JLG Codes PDF

Service Manual
Models
G5-18A & 2505H
Agrovector
25.5
S/N 0160053000 & After including
0160051045, 0160051047, 0160051049,
0160051194 & 0160051359
31200926
Original
May 9, 2013
An Oshkosh Corporation Company

EFFECTIVITY PAGE
May 9, 2013 - A - Original Issue Of Manual
31200926 G5-18A, 2505H, 25.5 a

READ THIS FIRST
Modifications
Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations.
Any modification must be approved by JLG.
Machine Configuration
Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur
Fuel Decal (1) as indicated below.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as
Ultra Low Sulfur (ULS) from this point forward.
• If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to
as Low Sulfur (LS) from this point forward.
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
1
S < 15 mg/kg
1001125387 A
OAH2300
b G5-18A, 2505H, 25.5 31200926

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Two Section Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Section 4
Cab ........................................................... 4-1
4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
G5-18A, 2505H, 25.5 i

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.7 Steering Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Section 7
Engine ........................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.9 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.12 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
ii G5-18A, 2505H, 25.5

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.6 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.7 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.8 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.9 Cab Heater/AC and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.10 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.11 Load Stability Indicator System (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.12 Hand Held Analyzer (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.13 Diagnostic Trouble Codes (DTC) on Ground Module. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.14 Engine Diagnostic Trouble Code EMR4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
G5-18A, 2505H, 25.5 iii

iv G5-18A, 2505H, 25.5

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
G5-18A, 2505H, 25.5 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any
the procedures in this manual will help assure safety and service or maintenance. Remove key and disconnect
equipment reliability. battery leads.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.5 SAFETY INFORMATION
procedures, rules, codes, regulations and laws.
To avoid possible death or injury, carefully read,
These instructions cannot cover all details or variations in understand and comply with all safety messages.
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency In the event of an accident, know where to obtain medical
during operation, maintenance, or testing. When additional assistance and how to use a first-aid kit and fire
information is desired consult the local JLG Dealer. extinguisher/fire suppression system. Keep emergency
telephone numbers (fire department, ambulance, rescue
Many factors contribute to unsafe conditions: carelessness, squad/paramedics, police department, etc.) nearby. If
fatigue, overload, inattentiveness, unfamiliarity, even working alone, check with another person routinely to
drugs and alcohol, among others. For optimal safety, help assure personal safety.
encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair 1.5.1 Safety Alert System and Signal Words
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
DANGER
operator’s seat looking in a forward direction.
Supplementary information is available from JLG in the DANGER indicates an imminently hazardous situation
form of Service Bulletins, Service Campaigns, Service which, if not avoided, will result in death or serious injury.
Training Schools, the JLG website, other literature and
through updates to the manual itself.
WARNING
1.2 DISCLAIMER
All information in this manual is based on the latest WARNING indicates a potentially hazardous situation
product information available at the time of publication. which, if not avoided, could result in death or serious
JLG reserves the right to make changes and injury.
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation. CAUTION
1.3 OPERATION & SAFETY MANUAL
CAUTION indicates a potentially hazardous situation
The mechanic must not operate the machine until the which, if not avoided, may result in minor or moderate
Operation & Safety Manual has been read and injury.
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 manual holder located
in the cab. In the event that the Operation & Safety
Manual is missing, consult the local JLG Dealer
before proceeding.
1-2 G5-18A, 2505H, 25.5

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known
Following are general safety statements to consider
to be safe for use.
BEFORE performing maintenance procedures on the
telehandler. Additional statements related to specific HOUSEKEEPING: Keep the work area and operator’s
tasks and procedures are located throughout this manual cab clean, and remove all hazards (debris, oil, tools, etc.).
and are listed prior to any work instructions to provide FIRST AID: Immediately clean, dress and report all injuries
safety information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the
For all safety messages, carefully read, understand and injury may seem. Know the location of a First Aid Kit, and
follow the instructions BEFORE proceeding. know how to use it.
CLEANLINESS: Wear eye protection and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner
PERSONAL SAFETY GEAR: Wear all the protective before attempting service.
clothing and personal safety gear necessary to perform When removing hydraulic components, plug hose ends
the job safely. This might include heavy gloves, safety and connections to prevent excess leakage and
glasses or goggles, filter mask or respirator, safety shoes contamination. Place a suitable catch basin beneath the
or a hard hat. machine to capture fluid run-off.
LIFTING: NEVER lift a heavy object without the help of at It is good practice to avoid pressure-washing electrical/
least one assistant or a suitable sling and hoist. electronic components. In the event pressure-washing
the machine is needed, ensure machine is shut down
1.6.2 Equipment Hazards before pressure-washing. Should pressure-washing be
utilized to wash areas containing electrical/electronic
LIFTING OF EQUIPMENT: Before using any lifting
components, it is recommended a maximum pressure of
equipment (chains, slings, brackets, hooks, etc.), verify
750 psi (52 bar) at a minimum distance of 12 in (30,5 cm)
that it is of the proper capacity, in good working order, and
away from these components. If electrical/electronic
is properly attached.
components are sprayed, spraying must not be direct
NEVER stand or otherwise become positioned under a and for brief time periods to avoid heavy saturation,
suspended load or under raised equipment. The load or
Check and obey all Federal, State and/or Local
equipment could fall or tip.
regulations regarding waste storage, disposal
DO NOT use a hoist, jack or jack stands only to support and recycling.
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.
G5-18A, 2505H, 25.5 1-3

Safety Practices
1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
ENGINE: Stop the engine before performing any service
condition. Use the correct equipment in the proper
unless specifically instructed otherwise.
manner, and make changes or repairs as indicated by the
VENTILATION: Avoid prolonged engine operation in test procedure to achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to
SOFT SURFACES AND SLOPES: NEVER work on a the ground before leaving the machine.
machine that is parked on a soft surface or slope. The
TIRES: Always keep tires inflated to the proper pressure
machine must be on a hard level surface, with the wheels
to help prevent tipover. DO NOT over-inflate tires.
blocked before performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID PRESSURE: Before loosening any hydraulic or
Always use matched sets according to machine
diesel fuel component, hose or tube, turn the engine
specifications.
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use MAJOR COMPONENTS: Never alter, remove, or
a piece of cardboard or wood instead. If injured, seek substitute any items such as counterweights, tires,
medical attention immediately. Diesel fluid leaking under batteries or other items that may reduce or affect the
pressure can explode. Hydraulic fluid and diesel fuel overall weight or stability of the machine.
leaking under pressure can penetrate the skin, cause BATTERY: DO NOT charge a frozen battery.Charging
infection, gangrene and other serious personal injury. a frozen battery may cause it to explode. Allow the
Refer to the engine manufacturers manual for specific battery to thaw before jump-starting or connecting a
details concerning the fuel system. battery charger.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and 1.7 SAFETY DECALS
allow release of residual pressure before removing any
Check that all safety decals are present and readable on
part or component. Before starting the engine or applying
the machine. Refer to the Operation & Safety Manual
pressure, use components, parts, hoses and pipes that
supplied with machine for information.
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.
COOLANT SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns
and eye injury. To prevent personal injury, NEVER
remove the coolant system cap while the cooling system
is hot. Wear safety glasses. Turn the coolant system cap
to allow pressure to escape before removing the cap
completely. Failure to follow the safety practices could
result in death or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
Properly disconnect battery prior to servicing the fuel or
hydraulic systems.
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.
1-4 G5-18A, 2505H, 25.5

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.1 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.2 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . 2-11
2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.1 Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5.2 1st 250, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . 2-17
2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.6.1 250 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
G5-18A, 2505H, 25.5 2-1

2.1 REPLACEMENT PARTS AND

WARRANTY INFORMATION
MY8350
Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located as indicated in the figure.
Note: The replacement of any part on this machine with
any other than JLG authorized replacement parts 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
Dealer.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed to
guarantee full warranty service.
2-2 G5-18A, 2505H, 25.5

