9 13 14 14 16 17 17 19 22 22 26 27 27 28 28 29 30 30 30 33 33 34 34 10 11 42 43 44 44 46 47 3945 104 101105 103 102 NOTE: USE ITEM 1 ON ALL BOLT THREADS.APPLY A THIN COAT OF ITEM 31 TO ALL PIN BORES.

Page 40 - Figure 2-3 Boom Pin Installation

G5-18A/2505 31200360 2-6 BOOM Figure 2-3 Boom Pin Installation 2 1 12 11 10 3 6 8 9 5 7 10 10 7 4 9 8 6 PAL3810 13

Page 42 - Figure 2-4 Quick Coupler

G5-18A/2505 31200360 2-8 BOOM Figure 2-4 Quick Coupler 1 2 3 4 5 6 7 8 9 10 PAL3941 101 102 103 104 105 106 107 108 109 109 110 110 111 112 112 113 113 114 115 116 201 202 203 204 205 301 302 303 304 HYDRAULIC QUICK COUPLER MECHANICAL QUICK COUPLER

Page 44 - Figure 2-5 Universal Quick Coupler

G5-18A/2505 31200360 2-10 BOOM Figure 2-5 Universal Quick Coupler 115 114 101 103 106 108 116 102 104 112 107 111 110 112 109 113 105 117 PAL4021 5 4 3 1 2 2 1 201 202 203 204 301 303 306 304 305 302

Page 48 - ATTACHMENTS; Figure 3-1 Standard Carriage

G5-18A/2505 31200360 3-2 ATTACHMENTS Figure 3-1 Standard Carriage 1 4 5 7 6 3 2 105 106 101 104 103 102 201 205 203 204 206 202 PAL4512 207 48 IN CARRIAGE 50 IN CARRIAGE 1200 MM CARRIAGE

Page 50 - Figure 3-2 Universal Standard Carriage

G5-18A/2505 31200360 3-4 ATTACHMENTS Figure 3-2 Universal Standard Carriage PAP17370 105 106 101 104 103 102 1 5 3 4 6 2 201 202 203 204 204 201 202 203 2505 - CE G5-18A, 2505 - AUS

Page 52 - Figure 3-3 Side Tilt Carriage

G5-18A/2505 31200360 3-6 ATTACHMENTS Figure 3-3 Side Tilt Carriage PAL4400 1 1 3 5 3 5 16 10 25 15 14 20 18 23 19 24 8 12 27 26 13 2 4 7 28 29 17 6 11 9 21 22

Page 54 - Figure 3-4 Universal Side Tilt Carriage

G5-18A/2505 31200360 3-8 ATTACHMENTS Figure 3-4 Universal Side Tilt Carriage

Page 56 - Figure 3-5 Universal Side Shift Carriage

G5-18A/2505 31200360 3-10 ATTACHMENTS Figure 3-5 Universal Side Shift Carriage

Page 59 - Ref

31200360 G5-18A/2505 3-13 ATTACHMENTS Figure 3-6 Forks Item Part Number Qty. Description Rev. 2340037 4 CUBING FORK, 2X2X48, (G5-18A, 2505 - AUS) , (7760 lb) A 1001099458 2 PALLET FORK, 2X4X48, (G5-18A, 2505 - AUS) , (7600 lb) B 1001099457 2 LUMBER FORK, 1.5X6X60, (G5-18A, 2505 - AUS) , (7300 lb) B ...

Page 60 - Figure 3-7 Grapple Bucket

G5-18A/2505 31200360 3-14 ATTACHMENTS Figure 3-7 Grapple Bucket G5-18A, 2505 - AUS

Page 64 - Figure 3-8 Light Material Buckets

G5-18A/2505 31200360 3-18 ATTACHMENTS Figure 3-8 Light Material Buckets PAP17431 23 1 4 101 201 202 203 204 205 206 207 209 208 201 207 203

Page 66 - Figure 3-9 Fork Mounted Hook

G5-18A/2505 31200360 3-20 ATTACHMENTS Figure 3-9 Fork Mounted Hook 2 1 6 7 4 5 3 PAL4560 G5-18A

