JLG G5-18A & 2505H, Agrovector 25.5 Telehandler Service Manual

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This service manual PDF download for the G5-18A & 2505H, Agrovector 25.5 JLG Telescopic Forklift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

G5-18A & 2505H
Agrovector 25.5

S/N 0160053000 & After
including 0160051045, 0160051047,
0160051049, 0160051194 & 0160051359

TABLE OF CONTENTS :

Section 1 Safety Practices
Section 2 General Information and Specifications
Section 3 Boom
Section 4 Cab
Section 5 Axles, Drive Shafts, Wheels and Tires
Section 6 Transmission
Section 7 Engine
Section 8 Hydraulic System
Section 9 Electrical System

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200926
Total Pages : 180

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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31200926_A_JLG_G5-18A,2505H,25.5_Service Manual
Effectivity Page
Read This First
Table of Contents
Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Safety Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.5.1 Safety Alert System and Signal Words
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals
Section 2 General Information and Specifications
2.1 Replacement Parts and Warranty Information
2.2 Torque Charts
2.2.1 SAE Fastener Torque Chart
2.2.2 Metric Fastener Torque Chart
2.2.3 Hydraulic Hose Torque Chart
2.3 Specifications
2.3.1 Travel Speed
2.3.2 Hydraulic Cylinder Performance Specifications
2.3.3 Electrical System
2.3.4 Engine Performance Specifications
2.3.5 Tires
2.4 Fluids, Lubricants and Capacities
2.4.1 Fluids
2.4.2 Capacities
2.5 Maintenance Schedule
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule
2.5.2 1st 250, 250 & 500 Hour Maintenance Schedule
2.5.3 1000 & 1500 Hour Maintenance Schedule
2.6 Lubrication Schedule
2.6.1 250 Hour Lubrication Schedule
Section 3 Boom
3.1 Boom System Component Terminology
3.2 Safety Information
3.3 Two Section Boom System
3.3.1 Boom System Description
3.4 Boom Assembly Maintenance
3.4.1 Complete Boom Removal
3.4.2 Complete Boom Installation
3.4.3 Second Boom Section Removal
3.4.4 Second Boom Section Installation
3.4.5 Extend/Retract Cylinder Removal
3.4.6 Extend/Retract Cylinder Installation
3.5 Boom Wear Pads
3.5.1 Wear Pad Inspection
3.5.2 Wear Pad Installation and Lubrication
3.5.3 Boom Wear Pad Lubrication
3.6 Quick Attach Assembly
3.6.1 Quick Attach Assembly Removal
3.6.2 Quick Attach Assembly Installation
3.7 Forks
3.8 Boom Prop (If Equipped)
3.8.1 Prop Installation
3.8.2 Prop Removal
3.9 Emergency Boom Lowering Procedure
3.9.1 Equipment and Supplies Required
3.9.2 Lowering Procedure
3.10 Troubleshooting
Section 4 Cab
4.1 Operator Cab Component Terminology
4.2 Safety Information
4.3 Operator Cab
4.3.1 Operator Cab Description
4.3.2 Serial Number Decal
4.4 Cab Components
4.4.1 Steering Wheel
4.4.2 Steering Column/Valve Replacement
4.4.3 Brake Pedal and Valve
4.4.4 Accelerator Pedal Replacement
4.4.5 Joystick Replacement
4.4.6 Windshield Wiper Assembly (If Equipped)
4.4.7 Windshield Washer Assembly (If Equipped)
4.4.8 Heater/Air Conditioning System (If Equipped)
4.4.9 Air Conditioning (If Equipped)
4.4.10 Air Filter System (If Equipped)
4.5 Cab Removal
4.6 Cab Installation
Section 5 Axles, Drive Shafts, Wheels and Tires
5.1 Axle, Drive Shaft and Wheel Component Terminology
5.2 Safety Information
5.3 General Information
5.4 Axle Assemblies
5.4.1 Axle Serial Number Plate
5.4.2 Axle Specifications
5.4.3 Axle Internal Service
5.4.4 Axle Maintenance
5.4.5 Axle Removal
5.4.6 Axle Installation
5.4.7 Axle Assembly and Drive Shaft Troubleshooting
5.5 Drive Shafts
5.5.1 Drive Shaft Inspection
5.5.2 Drive Shaft Maintenance
5.5.3 Drive Shaft Removal
5.5.4 Drive Shaft Cleaning and Drying
5.5.5 Drive Shaft Installation
5.6 Wheels and Tires
5.6.1 Removing Wheel and Tire Assembly from Machine
5.6.2 Installing Wheel and Tire Assembly onto Machine
5.7 Steering Angle Adjustment
5.8 Brakes
5.8.1 Brake Disc Inspection
5.9 Towing a Disabled Machine
5.9.1 Equipment and Supplies Required
5.9.2 Towing Procedure