2.2 TORQUE CHARTS
2.2.1 SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Torque Torque Loctite® 242™ or 271™ Loctite® 262™
Size TPI Bolt Dia Clamp Load OR OR
Stress Area (Dry) Lubricated
Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N Description
0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red) MY4650J
G5-18A, 2505H, 25.5 2-3

2.2.1 SAE Fastener Torque Chart (Continued)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque Loctite® 242™ or 271™ Loctite® 262™
Tensile
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263) OR OR
Stress Area
K= 0.20 Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

3. * ASSEMBLY USES HARDENED WASHER MY4660J
2-4 G5-18A, 2505H, 25.5

SOCKET HEAD CAP SCREWS

Magni Coating*
Torque Torque
Loctite® 242™ or 271™ Loctite® 262™
Tensile Clamp Load Torque OR
Size TPI Bolt Dia OR
Stress Area See Note 4 (Dry) K = .17 Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
OR Precoat 85®
K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4670J
G5-18A, 2505H, 25.5 2-5

SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4680J
2-6 G5-18A, 2505H, 25.5

2.2.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS
Torque
Torque Torque Loctite®
Tensile
Clamp Torque Loctite® 262™ 242™ or 271™
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR OR
Area 263TM) Vibra-TITE™ 131 Vibra-TITE™
111 or 140
Sq mm KN [N.m] [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4690J
G5-18A, 2505H, 25.5 2-7

2.2.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™
Clamp or Loctite® 262™
Size PITCH Stress OR OR
Load Loctite® 263™
Area Vibra-TITE™ Vibra-TITE™ 131
111 or 140
K = 0.20 K= 0.18 K=0.15
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

2-8 G5-18A, 2505H, 25.5

2.2.2 Metric Fastener Torque Chart (Continued)
Magni Coating*
CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*
Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™ Loctite® 262™
Clamp Load or
Size PITCH Stress OR OR
See Note 4 Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131
Area
111 or 140
K = .17 K = .16 K = .15
Sq mm kN [N.m] [N.m] [N.m]
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

G5-18A, 2505H, 25.5 2-9

2.2.3 Hydraulic Hose Torque Chart Torque Wrench:

1. Identify the appropriate application and refer to the
O-Ring Face Seal & JIC Torque Chart above chart for the correct torque value.
Size ORFS JIC Flats Method 2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
13 lb-ft 13 lb-ft the swivel nut can be detected. Average hand torque
4 1.5 to 1.75
(18 Nm) (18 Nm) is 3 lb-ft (4 Nm).
23 lb-ft 23 lb-ft 3. Use the double wrench method while tightening to
6 1 to 1.5
(31 Nm) (31 Nm) avoid hose twist.
40 lb-ft 40 lb-ft 4. Torque wrench must be held at the center of the grip.
8 1.5 to 1.75
(54 Nm) (54 Nm) Apply constant force until it clicks.
60 lb-ft 60 lb-ft 5. After connection has been properly tightened, mark
10 1.5 to 1.75 a straight line across connecting parts indicating that
(81 Nm) (81 Nm)
connection has been properly tightened.
136 lb-ft 136 lb-ft
12 1.0 to 1.5 Flats Method:
(100 Nm) (100 Nm)
1. If equipped, lubricate o-ring with hydraulic oil. Hand
115 lb-ft 115 lb-ft
16 0.75 to 1.0 tighten the swivel nut until no lateral movement of
(156 Nm) (156 Nm)
the swivel nut can be detected. Average hand torque
170 lb-ft 170 lb-ft is 3 lb-ft (4 Nm).
20 0.75 to 1.0
(230 Nm) (230 Nm) 2. Mark a dot on one of swivel nut flats and another dot
200 lb-ft 200 lb-ft in line on hex of adapter it’s connecting to.
24 0.75 to 1.0
(271 Nm) (271 Nm) 3. Use double wrench method while tightening to avoid
270 lb-ft hose twist.
32 N/A 0.75 to 1.0
(366 Nm) 4. After connection has been properly tightened, mark
a straight line across the connecting parts, not
Note: By definition the “Flats Method” will contain some covering dots indicating that connection has been
variance. Use the “Flats Method” only when accessibility properly tightened.
with a torque wrench is not possible.
2-10 G5-18A, 2505H, 25.5

2.3 SPECIFICATIONS
2.3.1 Travel Speed
Tires Approximate Speed

12–16.50 (305/70D16.5) 15 mph (24 km/h)
14–17.50 (355/70D17.5) 17 mph (27 km/h)
10.5–18 17 mph (27 km/h)
2.3.2 Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 15.6° C (60° F) minimum, engine at
operating temperature.
Approximate Times (sec.)

Function
ANSI CE & AUS
Boom Extend (Boom Level) 6.7 6.7
Boom Retract 3.8 3.5
Boom Lift 6.8 6.6
Boom Lower 4.6 8.2
Quick Attach—UP 2.0 1.8
Quick Attach—DOWN 2.5 2.3
2.3.3 Electrical System

Note: Refer to Section 9.3, “Fuses and Relays,” for more information.
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Cold Cranking Amps @ 0° F (-18° C) 950
Cranking Amps @ 32° F (-18° C) 1190
Reserve Capacity Minutes @ 25 Amps 185
Group/Series Group 31
Alternator 14V, 95 Amps
G5-18A, 2505H, 25.5 2-11

2.3.4 Engine Performance Specifications
Description
Engine Make/Model Deutz TD L4
Displacement 177 in³ (2.9 L)
Low Idle 975 - 1075 rpm
High Idle 2300 - 2400 rpm
Horsepower 74 HP (55 kW) @ 2300 rpm
Peak Torque 192 lb-ft (260 Nm) @ 1800 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
2.3.5 Tires
Note: Standard wheel lug nut torque is 220 lb-ft (300 Nm).
Note: Pressures for Foam filled tires are for initial fill ONLY.
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
Duraforce Pneumatic 80 psi (5,5 bar)

12–16.50 (305/70D16.5) Bias 12 Ply
DT Foam - Approximately 220 lb (100 kg)
Pneumatic 70 psi (4,8 bar)
14–17.50 (355/70D17.5) Outrigger Bias 14 Ply
Foam - Approximately 220 lb (100 kg)
10.5–18 MPT-01 TL Bias 16 Ply Pneumatic 87 psi (6,0 bar)
33x12–20 Non–Marking (White)
2-12 G5-18A, 2505H, 25.5

2.4 FLUIDS, LUBRICANTS AND CAPACITIES
2.4.1 Fluids
a. If Equipped for ULS
Ambient Temperature Range

Compartment
Type and Classification Viscosities °F °C
or System
Min Max Min Max
SAE 0W-30 -20 0 -29 -18
SAE 5W-30 -15 70 -26 21
Engine Crankcase API CJ-4 Plus
SAE 10W-30 -9 70 -22 21
SAE 15W-40 5 120 -15 49
Axle Differential*
MobilFluid 424 10W-30 15 120 -10 49
and Wheel End
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System MobilFluid DTE-13 32 -8 80 -21 27
Exxon Univis HVI 26 -20 120 -29 49
Brake System MobilFluid 424 10W-30 15 120 -10 49
Boom Wear Pad
Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
Grease
Cylinder Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Axle Grease Multipurpose Grease NLGI Grade 3 -22 104 -30 40
Ethylene Glycol 50/50 Mix Standard