Page 70 - Figure 3-10 Universal Hitch Attach

G5-18A/2505 31200360 3-24 ATTACHMENTS Figure 3-10 Universal Hitch Attach

Page 74 - ENGINE & ATTACHING PARTS; Figure 4-1 Engine Installation

G5-18A/2505 31200360 4-2 ENGINE & ATTACHING PARTS Figure 4-1 Engine Installation PAP17261 101 44 41 43 59 41 38 555860 6667 1 615 10 28 32 34 3351 52 41 56 45 9 23 68 65 64 41 43 44 59 7 1316181940 8 17 204849 22 35 375462 5253 39 57 61 69 577071 4954

Page 76 - LOCTITE; THROTTLE CONTROL CABLE

G5-18A/2505 31200360 4-4 ENGINE & ATTACHING PARTS 70 0761008 1 HEX HD CAPSCREW, M10X16, GR8.8 71 0100011 AR LOCTITE ® 242 TM 101 1001080564 1 THROTTLE CONTROL CABLE Figure 4-1 Engine Installation (Continued) Item Part Number Qty. Description Rev.

Page 78 - Figure 4-2 Engine Assembly

G5-18A/2505 31200360 4-6 ENGINE & ATTACHING PARTS Figure 4-2 Engine Assembly PAP17250 25104 201202 1618 27 36 12 2 33 1317 102 103 5 16 17 18 35 46 36 34 13 31 4 8 1532 29 384041 44 142642 101 192237 45 23 20 21

Page 80 - Figure 4-3 Perkins Engine

G5-18A/2505 31200360 4-8 ENGINE & ATTACHING PARTS Figure 4-3 Perkins Engine PAL4660

Page 82 - Figure 4-4 Radiator/Oil Cooler Installation

G5-18A/2505 31200360 4-10 ENGINE & ATTACHING PARTS Figure 4-4 Radiator/Oil Cooler Installation PAP17240 1 101 2 3 4 5 5 6 7 20 10 11 13 16 17 18 18 19 19 19 201 102 103 104 105 105 106 106 14 104 105 104107 108

Page 84 - Figure 4-5 Air Cleaner Installation

G5-18A/2505 31200360 4-12 ENGINE & ATTACHING PARTS Figure 4-5 Air Cleaner Installation PAP17100 1 1 1 1 12 12 3 7 1 2 1013 10 13 913 9 13

Page 86 - Figure 4-6 Exhaust Installation

G5-18A/2505 31200360 4-14 ENGINE & ATTACHING PARTS Figure 4-6 Exhaust Installation 3 7 1 2 9 7 10 6 11 12 10 PAL4082 4 5 8

Page 90 - DRIVE TRAIN; Figure 5-1 Front Axle Assembly

DRIVE TRAIN G5-18A/2505 31200360 5-2 Figure 5-1 Front Axle Assembly PAP17580 102 103 104 7 2 4 10 3 12 6 101 18 11

Page 92 - Figure 5-2 Front Differential & Central Housing

DRIVE TRAIN G5-18A/2505 31200360 5-4 Figure 5-2 Front Differential & Central Housing

Page 96 - Figure 5-3 Front Hub Reduction

DRIVE TRAIN G5-18A/2505 31200360 5-8 Figure 5-3 Front Hub Reduction

Page 98 - Figure 5-4 Front Brakes

G5-18A/2505 31200360 5-10 DRIVE TRAIN Figure 5-4 Front Brakes

Page 100 - Figure 5-5 Front Steering Components

DRIVE TRAIN G5-18A/2505 31200360 5-12 Figure 5-5 Front Steering Components

Page 101 - CYLINDER

31200360 G5-18A/2505 5-13 DRIVE TRAIN Figure 5-5 Front Steering Components Item Part Number Qty. Description Rev. 1 70020300 1 CYLINDER 2 70020301 2 O-RING 3 70020302 2 ARTICULATED TIE ROD 70023472 2 SELF-LOCKING NUT 4 70020269 4 CYLINDER BOLT K1 70022613 1 STEER CYLINDER SEAL KIT