Section 6 Transmission
6.1 Transmission Assembly Component Terminology
6.2 Safety Information
6.3 Transmission Description
6.4 Transmission Specifications
6.4.1 Transmission Maintenance
6.5 Transmission Replacement
6.5.1 Transmission Removal
6.5.2 Transmission Disassembly
6.5.3 Transmission Installation
Section 7 Engine
7.1 Introduction
7.1.1 Disclaimer and Scope
7.1.2 Engine Serial Number
7.1.3 Specifications and Maintenance Information
7.1.4 Component Terminology
7.2 Engine Cooling System
7.2.1 Surge Tank Cap
7.2.2 Radiator/Oil Cooler Replacement
7.3 Engine Electrical System
7.4 Fuel System
7.4.1 Diesel Fuel
7.4.2 Fuel/Hydraulic Oil Tank
7.4.3 After Fuel System Service
7.5 Engine Exhaust System
7.5.1 Exhaust System Removal
7.5.2 Exhaust System Installation
7.6 Air Cleaner Assembly
7.6.1 Air Cleaner Assembly Removal
7.6.2 Air Cleaner Assembly Installation
7.7 Engine Replacement
7.7.1 Engine Removal
7.7.2 Engine Disassembly, Inspection and Service
7.7.3 Engine Installation
Section 8 Hydraulic System
8.1 Hydraulic Component Terminology
8.2 Safety Information
8.3 General Information
8.4 Specifications
8.5 Hoses, Tube Lines, Fittings, Etc.
8.5.1 Replacement Considerations
8.5.2 Hose, Tube, Line and Fitting Replacement
8.6 Hydraulic Pressure Diagnosis
8.6.1 Pressure Checks and Adjustments
8.6.2 Main Control Valve Pressure Checking
8.6.3 Charge Pressure Checking
8.6.4 Boom Function Pressure Checking
8.6.5 Steering Pressure Checking
8.6.6 Fan Speed Pressure and Direction Checking
8.7 Hydraulic Schematic
8.8 Hydraulic Reservoir
8.8.1 Pressurized Hydraulic Oil Fill Cap
8.8.2 Hydraulic Oil Reservoir Draining
8.8.3 Hydraulic Oil Reservoir Filling
8.9 Hydraulic System Pump
8.9.1 Implement Pump Removal
8.9.2 Implement Pump Installation
8.9.3 Pump Test
8.10 Front Drive Motor
8.10.1 Front Drive Motor Removal
8.10.2 Front Drive Motor Installation
8.11 Control Valves
8.11.1 Main Control Valve
8.11.2 Service Brake Valve
8.11.3 Park Brake Valve (G5-18A)
8.11.4 Hand Brake Valve (2505H & 25.5)
8.11.5 Steering Orbitrol Valve
8.11.6 Pilot Select Valve
8.11.7 Inching Valve
8.11.8 Priority Valve
8.11.9 Steer Select Valve
8.11.10 Quick Attach Valve
8.11.11 Variable Speed Fan Valve
8.12 Hydraulic Cylinders
8.12.1 General Cylinder Removal Instructions
8.12.2 General Cylinder Disassembly
8.12.3 Cylinder Cleaning Instructions
8.12.4 Cylinder Inspection
8.12.5 General Cylinder Assembly
8.12.6 General Cylinder Installation
8.12.7 Steering Cylinders
8.12.8 Hydraulic Cylinder Torque Specifications
Section 9 Electrical System
9.1 Electrical Component Terminology
9.2 Safety Information
9.3 Fuses and Relays
9.3.1 Engine Compartment Relays and Fuses
9.3.2 Cab Compartment Fuses and Relays
9.3.3 Power Distribution Module
9.3.4 Cab Fuses / Relays
9.4 Electrical System Schematics
9.5 Engine Start Circuit
9.5.1 Starter
9.6 Charging Circuit
9.6.1 Alternator
9.7 Electrical System Components
9.7.1 Back-up Alarm
9.7.2 Gauge Cluster
9.8 Window Wiper/Washer
9.8.1 Windshield Wiper Motor
9.8.2 Rear Window or Roof Wiper Motor (if equipped)
9.8.3 Windshield Washer Reservoir and Pump
9.9 Cab Heater/AC and Fan
9.9.1 Cab Heater/AC Controls
9.10 Switches, Solenoids and Senders
9.10.1 Ignition Key Switch
9.10.2 Dash Switches
9.10.3 Fuel Level Indicator and Fuel Level Sender
9.10.4 Hourmeter
9.10.5 Coolant Temperature Sender
9.10.6 Oil Pressure Sender
9.11 Load Stability Indicator System (2505H & 25.5)
9.11.1 LSI Axle Sensor
9.11.2 LSI Boom Sensors
9.11.3 LSI Modules
9.11.4 LSI System Calibration
9.11.5 LSI-CAN Check PT
9.11.6 500 Hour – LSI UGM Calibration Check
9.12 Hand Held Analyzer (2505H & 25.5)
9.12.1 Analyzer Usage
9.12.2 Analyzer Software – Version 1.0
9.13 Diagnostic Trouble Codes (DTC) on Ground Module
9.13.1 Gauge Fault Code Display
9.13.2 Fault Codes
9.14 Engine Diagnostic Trouble Code EMR4
9.14.1 Gauge Fault Code Display

 

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JLG G5-18A & 2505H, Agrovector 25.5 Telehandler Service Manual.pdf

Source : Sitelux.com

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