Engine Coolant
and Water 60/40 Mix Cold Weather
#2 Diesel Standard
Ultra Low Sulfur
Fuel Blend of #1 diesel and #2 diesel (S ≤ 15 mg/kg) Cold Weather
fuels ("winterized" #2)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane
Note: Friction Modifier required for axle differentials, refer to Section 2.4.2, “Capacities.”
G5-18A, 2505H, 25.5 2-13

b. If Equipped for LS
Ambient Temperature Range

Compartment
Type and Classification Viscosities °F °C
or System
Min Max Min Max
SAE 0W-30 -20 0 -29 -18
SAE 5W-30 -15 70 -26 21
Engine Crankcase API CI-4 Plus
SAE 10W-30 -9 70 -22 21
SAE 15W-40 5 120 -15 49
Axle Differential*
MobilFluid 424 10W-30 15 120 -10 49
and Wheel End
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System MobilFluid DTE-13 32 -8 80 -21 27
Exxon Univis HVI 26 -20 120 -29 49
Brake System MobilFluid 424 10W-30 15 120 -10 49
Boom Wear Pad
Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
Grease
Cylinder Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Axle Grease Multipurpose Grease NLGI Grade 3 -22 104 -30 40
Ethylene Glycol 50/50 Mix Standard

Engine Coolant
and Water 60/40 Mix Cold Weather
#2 Diesel Standard
Low Sulfur
Fuel Blend of #1 diesel and #2 diesel (S ≤ 500 mg/kg) Cold Weather
fuels ("winterized" #2)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane
Note: Friction Modifier required for axle differentials, refer to Section 2.4.2, “Capacities.”
2-14 G5-18A, 2505H, 25.5

2.4.2 Capacities
Engine Crankcase Oil

Capacity w/Filter Change 9.6 qt (9,1 L)
Fuel Tank
Capacity 24 gal (91 L)
Cooling System
System Capacity 14 qt (13,2 L)
Hydraulic System
System Capacity 24 gal (91 L)
Reservoir Capacity to Full Mark 16 gal (61 L)
Auxiliary Hydraulic Circuit Max Flow 18.7 gpm (71 lpm)
Brake System
System Capacity 0.7 qt (0,7 L)
Axles
Differential Housing Capacity 3.5 qt (3,3 L)
Friction Modifier (Front Axle Only) 5.4 oz (0,16 L)
Wheel End Capacity 24 oz (0,7 L)
Front Axle Drop Box 21 oz (0,6 L)
Air Conditioning System (if equipped)
System Capacity 1.7 lb (771 g)
G5-18A, 2505H, 25.5 2-15

2.5 MAINTENANCE SCHEDULE
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule
EVERY
10
Check Fuel Check Engine Check Hydraulic Check Tire Additional

Level Oil Level Oil Level Condition & Checks -
Pressure Section 8
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
Drain Fuel/ Check Engine Check Check Check Brake

Water Coolant Level Air Filter Battery Fluid Level
Separator
Check Washer
Fluid Level
(if equipped)
OAH2341
2-16 G5-18A, 2505H, 25.5

2.5.2 1st 250, 250 & 500 Hour Maintenance Schedule
1st
250
Change Axle Change Wheel Change Front

Differential Oil End Oil Axle Drop
Box Oil
EVERY
250
Check Axle Check Wheel Check Front Check Check Boom

Differential Oil End Oil Levels Axle Drop Fan Belt Wear Pads
Level Box Oil Level
Check Enclosed Lubrication

Cab Air Filter Schedule
(if equipped)
EVERY
500
LB/F
T (N
m)
Change Engine Change Change Fuel Filter Check LSI Check Wheel
Oil and Filter Air Filter (if equipped for LS) Calibration Lug Nut
Elements (CE & AUS) Torque
OAH2211
G5-18A, 2505H, 25.5 2-17

2.5.3 1000 & 1500 Hour Maintenance Schedule
EVERY
1000
Change Axle Change Wheel Change Front Change Check

Differential Oil End Oil Axle Drop Hydraulic Hydraulic Tank
Box Oil Fluid & Filters Cap
Change Change Fuel Filter

Transmission (if equipped for ULS)
Filter
EVERY
1500
Change
Engine Coolant
OAH2220
2-18 G5-18A, 2505H, 25.5

2.6 LUBRICATION SCHEDULE
2.6.1 250 Hour Lubrication Schedule
EVERY
250
OAL1980
G5-18A, 2505H, 25.5 2-19

This Page Intentionally Left Blank
2-20 G5-18A, 2505H, 25.5

Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Two Section Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.4 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.5 Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.6 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.2 Wear Pad Installation and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6.1 Quick Attach Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6.2 Quick Attach Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8.1 Prop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8.2 Prop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
G5-18A, 2505H, 25.5 3-1

Boom
3.1 BOOM 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 PIVOT PIN

BOOM
SECTION
LIFT/LOWER
CYLINDER
TILT
CYLINDER
EXTEND/RETRACT
CYLINDER
AUXILIARY HYDRAULIC
QUICK CONNECTS
MY8380
3-2 G5-18A, 2505H, 25.5

Boom
3.2 SAFETY INFORMATION 3.4.1 Complete Boom Removal

1. Remove any attachment from quick attach assembly.
WARNING 2. Park machine on a hard, level surface.

3. Fully retract boom, lower boom, place transmission
DO NOT service the machine without following all control lever in (N) NEUTRAL.
safety precautions as outlined in the “Safety Practices”
4. Engage park brake and shut engine OFF.
section of this manual.
5. Place a Do Not Operate Tag on both ignition key
switch and steering wheel.
3.3 TWO SECTION BOOM SYSTEM
6. Allow system fluids to cool.
3.3.1 Boom System Description 7. Remove the quick attach assembly. Refer to Section
3.6.1, “Quick Attach Assembly Removal.”
Boom operates via an interchange among electrical,
hydraulic and mechanical systems. Components Note: The use of two slings will allow for better stability.
involved include joystick, tilt cylinder, extend/retract
cylinder, lift/lower cylinder, compensating cylinder,
electronic sensors, various pivots, supporting hardware
and other components.
1
WARNING 2
NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
3.4 BOOM ASSEMBLY MAINTENANCE

Boom assembly consists of first and second section
booms and supporting hardware.
Note: Before removing boom or boom section, carriage MY8570
or any other attachment must be removed from quick

attach assembly. 8. Start machine and raise boom to position that will
allow for pin (1) to clear frame for removal.
Before beginning, conduct a visual inspection of machine
and work area, and review task about to be undertaken. 9. Remove the lock bolt (2) and pin (1) from
Read, understand and follow these instructions. compensating cylinder.
During service of boom, perform following:
1. Check wear pads. (Refer to Section 3.5.1, “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 removal/installation of complete
boom or removal/installation of individual boom sections.
G5-18A, 2505H, 25.5 3-3

Boom
16. Lower boom to a level position and place a suitable

support under rear of boom. Reposition slings to
each end of boom.
3
17. Remove capscrew (5) and locknut (6) securing boom
pivot pin (7) and remove boom pivot pin.
4 18. Lift complete boom off machine and set on level
ground or supports being careful not to damage
tubes on bottom of boom.
MY8580 3.4.2 Complete Boom Installation