Page 102 - Figure 5-6 Rear Axle Assembly

DRIVE TRAIN G5-18A/2505 31200360 5-14 Figure 5-6 Rear Axle Assembly PAP17530 2 103 101 102 1 3

Page 104 - Figure 5-7 Rear Differential

DRIVE TRAIN G5-18A/2505 31200360 5-16 Figure 5-7 Rear Differential

Page 106 - Figure 5-8 Rear Hub Reduction & Central Housing; LEFT

DRIVE TRAIN G5-18A/2505 31200360 5-18 Figure 5-8 Rear Hub Reduction & Central Housing LEFT 201 202 203 44 102 103 101 105 104 22 42 43 25 42 26 27 41 40 28 29 52 53 54 39 38 37 21 48 32 34 33 32 31 30 11 10 9 16 13 15 17 55 18 5 6 7 6 14 13 12 8 9 10 11 45 46 47 1 21 2 3 5 20 19 106 K1 23 4 PAP1...

Page 110 - Figure 5-9 Rear Steering Components

G5-18A/2505 31200360 5-22 DRIVE TRAIN Figure 5-9 Rear Steering Components

Page 112 - Figure 5-10 Drive Shaft Installation

DRIVE TRAIN G5-18A/2505 31200360 5-24 Figure 5-10 Drive Shaft Installation 4 5 6 1 2 3 PAL4181 4 5 6

Page 116 - TIRE VALVE

DRIVE TRAIN G5-18A/2505 31200360 5-28 101 1001081224 1 WHEEL, 16.5 1001112913 1 WHEEL, 17.5, (no longer available, use 1001141863 for replacement) 1001141863 1 WHEEL, 17.5 102 1001081222 1 TIRE, 12X16.5 1001080228 1 TIRE, 14X17.5, (no longer available, use 4520259 for replacement) 4520259 1 TIRE, 14...

Page 120 - CAB; Figure 6-1 Cab Installation

CAB G5-18A/2505 31200360 6-2 Figure 6-1 Cab Installation 1819 201203 MIRROR - BEFORE S/N 0160037133MOUNTING HARDWARE & ARMBEFORE S/N 0160042155 115 144 651 653 653 653 961 962 963 16 401402404 108119120 111 2 504 4 7 11 117121 118 122 202 409 1 3 8 9 10 13 14 15138139140 105 114 127 137 142 3013...

Page 127 - NSS

CAB 31200360 G5-18A/2505 6-9 Figure 6-2 Open Cab Item Part Number Qty. Description Rev. 1001081291 1 OPEN CAB, (G5-18A) , (includes items 1 thru 3) H 1 NSS 1 CAB WELDMENT 2 1001080798 1 RIGHT SIDE GLASS 3 Ref REAR HINGED WINDOW, (see Figure 6-4 for details)

Page 128 - Figure 6-3 Enclosed Cab Installation

CAB G5-18A/2505 31200360 6-10 Figure 6-3 Enclosed Cab Installation PAP17490 4 3 5 61 7 8 6 1 355673 48 51 50 54 13 41 60 70 68 44 36 55 42 45 52 57 49 38 39 45 45 61 66 62 65 67 63 71 64 39 45 74 6972 46 47 3743 53 58 101102103 11 40 43

Page 132 - Figure 6-4 Rear Hinged Window Installation

CAB G5-18A/2505 31200360 6-14 Figure 6-4 Rear Hinged Window Installation 14 2 4 1 6 8 15 13 7 9 3 5 11 12 16 10 PAL5120

Page 134 - Figure 6-5 Suspension Seat

CAB G5-18A/2505 31200360 6-16 Figure 6-5 Suspension Seat PAP17280 5 1 7 2 3 10 6 4

Page 136 - Figure 6-6 Wiper Installation

CAB G5-18A/2505 31200360 6-18 Figure 6-6 Wiper Installation 7 5 4 6 3 2 1 108 108 102107109 105 111 101103104 101103104 106 110 110 105 8 PAP17210

Page 144 - Figure 6-9 Overhead Console

CAB G5-18A/2505 31200360 6-26 Figure 6-9 Overhead Console PAP17190 1 602 34110111 2 305401 5 34 111 6 34111 301 305306 303308309601 304310 311 305 101 102 302 305307 402 501 503 502 505 506 312313

Page 150 - CONTROLS; Figure 7-1 Boom Joystick

CONTROLS G5-18A/2505 31200360 7-2 Figure 7-1 Boom Joystick PAP17290 1 3 4 2 9 4 6 K1 20 19 11 18 17 16 10 14 15 13 12 8 2 3 5 1 109 7

Page 152 - Figure 7-2 Steering Column & Attaching Parts

CONTROLS G5-18A/2505 31200360 7-4 Figure 7-2 Steering Column & Attaching Parts PAP17200 201202 203 7 3 4 5 2 6 303 301 302 101 102 103 104 105 106 107 401 1 203 3 4 5 9 8

Page 154 - Figure 7-3 Accelerator Pedal Assembly

CONTROLS G5-18A/2505 31200360 7-6 Figure 7-3 Accelerator Pedal Assembly PAP17500 1 5 8 7 5 4 5 8 7 8 8 7 5 2 156 104 9 6 3

Page 156 - Figure 7-4 Brake Assembly

CONTROLS G5-18A/2505 31200360 7-8 Figure 7-4 Brake Assembly 1 3 14 2 4 11 6 6 12 5 101 102 103 205 201 201 205 203 204 202 215 155 151 PAL4692 13 7 9 10 8

Page 160 - HYDRAULIC CIRCUITS; Figure 8-1 Supply Circuit

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-2 Figure 8-1 Supply Circuit 1 2 3 4 4 31 12 6 8 9 10 11 11 13 14 31 16 17 18 19 19 20 21 22 22 23 24 27 28 31 114 123 126 129 223 227 252 253 210 211 609 606 311 312 312 311 319 319 319 645 645 320 401 401 403 403 404 416 421 421 426 404 426 414 701 702 703 ...

Page 164 - Figure 8-2 Dump Circuit

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-6 Figure 8-2 Dump Circuit 1 2 3 3 4 5 6 7 8 9 10 11 14 17 16 18 18 18 19 23 23 35 36 37 45 45 106 115 117 124 125 126 128 129 146 147 202 203 313 315 327 328 701 702 703 704 705 706 707 707 707 PAL4121 708 533 402 608 19 23 36 37 CONNECTIONS TO TANK TO TANK ...

Page 170 - Figure 8-3 Steer Select

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-12 Figure 8-3 Steer Select 2 2 2 2 101 102 103 103 104 201 301 344 344 403 409 505 507 506 PAL4040 3 4 5 TO FRONT STEERING CYLINDER TO REAR STEERING CYLINDER

Page 174 - Figure 8-5 Boom Joystick

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-16 Figure 8-5 Boom Joystick 805 2 2 2 P 4 T 1 3 2 P 2 1 3 4 T 106 107 110 115 301 504 803 PAL4033 806 301 723 724 402 445 418 801 804 TO DRIVE PUMP TO TANK G5-18A Before S/N 0160042093

Page 182 - Figure 8-6 Lift Cylinder

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-24 Figure 8-6 Lift Cylinder 501 504 505 402 403 404 PAL3991 9 7 301 205 130 300 403 402 404 401 405 401 405 503 601 602 G5-18A 2505 G5-18A 2505 Before S/N 0160042694

Page 190 - Figure 8-9 Auxiliary Hydraulics

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-32 Figure 8-9 Auxiliary Hydraulics PAP17130 NOTE:LOCTITE® 242 TM ( ITEM 301) MUST BE USED ON ALL BOLT THREADS. 3 110 111 240 241 242 302 320 319 302319320 302319320 327 328 334 319 321 332 320 303 317 316 325 311 335 336 326 324 306 310 308 323 418 501 308 3...