Note: Lubrication of boom wear surfaces with grease is
10. Lower the boom to a position that allows for the recommended to keep boom wear surfaces lubricated
removal of rod end pin (3) connecting lift/lower properly. Lubrication of boom wear surfaces is also
cylinder to boom. recommended when machine is stored, to help
11. Support boom by placing a sling(s) around boom prevent rusting. Refer to Section 2.4, “Fluids, Lubricants
head. Support lift/lower cylinder and remove lock and Capacities.”
bolt (4) and rod end pin (3). Lower lift/lower cylinder
1. Park machine on a hard, level surface.
onto frame rails.
2. Place transmission control lever in (N) NEUTRAL.
12. Properly disconnect battery.
13. Label and disconnect tilt and (if equipped) auxiliary
hydraulic hoses attached to machine at tubes on top 4. Place a Do Not Operate Tag on both ignition key
of boom. Plug and cap hose ends to prevent dirt and switch and steering wheel.
debris from entering hydraulic system. 5. Allow system fluids to cool.
14. Label and disconnect extend/retract hydraulic Note: Grease the boom pivot bore, compensating
hoses at tubes on side of boom. Plug and cap cylinder rod ends, lift/lower cylinder rod end and pins
hose ends to prevent dirt and debris from entering before installing.
hydraulic system.
6. Balance boom assembly using suitable slings and
15. If equipped, disconnect the LSI boom proximity
carefully guide the boom into position for attachment
sensor at rear of first boom section.
to frame.
Note: Tag or identify each hose to the corresponding 7. Align frame pivot bore with the boom assembly pivot
fitting it was removed from. bore. Install boom pivot pin (7)
8. Install capscrew (5). Apply locking compound and
5 torque locknut (6) to 66 lb-ft (90 Nm).
6
9. With sling still in place, install rod end of the lift/lower
cylinder, pin (3) and lock bolt (4). Apply locking
compound and torque to 66 lb-ft (90 Nm).
7
Note: Raising boom up or down with sling may be
necessary so boom, compensating and lift/lower cylinder
bores can be aligned for easier pin installation.
MY8590
3-4 G5-18A, 2505H, 25.5

Boom
10. Uncap and reconnect extend/retract cylinder fittings 3.4.3 Second Boom Section Removal
and plugs to extend/retract cylinder tubes and
tighten until wrench-tight. Mark fitting, then torque to
specification. Refer to Section 2.2.3, “Hydraulic 2. Be sure there is enough room in front of machine to
Hose Torque Chart.” allow boom sections to be removed.
11. Uncap and reconnect tilt hoses and (if equipped) 3. Park machine on a hard, level surface.
auxiliary hoses. Attach both sets to their appropriate 4. Fully retract boom, lower boom, place transmission
fittings until wrench-tight. Mark fitting, then torque to control lever in (N) NEUTRAL.
specification. Refer to Section 2.2.3, “Hydraulic
Hose Torque Chart.”
8. Open engine cover. Allow system fluids to cool.
8 9. Remove quick attach assembly. Refer to Section
3.6.1, “Quick Attach Assembly Removal.”
9
10. Label and disconnect tilt hoses and (if equipped)
auxiliary hydraulic hoses attached to machine at
boom head. Plug and cap hose ends to prevent dirt
and debris from entering hydraulic system.
Note: Tag or identify each hose to corresponding fitting
it was removed from.
11. Label and disconnect extend/retract hydraulic tubes
on extend/retract cylinder at the rear of boom. Plug
and cap hose ends to prevent dirt and debris from
entering hydraulic system.
MY8570 12. Remove top and side wear pads from rear of second
12. Raise boom to height that allows for installation of boom section.
compensating cylinder, pin (8) and lock bolt (9). Note: Tag each pad, backing plate, shim and bolts from
Apply locking compound and torque to each location.
66 lb-ft (90 Nm).
13. Adjust and shim each wear pad as needed.
14. Start engine and operate all boom functions several
times to bleed any air out of hydraulic system.
15. Check for fluid leaks.
16. Check the hydraulic fluid level in tank and add fluid 10
as required.
17. Clean up all debris, hydraulic fluid, etc., in, on, near 11
and around the machine.
18. Close and secure engine cover.
19. Remove Do Not Operate Tags from both ignition key MY1960
switch and the steering wheel.

20. Install previously removed attachment to quick 13. Remove lock bolt and nut (10) from rear of
attach assembly. extend/retract cylinder.
14. Remove extend/retract cylinder mounting pin (11).
15. Support front of boom by placing a sling behind
boom head.
G5-18A, 2505H, 25.5 3-5

Boom
16. Pull second boom section out of first boom section 3.4.4 Second Boom Section Installation
approximately 6 in to 8 in (15 cm to 20 cm).
Note: Lubrication of boom wear surfaces with grease is
17. Pull tilt hoses and (if equipped) auxiliary hydraulic recommended to keep boom wear surfaces lubricated
hoses through rear of boom. properly. Lubrication of boom wear surfaces is also
18. Remove top, side and bottom wear pads from front recommended when machine is stored, to help
of first boom section. prevent rusting. Refer to Section 2.4, “Fluids, Lubricants
and Capacities.”
Note: Tag each pad, backing plate, shim and bolts from
each location. 1. If previously removed, install extend/retract cylinder
into rear of second boom section. Pin and clip barrel
Note: The use of two slings will allow for better stability. end of cylinder in place.
19. Pull second boom section halfway out of first boom 2. Install wear pads, shims and bolts to their proper
section, reposition sling(s), balancing second boom location at front inside of first boom section.
section and remove from first boom section. DO NOT tighten wear pads at this time.
20. Place second boom section on suitable stands to 3. Feed the tilt cylinder hoses and if equipped, the
begin tear down. auxiliary hoses through the channel above the
21. Inspect boom and welds. Consult local JLG Dealer if extend/retract cylinder.
structural damage is detected. 4. Using suitable sling(s), balance second boom
22. Inspect hoses, hardware, wear pads, mounting section, lift and carefully guide boom into place.
points and other components visible with first boom
section. Replace any item if damaged.
23. Inspect all wear pads for wear. (Refer to Section
3.5.1, “Wear Pad Inspection.”)
10
11
MY1960
5. Install extend/retract cylinder mounting pin (11).

6. Install lock bolt and nut (10) at rear of
extend/retract cylinder.
7. Install wear pads, shims and bolts previously
removed from rear of second boom section.
DO NOT tighten the wear pads at this time.
8. Uncap and reconnect extend/retract cylinder fittings
and plugs from extend/retract cylinder tubes and
tighten until wrench-tight. Mark fitting, then torque to
9. Uncap and reconnect tilt hoses and (if equipped)
auxiliary hoses. Attach both sets to their appropriate
fittings until wrench-tight. Mark fitting, then torque to
10. Adjust and shim each wear pad as needed.
11. Properly connect battery.
3-6 G5-18A, 2505H, 25.5
Boom
12. Start engine and operate all boom functions several 3.4.5 Extend/Retract Cylinder Removal
times to bleed any air out of hydraulic system. Check
Note: Boom must be properly aligned (level) with
for fluid leaks. Check hydraulic fluid level in tank and
access hole at rear of frame to allow removal of
add fluid as required.
extend/retract cylinder barrel mounting pin.
2. Be sure there is enough room in front of machine to
12 allow boom sections to be removed.
control lever in (N) NEUTRAL.
7. Open engine cover and properly disconnect battery.
MY2000
8. Allow system fluids to cool.
13. Check clearance (12) between the tilt hoses (and if 9. Remove the quick attach assembly. Refer to Section
equipped) auxiliary hoses and the front of the 3.6.1, “Quick Attach Assembly Removal.”
extend/retract cylinder trunnion. There should be
approximately 1/2 in. (12,7 mm) of clearance.
14. If adjustment is needed, loosen the tilt tubes (and if
equipped) auxiliary tubes. Move tubes to achieve the
proper clearance.
15. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine. 13
16. Close and secure the engine cover.
17. Remove Do Not Operate Tags from both ignition key
18. Install previously removed attachment to quick
attach assembly.
MY2680
10. Remove cylinder rod eye retaining clips and

mounting pin (13) at side of second boom section.
G5-18A, 2505H, 25.5 3-7

Boom
15
18
14
19
17
MY2670 16
MY8610
11. Loosen and remove hose clamps and cover
plate (14) from rear of boom assembly. 14. Loosen and remove both extend/retract cylinder
12. Remove any miscellaneous parts such as mirror if tubes (16) at rear of first boom section. Plug
they will interfere with removal of cylinder. tube ends to prevent dirt and debris from entering
hydraulic system.
13. Label and disconnect tilt and (if equipped) auxiliary
hydraulic hoses attached to machine on top of 15. Loosen and remove both fittings (17) from bottom of
boom (15). Plug and cap hose ends to prevent dirt extend/retract cylinder barrel. Plug openings in
and debris from entering hydraulic system. extend/retract cylinder barrel.
16. Loosen and remove hardware (18) securing on
cylinder barrel mounting pin.
17. Remove cylinder barrel mounting pin (19). Note
location of spacers and washers.
18. Attach a sling or other suitable lifting device to
extend/retract cylinder and carefully pull cylinder free
from machine through rear of boom/chassis.
Note: The tilt hoses and if equipped, auxiliary
hoses may need to be moved during removal of
extend/retract cylinder.
3-8 G5-18A, 2505H, 25.5