Page 192 - Figure 8-10 Rear Auxiliary Hydraulics

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-34 G5-18A S/N 0160035962 thru 0160042086 2505 S/N 0160036070 thru 0160042693 Figure 8-10 Rear Auxiliary Hydraulics PAL3983 121 7 11 202 201 203 204 16 14 15 17 103 421 20 1821 19 102 101 101 403 303 301 302 304 23 22 101 104

Page 196 - Figure 8-11 Auxiliary Hydraulics Pressure Relief

HYDRAULIC CIRCUITS G5-18A/2505 31200360 8-38 G5-18A Before S/N 0160035962 2505 Before S/N 0160036070 Figure 8-11 Auxiliary Hydraulics Pressure Relief 1 3 4 2 13 14 101 102 106 103 107 104 105 201 202 PAL4770 203 8 108 6 9 10 5 11 2505

Page 204 - HYDRAULIC COMPONENTS; Figure 9-1 Lift Cylinder

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-2 Figure 9-1 Lift Cylinder PAP17380 8 1 17 13 17 9 3 6 7 2 15 1 1 14 16 18 10 12 4 K1 1 7 5 1 1 G5-18A 2505 Before S/N 0160042694

Page 210 - Figure 9-3 Tilt Cylinder

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-8 Figure 9-3 Tilt Cylinder 10 10 2 8 7 3 11 20 20 16 4 9 12 6 1 1 PAL4132 1 1 5 21 18 17 19 14 15 13 22 K 1

Page 212 - Figure 9-4 Compensating Cylinder

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-10 Figure 9-4 Compensating Cylinder 7 2 1 1 16 12 16 3 8 6 5 9 11 10 15 13 14 17 4 1 1 K1 PAL4143 7

Page 214 - Figure 9-5 Hydraulic Quick Coupler Cylinder

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-12 Figure 9-5 Hydraulic Quick Coupler Cylinder 4 13 3 1 6 2 11 7 15 14 14 9 10 12 8 16 PAL3832 5 K 1

Page 218 - Figure 9-7 Universal Side Shift Cylinder

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-16 Figure 9-7 Universal Side Shift Cylinder

Page 220 - Figure 9-8 Main Control Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-18 Figure 9-8 Main Control Valve 18 1 PAL3862 2 3 4 5 6 7 8 12 13 10 11 15 16 10 11 15 16 10 11 10 11 14 16 12 13 9 11 15 16 9 11 9 11 15 16 9 11 12 13 17 101 102 K 1

Page 222 - Figure 9-9 Front Drive Motor

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-20 Figure 9-9 Front Drive Motor 1 2 5 4 3 6 K1 101 102 PAP17480

Page 224 - Figure 9-10 Hydrostatic Transmission

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-22 Figure 9-10 Hydrostatic Transmission PAP17450 K1 1721 18 18 12 3 4 5 6 7 8 9 8 7 6 20 11 13 22 16 10 11 12 19 15 14 23

Page 226 - Figure 9-11 Divertor Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-24 Figure 9-11 Divertor Valve PZ0673 1 4 2 3 K 1 Before S/N 0160037453

Page 227 - COIL

HYDRAULIC COMPONENTS 31200360 G5-18A/2505 9-25 Figure 9-11 Divertor Valve Item Part Number Qty. Description Rev. 1001006487 1 DIVERTOR VALVE, (includes all items) E 1 70020764 1 COIL 2 Use Kit K1 2 O-RING 3 70020766 1 RETAINER KIT, (includes o-rings & nut) 4 Use Kit K1 1 O-RING K1 70020765 1 SEA...

Page 230 - Figure 9-12 Steering Select Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-28 Figure 9-12 Steering Select Valve PZ1771 1 2 3

Page 231 - VALVE BODY

HYDRAULIC COMPONENTS 31200360 G5-18A/2505 9-29 Figure 9-12 Steering Select Valve Item Part Number Qty. Description Rev. 4641519 1 STEERING SELECT VALVE, (includes all items) A 1 70020866 1 VALVE BODY 2 70020867 2 SEAL KIT 3 70020868 2 COIL

Page 232 - Figure 9-13 Blocking Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-30 Figure 9-13 Blocking Valve 1 3 2 PAL4050 2505 Before S/N 0160042694

Page 233 - SEAL KIT

HYDRAULIC COMPONENTS 31200360 G5-18A/2505 9-31 Figure 9-13 Blocking Valve Item Part Number Qty. Description Rev. 1001080353 1 BLOCKING VALVE, (includes all items) B 1 70021266 1 CARTRIDGE, (includes item 3) 7012953 1 SEAL KIT 2 70021267 1 BODY 3 7024885 1 COIL Before S/N 0160042694

Page 234 - Figure 9-14 Pilot Select Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-32 Figure 9-14 Pilot Select Valve 2 1 PAL4060 G5-18A Before S/N 0160042093 2505 Before S/N 0160042694

Page 235 - SOLENOID VALVE

HYDRAULIC COMPONENTS 31200360 G5-18A/2505 9-33 Figure 9-14 Pilot Select Valve Item Part Number Qty. Description Rev. 1001098088 1 PILOT SELECT VALVE, (includes all items) D 1 70021054 3 SOLENOID VALVE 2 70021055 3 COIL G5-18A Before S/N 01600420932505 Before S/N 0160042694

Page 238 - Figure 9-15 Brake Valves

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-36 Figure 9-15 Brake Valves PAP17390 202 201 203 301 101 1 303 302 102 PARK BRAKE RELEASE VALVE - G5-18A PARK BRAKE RELEASE VALVE - 2505 BRAKE VALVE BRAKE VALVE MASTER CYLINDER

Page 240 - Figure 9-16 LSI Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-38 Before S/N 0160042694 Figure 9-16 LSI Valve 102 1 2 101 3 PAL4241 2505

Page 241 - FITTING

HYDRAULIC COMPONENTS 31200360 G5-18A/2505 9-39 Before S/N 0160042694 Figure 9-16 LSI Valve Item Part Number Qty. Description Rev. 1001081157 1 LSI VALVE ASSY, (includes items 1 thru 3) C 1 1001081156 1 LSI VALVE, (includes items 101 & 102) C 2 2110404 5 FITTING 3 2220235 2 FITTING, (includes o-r...

Page 242 - Figure 9-17 Auxiliary Hydraulic Pressure Relief Valve

HYDRAULIC COMPONENTS G5-18A/2505 31200360 9-40 G5-18A S/N 0160035962 thru 0160042086 2505 S/N 0160036070 thru 0160042693 Figure 9-17 Auxiliary Hydraulic Pressure Relief Valve 101102103 3 104105106107108 12 PAL5113 K1K2

Page 245 - ELECTRICAL

Page 246 - Figure 10-1 Electrical Installation

ELECTRICAL G5-18A/2505 31200360 10-2 Figure 10-1 Electrical Installation 35 204 206 19 9 31 30 29 105 102 104 101 4 11 1618 71521 6 1420 28 39 2240 363738 8 31213172425 23 26 27 34 513 301 302 305 303 304 106 102 401 405 205 PY8320 46

Page 250 - Figure 10-2 Road Lights Installation

ELECTRICAL G5-18A/2505 31200360 10-6 Figure 10-2 Road Lights Installation PAP17170 2202408409 9 101114 45 3 301302303304 7301302 12 13 201 122 152 151 104 103 102 101 105 304305 118119120121

Page 252 - LH DRIVING LIGHT

ELECTRICAL G5-18A/2505 31200360 10-8 7029969 1 BULB, 12V 7029970 1 BULB, 12V-55W 7029971 1 BULB, 12V-21W 409 1001002779 1 LH DRIVING LIGHT 7029969 1 BULB, 12V 7029970 1 BULB, 12V-55W 7029971 1 BULB, 12V-21W 501 Ref FRAME BASE HARNESS, (not shown), (see Figure 10-6 for details) Figure 10-2 Road Light...

Page 254 - Figure 10-3 Work Lights Installation

ELECTRICAL G5-18A/2505 31200360 10-10 Figure 10-3 Work Lights Installation PAL4552 102 7 8 6 101103 5 104105106 12 3 124 9 10 213 13 211 214215217 214215216 105106 107108109 107108109 107108109 105106 301 302 303 10 215216 211 215216 211 211 215216 211 211 215216

Page 256 - CONNECTOR

ELECTRICAL G5-18A/2505 31200360 10-12 302 4460899 1 CONNECTOR 4460464 2 TERMINAL 303 91503104 1 WEDGE LOCKING 1001104519 2 TERMINAL Figure 10-3 Work Lights Installation (Continued) Item Part Number Qty. Description Rev.