Boom
3.4.6 Extend/Retract Cylinder Installation 3.5 BOOM WEAR PADS

1. Carefully install the extend/retract cylinder into rear
A total of 14 wear pads are installed on the boom.
of boom using a suitable sling.
Twelve of fourteen wear pads on this boom are flat
2. Line up barrel end of cylinder with pin bores on first
rectangular wear pads with metal inserts. Two wear pads
boom section.
on bottom of second section boom are channeled for tilt
Note: The tilt hoses and (if equipped) the auxiliary hose and auxiliary hose clearance.
hoses may need to be moved during installation of the
extend/retract cylinder. 3.5.1 Wear Pad Inspection
3. Install mounting pin (19), spacers and washers
through frame access hole on chassis and first boom 1 1
section bore and cylinder barrel. Secure with
hardware (18) removed earlier.
4. Remove plugs in bottom of extend/retract cylinder
and install previously removed fittings (17). Ma2070
5. Uncap and connect tubes (16) to previously labeled

Inspect all wear pads for wear. If angle indicators (1) on
fittings at extend/retract cylinder. Apply locking
end of wear pads are visible, wear pads can be reused. If
compound to fittings.
the wear pads show uneven wear (front to back), they
6. Uncap and reconnect tilt hoses and (if equipped) should be replaced. Replace wear pads as a set if worn
auxiliary hoses (15) to their appropriate fittings until or damaged.
wrench-tight. Mark the fitting and torque to
specification. Refer to Section 2.2.3, “Hydraulic 3.5.2 Wear Pad Installation and Lubrication
Note: Inspect all wear pads. Replace as necessary.
7. Install cover plate (14) and hose clamps at rear of
boom assembly. The following wear pad procedure must be followed to
insure proper wear pad installation:
8. Reinstall any miscellaneous parts, such as mirror, if
removed previously. Note: MUST clean wear pad inserts and mounting bolts
9. Properly connect battery. of any grease, oil or other contaminates before applying
locking compound and installing mounting bolts.
10. Start machine and extend the extend/retract cylinder
until rod eye of cylinder aligns with pin bore in • Apply locking compound to all the wear pad
second boom section. mounting bolts.
11. Shut the engine OFF.
12. Install mounting pin through side of second boom
section (13) and secure with retaining clips. 4
13. Start machine and cycle extend/retract cylinder to
bleed any air out of hydraulic system. 3
14. Check for fluid leaks or any alignment problems.
2
15. Check the hydraulic fluid level in tank and add fluid
as required.
and around the machine.
17. Close and secure the engine cover. MAM1390
18. Remove Do Not Operate Tags from both ignition key

switch and the steering wheel. • Assemble as shown using spacer (2) with holes
before any shim (3 is used.
19. Install previously removed attachment to quick
attach assembly. • If required, a shim (3) must inserted between the
spacer (2) and wear pad support plate, block or
boom section (4).
G5-18A, 2505H, 25.5 3-9

Boom
• The number of shims can vary at each shim point. 3.6 QUICK ATTACH ASSEMBLY
• The bottom wear pads must be shimmed equally on
each side. 3.6.1 Quick Attach Assembly Removal
• Maintain a total boom section clearance of 1. Park machine on a hard, level surface.
0.070-0.130 in (1,78-3,30 mm) both the horizontal
and vertical directions. 2. Fully retract boom, lower boom, place transmission
A 3. Engage park brake and shut engine OFF.
B
MY3620
• The length of wear pad bolt depends on number of

shims, spacers and washers being used.
• The thickness of each threaded wear pad insert is
0.312 in (7,92 mm)(A).
• The bolt length should be determined by measuring
distance from face of insert to face of boom (B) 5
including any spacer, shim(s) and washer(s).
• Bolt thread engagement in wear pad insert should
be 0.275 ± 0.040 in (6,98 ± 1,0 mm).
• One or two hardened washers are to be used on 8
each wear pad bolt except where noted otherwise. 9
DO NOT use more than two hardened washers. 6
• Use only one hardened washer if mounting bolts 7
are recessed. MY2660
• Wear Pad Bolt Torque:
3/8–24 Bolt, 32–37 lb-ft (43–50 Nm) 7. If equipped with a hydraulic quick attach device,
3/8–24 Hollow Bolt, 15–17 lb-ft (20–23 Nm) remove both hydraulic hoses (5) from valve on left
1/2–20 Bolt, 76–86 lb-ft (103–116 Nm)
side of boom head. Plug and cap hose ends to
1/2–20 Hollow Bolt, 45–50 lb-ft (61–68 Nm)
prevent dirt and debris from entering system.
• Torque wear pad bolts after shimming is completed.
8. Remove the lock bolt (6) holding tilt cylinder rod
• Lubricate face and pockets of each wear pad after
being installed. end pin (7) to quick attach assembly. Remove pin.
9. Support quick attach assembly. Remove lock
3.5.3 Boom Wear Pad Lubrication bolt (8) holding quick attach pin (9) to quick attach
assembly. Remove pin.
After replacing any wear pads or after prolonged periods
of inoperation, Lubrication of boom wear surfaces with 10. Inspect pins for nicks or surface corrosion.
grease is recommended to keep boom wear surfaces Use fine emery cloth to fix minor nicks or corrosion.
lubricated properly. Lubrication of boom wear surfaces is 11. Replace pins if damaged or beyond repair.
also recommended when machine is stored, to help
prevent rusting. Refer to Section 2.4, “Fluids, Lubricants
and Capacities.”
Note: The first shim under the pad needs to contain
holes, instead of slots.
3-10 G5-18A, 2505H, 25.5

Boom
3.6.2 Quick Attach Assembly Installation 3.7 FORKS

1. Line up quick attach assembly between mounts on
Forks should be cleaned and inspected prior to being
boom head. Quick attach assembly should be
attached to carriage. If the following criteria is not met,
centered in boom head.
forks must be removed from service immediately.
2. Coat quick attach pivot pin (9) with an anti-seize
Daily Inspection
compound. Insert quick attach pivot pin through
quick attach assembly and boom head. Align pivot
pin and quick attach assembly. Install lock bolt (8).
Torque to 72 lb-ft (97 Nm).
12
3. Align quick attach assembly with tilt cylinder rod end
15
and insert tilt cylinder pin (7). Align tilt cylinder pin
and quick attach assembly. Install lock bolt (6). 16 13
14
Torque to 72 lb-ft (97 Nm).
4. If equipped, uncap and reconnect hydraulic quick 11
attach assembly device hoses (5) to valve on left 10
side of boom head. 18
and around machine.
7. Close and secure engine cover. 21 20
8. Remove a Do Not Operate Tag on both ignition key

switch and steering wheel. 19 MH6460
1. Inspect forks (10) for cracks, paying special attention

to heel (11) and mounting tubes (12).
2. Inspect forks for broken or bent tips (13) and twisted
blades (14) and shanks (15).
Yearly Inspection
1. Straightness of the upper face of blade (14) and the
front face of shank (15) should not exceed 0.5
percent of the length of blade or height of shank.
2. Angle (16) between upper face of blade and front
face of shank should not exceed 93 degrees.
3. Thickness of blade (17) and shank (18) should not
be reduced to 90 percent of original thickness.
Note: Contact local JLG dealer with fork part number to
find manufactured dimensions of fork blade.
4. Ensure that fork length (19) is adequate for the
intended loads.
5. Fork markings should be legible, re-stamp
if required.
6. Compare fork tips (20) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent
of length of blade (21).
G5-18A, 2505H, 25.5 3-11