Page 258 - Figure 10-4 Cab Switches

ELECTRICAL G5-18A/2505 31200360 10-14 Figure 10-4 Cab Switches PAL4521 13 12 11 9 10 1 2 3 4 5 6 7 8 14 15 16 17

Page 260 - Figure 10-5 Cab Fuse Holder

ELECTRICAL G5-18A/2505 31200360 10-16 Figure 10-5 Cab Fuse Holder PAP17520 101 5 1 7 6 4 2 3

Page 262 - Figure 10-6 Frame Base Harness

ELECTRICAL G5-18A/2505 31200360 10-18 Figure 10-6 Frame Base Harness PAL4611 1 2 3 4 5 6 7 8 9 10 11 10 11 17 18 16 15 13 12 14 16 14 9 10 11 10 11 19 10 11 23 24 20 21 22 17 18 25 23 24 10 11 10 11 26 10 11 JS52 SN127 X27 AH64 AH64-G X88 X89 AH135 HV49-AUX HV71 S97 X20 S98 S86 S85 S101 S46 RL205 RL...

Page 268 - Figure 10-7 Frame Options Harness

ELECTRICAL G5-18A/2505 31200360 10-24 Figure 10-7 Frame Options Harness LB81 LB82 X87-5 SN79 SN37 HV80 X25 LB83 MS125-5 MS125-4 MS125-7 MS125-1 MS125-3 MS125-6 LB60 HV134 SN78 LB84 1 2 3 4 5 6 7 5 8 5 9 7 PAP17440 G5-18A 2505 Before S/N 0160042694

Page 273 - PLUG

ELECTRICAL 31200360 G5-18A/2505 10-29 4460466 1 PLUG 34 4460761 1 CONNECTOR 4460227 4 TERMINAL Figure 10-7 Frame Options Harness (Continued) Item Part Number Qty. Description Rev. 2505 S/N 0160042694 & After

Page 274 - Figure 10-8 Cab Harness

ELECTRICAL G5-18A/2505 31200360 10-30 Figure 10-8 Cab Harness PAL4582 WH42 SW36 SW16 SW10 SW11 SW15 SW34 SW38-AC SW38-F SW26 SW08 HV93 HV31 SW09 FC29 SW35 WH39-AC WH39-F X20 X25 X87-3 FC65-L1 RL68-R SW18 SW12 X22 X21 X50B X50A GD138 GD17 GD139 SW19 SW27 SW28 X152 X151 SW32 SW13 SW14 WH41-R WH41-F WH...

Page 284 - Figure 10-9 Cab Roof Harness

ELECTRICAL G5-18A/2505 31200360 10-40 G5-18A Before S/N 0160046246 2505 Before S/N 0160042694 Figure 10-9 Cab Roof Harness PAP17110 5 12 23 12 12 12 X50B X50A GD30+ S173 GD102 GD30-S GD30- WH114-W WH114-G 4 6 S119 S121 S122 S123 8 7 4 LB107-G 11 LB107 MS118+ MS118- 9 10 4 WH115-W 6 WH115-G 4 WH115-P...

Page 288 - Figure 10-10 Roof Worklight Harness

ELECTRICAL G5-18A/2505 31200360 10-44 Before S/N 0160037441 Figure 10-10 Roof Worklight Harness PAL4671 1 2 3 4 4 3 3 4 3 4 5 X103-N X103-P X104-P X104-N MS109 S112 S113 X105-P X105-N S111 S110 X22 X106-NT X106-P

Page 292 - Figure 10-11 Boom Worklight Harness

ELECTRICAL G5-18A/2505 31200360 10-48 Figure 10-11 Boom Worklight Harness PAL4681 1 2 3 4 3 4 X88 S91 S95 LB74 LB73

Page 294 - Figure 10-12 AC System Harness

ELECTRICAL G5-18A/2505 31200360 10-50 Figure 10-12 AC System Harness PAL4631 1 2 3 3 X136 WH99 SN137-2 SN137-1