Boom
3.8 BOOM PROP (IF EQUIPPED)
3.8.1 Prop Installation NOTICE

EQUIPMENT DAMAGE. DO NOT operate with the
WARNING boom prop in place. Damage to the boom prop and/or
the lift/lower cylinder could occur.
A raised boom can fall if a hydraulic component is
removed. Remove any load, retract the boom and
install the boom prop or a suitable supporting stand 3.8.2 Prop Removal
before working under a raised boom. 1. If needed, start machine and slowly raise the boom
until the boom prop is clear of the lift/lower rod end.
1. Park the machine on a firm, level surface. Place the
transmission control lever in (N) NEUTRAL, engage 2. Remove the o-rings (2) and boom prop (1) from the
the park brake switch. cylinder. Return the boom prop to the proper location
and secure.
2. Raise the boom to an angle of approximately 20
degrees. Shut engine OFF. 3. Lower boom, shut engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
4. Before installing boom prop, inspect prop for
damage. Do not use if prop is damaged or if o-rings
are damaged or missing.
MAM1280
5. Install boom prop (1) onto lift/lower cylinder. Install

o-rings (2). Align lift cylinder lock so o-rings are on
bottom side of lift/lower cylinder rod.
6. Start engine and SLOWLY lower boom until there is
a clearance of 0.25 in (6 mm) between end of boom
prop and lift/lower cylinder rod end (3).
7. Shut engine OFF.
3-12 G5-18A, 2505H, 25.5

Boom
3.9 EMERGENCY BOOM LOWERING 3.9.1 Equipment and Supplies Required

PROCEDURE Auxiliary Hydraulic Power Supply:
• Portable hydraulic unit or another machine with
an auxiliary hydraulic power supply with a capac-
WARNING ity to hold up to 3 gal (11,4 L) of hydraulic oil from
the machine during lowering process.
To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting
the lift cylinder. If circumstances prevent retraction of NOTICE
the extend/retract cylinder first, lower the lift cylinder
the minimum amount necessary and resume EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
retraction of the extend/retract cylinder as soon as Supply hydraulic oil must be compatible with hydraulic
possible. oil shown in Section 2.4, “Fluids, Lubricants and
Capacities.”
WARNING Hoses:
• Two Hydraulic Hoses - Approximately 10 ft
Properly support the boom before attempting to (3,0 m) each, with a minimum I.D. of
proceed with the emergency boom lowering 0.375 in. (9,5 mm) and a minimum rating of
procedure. 4000 psi (275,8 bar).
Fittings:
WARNING • Two 1 in. (25,4 mm) - 14 ORFS Caps

• Two 1 in. (25,4 mm) - 14 ORFS Plugs
If possible, safely remove and/or secure the load on
Note: Machine extend/retract and lift/lower hoses are -
the machine before starting the boom lowering
14 ORFS. The adaptor size may vary depending on the
procedure. If load cannot be removed, the machine
hose ends of the auxiliary hydraulic power supply.
load chart MUST be followed.
G5-18A, 2505H, 25.5 3-13

Boom
3.9.2 Lowering Procedure b. Lower the boom as follows:

1. Place a suitable receptacle under main control valve.
a. Retract the boom as follows:
1. Place a suitable receptacle under hose connections.
4&5 6
MAP0040 7
VIEW FROM LEFT SIDE
MY3000
2. Locate the extend/retract cylinder connection (4 and 2. Label and disconnect lift/lower cylinder hoses
5) along the left side of the boom where the hoses (6 and 7) from main control valve. Install plugs in
from the valve connect to the steel tube. hoses to prevent fluid loss. Cap all fittings and
3. Label and disconnect hoses from steel tubes along openings to keep dirt and debris from entering
left side of boom. Install plugs in hoses to prevent hydraulic system.
fluid loss. Cap all fittings and openings to keep dirt
Note: Loss of hydraulic oil is limited to amount trapped
and debris from entering the hydraulic system.
within each hose.
Note: Loss of hydraulic oil is limited to amount trapped
3. Using hoses and fittings specified, connect hoses
within each hose.
between auxiliary hydraulic power supply and hoses
4. Using hoses and fittings specified previously, removed from main control valve lift/lower section of
connect jumper hoses between auxiliary hydraulic affected machine. Hose (7) is supply (lower) and
power supply and steel tubes (4 and 5) connected to hose (6) is return. Connect hoses in proper order to
extend/retract cylinder of affected machine. Ensure ensure that boom is lowered, not raised.
that supply and return lines are installed in proper 4. Use auxiliary power supply to retract lift cylinder.
order to ensure cylinder is retracted, not extended.
5. After boom has been lowered, loosen and remove
5. Use the auxiliary power supply to retract the jumper hoses and reconnect lift/lower cylinder hoses
extend/retract cylinder. at main control valve.
6. Loosen and remove the jumper hoses and reconnect 6. Transfer any hydraulic oil into a suitable, covered
extend/retract cylinder hoses. container, and label the container as “Used Oil.”
7. Transfer any hydraulic oil into a suitable, covered Dispose of used oil at an approved recycling facility.
container, and label the container as “Used Oil.” 7. Clean up all debris, hydraulic fluid, etc., in, on, near
Dispose of used oil at an approved recycling facility. and around the machine.
and around machine.
3-14 G5-18A, 2505H, 25.5

Boom
3.10 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.
Problem Possible Causes Remedy

1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract. tube(s) and/or connections or tube(s), tighten connections.
leaking.
2. Extend/Retract hydraulic system 2. Refer to Section 8.7, “Hydraulic

not operating properly. Schematic.”
3. Faulty extend/retract cylinder. 3. Repair cylinder (Refer to Section

8.12, “Hydraulic Cylinders.”)
2. Boom will not fully extend. 1. Extend/retract hydraulic system 1. Refer to Section 8.7, “Hydraulic
not operating properly. Schematic.”
3. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.5.2, “Wear
Pad Installation and
Lubrication.”
4. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.

and/or wear. (Refer to Section 2.6,
“Lubrication Schedule.”)
Replace worn pins as needed.
2. Worn bushing(s). 2. Replace bushing(s) and

lubricate at regular intervals
(Refer to Section 2.6,
“Lubrication Schedule.”)
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.7, “Hydraulic

operating properly. Schematic.”
3. Faulty lift cylinder. 3. Repair cylinder. (Refer to

Section 8.12, “Hydraulic
Cylinders.”)
4. Seized boom pivot pin bushing. 4. Replace bushing.
G5-18A, 2505H, 25.5 3-15

Boom

6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.5.2, “Wear Pad
Installation and Lubrication.”
2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.
3. Contaminated, corroded or 3. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).
4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.
7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.7, “Hydraulic
operate. operating properly. Schematic.”
3-16 G5-18A, 2505H, 25.5

Section 4
Cab
Contents

4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Operator Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4.2 Steering Column/Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4.3 Brake Pedal and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.4 Accelerator Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.5 Joystick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.6 Windshield Wiper Assembly (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.7 Windshield Washer Assembly (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.8 Heater/Air Conditioning System (If Equipped) . . . . . . . . . . . . . . . . . . . . . 4-8
4.4.9 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.4.10 Air Filter System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
G5-18A, 2505H, 25.5 4-1

Cab
4.1 OPERATOR CAB COMPONENT

TERMINOLOGY
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
LSI INDICATOR
(2505H & 25.5)
ACCESSORY CONTROL LEVER POWER OUTLET