Page 296 - Figure 10-13 Boom Aux Harness

ELECTRICAL G5-18A/2505 31200360 10-52 S/N 0160032766 & After Figure 10-13 Boom Aux Harness PAP17120 1 2 X1 X2

Page 298 - Figure 10-14 LSI Timer Installation

ELECTRICAL G5-18A/2505 31200360 10-54 Before S/N 0160042694 Figure 10-14 LSI Timer Installation 2 3 4 1 5 101 102103 104105 PAL5090 2505 - AUS

Page 300 - Figure 10-15 Speedometer Sensor Installation

ELECTRICAL G5-18A/2505 31200360 10-56 S/N 0160042694 & After Figure 10-15 Speedometer Sensor Installation 12 PAL5670 2505

Page 302 - Figure 10-16 LSI Installation

ELECTRICAL G5-18A/2505 31200360 10-58 Before S/N 0160042694 Figure 10-16 LSI Installation 456 7 PAL5240 2505

Page 304 - Figure 10-17 LSI Axle Sensor & Boom Proximity Sensor Installation

ELECTRICAL G5-18A/2505 31200360 10-60 S/N 0160042694 & After Figure 10-17 LSI Axle Sensor & Boom Proximity Sensor Installation 109 105 103 102 101 104 107 108 106 3 2 145 PAL5890 X160 201 X160 CONNECTS TO X98 FRAME OPTIONS HARNESS 202 202 2505

Page 306 - Figure 10-18 Function Cutout Jump Harness

ELECTRICAL G5-18A/2505 31200360 10-62 Figure 10-18 Function Cutout Jump Harness PAP17350 S185 S186 X188 X192 X191 X189 1 2 3 3 4 4 X190 X187

Page 308 - Figure 10-19 Heater Jumper Harness; TO HVAC FAN

ELECTRICAL G5-18A/2505 31200360 10-64 Figure 10-19 Heater Jumper Harness 1 2 WH39-F X39-F WH39-F CONN POS WIRE DESIGNATION COLOR GAUGE TYPE 1 073-3 YEL 14 AWG GXL 2 000-7-1 BLK 14 AWG GXL 3 073-1 ORG 14 AWG GXL 4 073-2 RED 14 AWG GXL X39-F CONN POS WIRE DESIGNATION DESIGNATION COLOR GAUGE TYPE A 073...

Page 311 - DECALS

Page 316 - or manual quick coupler)

DECALS G5-18A/2505 31200360 11-6 1101 1001117326 1 CAPACITY CHART BOOKLET, METRIC UNIT, (G5-18A) , (use with hydraulic or manual quick coupler) A 1001081374 1 HOMOLOGATION PLATE INSTALLATION, (2505 - Germany) , (includes items 2001 & 2002) D 2001 1001003536 1 HOMOLOGATION IDENTIFICATION PLATE 20...

Page 319 - RECOMMENDED SPARE PARTS

RECOMMENDED SPARE PARTS The following list will service fleets of machines (built to current production per date on the front cover) with repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For furt...

Page 320 - Electrical

RECOMMENDED SPARE PARTS The following list will service fleets of machines (built to current production per date on the front cover) with repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For furt...

Page 321 - PART NUMBER INDEX; SECTION 13 PART NUMBER INDEX

PART NUMBER INDEX Page Part Number Page Part Number Page Part Number Page Part Number 31200360 G5-18A/2505 13-1 SECTION 13 PART NUMBER INDEX 0100011 .. 1-4, 1-15, 2-3, 2-5, 4-4, 4-7, 4-11, 4-13, 8-9, 8-17, 8-19, 8-33, 8-35, 8-37 0100020 ........................... 1-50100071 ...........................

Page 332 - JLG Worldwide Locations; JLG Drive

JLG Worldwide Locations An Oshkosh Corporation Company www.jlg.com 31200360 JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: +61 2 65811111Fax: +61 2 65813058 JLG Latino Americana Ltda.Rua Antonia Martins Luiz, 580Distrito Industrial João Narezzi13347-4...