(IF EQUIPPED)
JOYSTICK
FRAME LEVEL
INDICATOR RIGHT HAND
CONSOLE
HORN BUTTON
LONGITUDINAL LEVEL
INDICATOR (AUS)
STEERING WHEEL
POWER
OUTLET
INSTRUMENT
PANEL
PARK BRAKE SWITCH

(G5-18A)
LSI OVERRIDE SWITCH
(2505H & 25.5)
TRANSMISSION
CONTROL LEVER
QUICK ATTACH SWITCH

(IF EQUIPPED)
TILT STEERING COLUMN

(IF EQUIPPED)
IGNITION SWITCH
SERVICE BRAKE PEDAL
ACCELERATOR PEDAL
MY8850
PARK BRAKE LEVER

(2505H & 25.5)
4-2 G5-18A, 2505H, 25.5

Cab
4.2 SAFETY INFORMATION 4.4 CAB COMPONENTS
4.4.1 Steering Wheel

WARNING
a. Steering Wheel Removal
DO NOT service the machine without following all
safety precautions as outlined in the “Safety Practices” 1. Park machine on a hard, level surface.
section of this manual. 2. Fully retract boom, lower boom, place transmission
4.3 OPERATOR CAB 3. Engage park brake and shut engine OFF.
4.3.1 Operator Cab Description switch and steering wheel.
The welded metal cab features a modular design, allowing 5. Properly disconnect battery.
for a relatively quick, simple exchange of entire cab and/
or component parts. Cab is bolted directly to frame.
The operator cab is a protective structure. The cab itself
contains rollover protective and falling object protective 1
structures (ROPS/FOPS) for operator. 3
WARNING
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement.
To help ensure optimum safety, protection and

performance, replace cab if it is damaged. Refer to
appropriate parts manual for ordering information. 2
The cab contains seat, operating controls, numerous
MAH0430
panels, steering and brake components and more.
Covers and mirrors on machine exist for safety, 7. Carefully pry center button (1) out of steering wheel.
protection and appearance. They are relatively simple 8. Mark steering wheel and shaft to ensure proper
to remove and replace. installation. Remove nut (2) securing steering
wheel (3) to splined steering column shaft.
4.3.2 Serial Number Decal
9. Use a steering wheel puller to remove steering
The cab serial number decal is located inside cab, under wheel (3) from splined shaft.
the seat. Information specified on serial number plate
includes cab model number, cab serial number and other b. Steering Wheel Installation
data. Write this information down in a convenient location
1. Install steering wheel (3) onto splined steering
to use in cab correspondence.
column shaft.
2. Secure steering wheel with nut (2).
3. Press center button (1) onto steering wheel.
G5-18A, 2505H, 25.5 4-3

Cab
4.4.2 Steering Column/Valve Replacement b. Steering Column and Valve Installation

1. Install four hex-flange capscrews (three if machine is
a. Steering Column and Valve Removal
equipped with tilt column) through steering column,
1. Park machine on a hard, level surface. mounting bracket and into top of orbitrol valve.
2. Fully retract boom, lower boom, place transmission Note: ALWAYS use new o-rings when servicing
control lever in (N) NEUTRAL. the machine.
3. Engage park brake and shut engine OFF. 2. Uncap and install new o-rings into fittings.
4. Place a Do Not Operate Tag on both ignition key Lubricate o-rings with clean hydraulic oil.
switch and steering wheel. 3. Uncap and reconnect previously labeled hydraulic
5. Properly disconnect battery. hoses to their appropriate locations.
6. Open engine cover. Allow system fluids to cool. 4. Install dash cover.
5. Install steering column cover.
6. Install steering wheel (Refer to Section 4.4.1,
4 “Steering Wheel.”), accessory lever and
transmission control lever.
6
5 8. Carefully examine all connections one last time
before engine start-up. Rectify any faulty conditions.
9. Start engine and check operation of all controls.
Check for fluid leaks. Check hydraulic fluid level in
7 tank and add fluid as required.
9 10. Clean up all debris, hydraulic fluid, etc., in, on, near
8 and around the machine.
MY2440
7. Remove steering wheel (4) (Refer to Section 4.4.1, c. Power Steering Test
“Steering Wheel.”), transmission control lever (5) and
accessory lever (if equipped)(6). Conduct a pressure check of the steering hydraulic
circuits at the test port on the implement pump. Refer to
8. Loosen and remove steering column cover.
Section 8.6.5, “Steering Pressure Checking.”
9. Loosen and remove dash cover.
10. Label, disconnect and cap hydraulic hoses (7) and
fittings on steering orbitrol valve (8).
11. Remove four hex-flange capscrews (9) (three if
machine is equipped with tilt column) connecting
orbitrol valve to steering column.
12. Pull steering column assembly and orbitrol valve
from machine cab.
Note: DO NOT disassemble the steering orbitrol valve.
The steering orbitrol valve is not serviceable and must
be replaced in its entirety, if defective.
4-4 G5-18A, 2505H, 25.5

Cab
4.4.3 Brake Pedal and Valve 8. Remove hardware (10).

9. Remove pin (11) and return spring securing service
a. Brake Valve Removal brake pedal to cab.
Refer to Section 8.11.2, a. “Service Brake Valve 10. Remove service brake pedal from cab.
Removal,” for removal information.
d. Service Brake Pedal Installation
b. Brake Valve Installation
1. Position service brake pedal in its mounting location
Refer to Section 8.11.2, b. “Service Brake Valve within cab.
Installation,” for installation information.
2. Install brake pedal being careful to reposition brake
plunger yoke.
c. Service Brake Pedal Removal
3. Install return spring and pin (11).
4. Install hardware (10) securing pin.
control lever in (N) NEUTRAL. 5. Adjust brake pedal as needed.
3. Engage park brake and shut engine OFF. 6. Install and secure lower dash cover.
4. Place a Do Not Operate Tag on both ignition key 7. Properly connect battery.
switch and steering wheel. 8. Close and secure engine cover.
5. Properly disconnect battery. 9. Remove a Do Not Operate Tag on both ignition key
6. Open engine cover. Allow system fluids to cool. switch and steering wheel.
7. Remove the lower dash cover.
11
10
MY8860
G5-18A, 2505H, 25.5 4-5

Cab
4.4.4 Accelerator Pedal Replacement b. Accelerator Pedal Installation

1. Reconnect sensor (13) to pedal assembly.
a. Accelerator Pedal Removal
2. Align pedal assembly with its mount holes under
1. Park machine on a hard, level surface. cab dash.
2. Fully retract boom, lower boom, place transmission 3. Install hardware (12) securing pedal assembly
control lever in (N) NEUTRAL. to mount.
3. Engage park brake and shut engine OFF. 4. Properly connect the battery.
4. Place a Do Not Operate Tag on both ignition key 5. Close and secure engine cover.
5. Properly disconnect battery. switch and steering wheel.
12
13
12
MY8870
7. Remove hardware (12) securing pedal assembly to

cab frame.
8. Disconnect sensor (13) from pedal assembly.
9. Remove accelerator pedal assembly from cab.
4-6 G5-18A, 2505H, 25.5

Cab
4.4.5 Joystick Replacement 4.4.6 Windshield Wiper Assembly

(If Equipped)
a. Joystick Removal
Refer to Section 9.8.1, “Windshield Wiper Motor,” for
1. Park machine on a hard, level surface. removal and installation information.
control lever in (N) NEUTRAL. 4.4.7 Windshield Washer Assembly
(If Equipped)
Refer to Section 9.8.3, “Windshield Washer Reservoir
and Pump,” for removal and installation information.
7. Support the boom by installing the lift cylinder lock or
a suitable support.
15
16
14
MY2410
8. Label, disconnect and cap hydraulic hoses and

electrical connections (14) to joystick.
9. Lift rubber boot (15) from base of joystick and
remove capscrews (16).
10. Remove joystick.
b. Joystick Installation
1. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.
2. Reconnect electrical connections.
3. Install capscrews in joystick base.
4. Re-seat rubber boot to joystick base.
5. Remove lift cylinder lock if previously installed.
8. Start engine and test joystick for proper functions.
G5-18A, 2505H, 25.5 4-7

Cab
4.4.8 Heater/Air Conditioning System 15. Loosen hose clamps and disconnect the two
(If Equipped) heater hoses.
16. Remove capscrews, nuts and lockwashers securing
a. Removal heater assembly to cab.
1. Park machine on a hard, level surface. 17. Carefully pull out heater assembly (18). Label and
2. Fully retract boom, lower boom, place transmission disconnect wiring harness connections at blower.
control lever in (N) NEUTRAL. 18. Remove heater assembly.
b. Installation
switch and steering wheel. 1. Install heater assembly (18) to original orientation.
5. Properly disconnect battery. 2. Connect wiring harness connections at blower.
6. Open engine cover. Allow system fluids to cool. 3. Install capscrews, nuts and lockwashers to secure
7. Place a suitable container beneath the radiator heater assembly to cab.
petcock 4. Reconnect heater hoses.
8. Slowly turn the coolant surge tank cap and allow any 5. Refill cooling system at recovery tank with a 50/50
pressure to escape. mixture of ethylene glycol and water allowing time for
9. Place a funnel at base of radiator to channel drained coolant to fill engine block. See Section 2.4, “Fluids,
coolant into container. Lubricants and Capacities,” for system capacities.
10. Open radiator petcock and allow coolant to drain. Note: If equipped with Air Conditioning, contact the local
JLG dealer or certified air conditioning service center for
11. Close the radiator petcock.
proper charging of the air conditioner system. Refer to
12. Transfer coolant into a suitable, covered container, Section 2.4.2, “Capacities.” for refrigerant type and
and label as "Used Coolant". capacity.
13. Dispose of used coolant at an approved recycling 6. Properly connect battery.
facility.
7. Start engine, run it briefly at low idle and check
Note: If equipped with Air Conditioning, contact the local machine for any visual sign of fluid leakage. STOP
JLG dealer or certified air conditioning service center for the machine immediately if any leakage is noted,
proper draining of the air conditioner system. and make any necessary repairs before continuing.
Note: Label all hoses to ensure correct installation. 8. Install front cover (17) in cab.
9. Check coolant level. Add or remove fluid as required.
4.4.9 Air Conditioning (If Equipped)

If the air conditioning system requires servicing, contact
the local JLG dealer or certified air conditioning service
center. Refer to Section 2.4.2, “Capacities.” for refrigerant
type and capacity.
17
MY2430
18
14. Remove front cover to expose heater/defroster
element (17).
4-8 G5-18A, 2505H, 25.5

Cab
4.4.10 Air Filter System (If Equipped)

2 1
MY9020
7. Remove access panel (1).

8. Remove cab air filter (2) and inspect. If required,
replace with new filter.
9. Place filter back under seat and secure.
10. Replace and secure access panel.
G5-18A, 2505H, 25.5 4-9

Cab
4.5 CAB REMOVAL 13. Remove hardware (2), securing cab to frame.
WARNING 1
The protection offered by this ROPS/FOPS will be

1
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners or correct size and grade, and torqued to
their specified value.
Note: To help ensure safety and optimum performance,

replace cab if it is damaged. Refer to appropriate parts
manual for ordering information.
Inspect cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
discovered, replace cab. Contact local JLG Dealer with 2
any questions about suitability or condition of a cab.
MY2420
Note: Remove and label cab components as needed
before removing cab from machine. Label, disconnect
and cap hydraulic hoses. Transfer cab parts to 14. Remove mirrors and all other cab components as
replacement cab after replacement cab is securely needed, if not previously removed.
mounted on machine. 15. When all wiring, hydraulic hoses and fasteners are
1. Park machine on a hard, level surface. disconnected or removed, carefully and slowly lift
cab and remove it from frame.
control lever in (N) NEUTRAL. 16. Readjust position of sling as needed to help balance
cab during removal.
17. When cab is completely clear of machine, carefully
4. Place a Do Not Operate Tag on both ignition key lower it to ground.
18. Block up or support cab so that it does not move or
5. Properly disconnect battery. fall. Assure that no personnel enter cab while it is
6. Open engine cover. Allow system fluids to cool. being removed from machine.
7. If equipped with a cab heater, Refer to Section 4.4.8, 19. Inspect condition of fittings, clamps, hydraulic hoses,
b. “Installation.” etc. Replace parts as indicated by their condition.
8. Working underneath cab, label, disconnect and cap 20. Inspect and replace other machine parts that
all hydraulic hoses at cab fittings. are exposed with cab removed. Repair or replace
9. Cap all fittings and openings to keep dirt & debris as required.
from entering hydraulic system.
10. Label and disconnect cab harness connectors. Move
harnesses clear of cab to prevent damage during
cab removal.
11. Install four lifting eye bolts with a minimal lifting
capacity of 800 lb (363 kg) in existing holes at top
corners of cab (1).
12. Use a hoist or overhead crane and sling with a
minimal lifting capacity of 800 lb (363 kg) attached to
four lifting eye bolts. DO NOT attempt to lift cab at
this point.
4-10 G5-18A, 2505H, 25.5

Cab
4.6 CAB INSTALLATION 21. Turn engine off and wait for engine to cool and check
coolant level. Add coolant as required to bring
1. Block all four wheels to help prevent machine from coolant to proper level.
moving. Assure that there is sufficient overhead and 22. Install protective cover to front of cab.
side clearance for cab installation.
23. Install mirrors and all other components as needed,
2. Attach a sling with minimal lifting capacity of 800 lb if removed.
(363 kg) through previously installed eye bolts.
24. Unblock wheels
3. Use a hoist or overhead crane and sling attached to
cab. Carefully begin to align cab with mounting holes 25. Close and secure engine cover.
in frame. 26. Start engine and test joystick for proper functions.
4. Stop and check that wiring, hydraulic hoses, cables, 27. Remove a Do Not Operate Tag on both ignition key
etc., will not be pinched or damaged as cab is switch and steering wheel.
positioned. Take special note of fuel fill tube as well.
5. Readjust position of sling as needed to help balance
cab during installation.
6. Install cab-to-frame hardware (2). WARNING
7. Torque upper cab bolts to 340 lb-ft (461 Nm). Avoid breathing exhaust fumes, and prevent engine
operation from becoming a cause of toxic emissions.
8. Torque lower cab bolts to 530 lb-ft (719 Nm).
9. Remove eye bolts from top of cab (1).
10. Uncap and reconnect hydraulic hoses at
cab locations.
11. Install cab-to-wiring harness connectors on side of
the cab.
12. Uncap and connect heater hoses to engine.
13. Secure with hose clamps.
14. If equipped with a cab heater, Refer to Section 4.4.8,
“Heater/Air Conditioning System (If Equipped).”
16. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
faulty conditions.
17. Start engine and check operation of all controls.
18. Check for hydraulic fluid leaks.
19. Check hydraulic fluid level in tank and add fluid
as required
NOTICE
When the engine is initially started, run it briefly at low
idle and check the machine for any visual sign of fluid
leakage. STOP the engine immediately if any leakage
is noted, and make any necessary repairs before
continuing.
20. If equipped with optional heater, operate engine until

operating temperature is achieved ensuring that
thermostat has opened.
G5-18A, 2505H, 25.5 4-11

Cab
4-12 G5-18A, 2505H, 25.5

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2
5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4.7 Axle Assembly and Drive Shaft Troubleshooting. . . . . . . . . . . . . . . . . . . . 5-6
5.5 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.4 Drive Shaft Cleaning and Drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . 5-10
5.6.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-11
5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8.1 Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9.2 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
G5-18A, 2505H, 25.5 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
FRONT AXLE
ASSEMBLY
DRIVE SHAFT
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER
FRONT AXLE WHEEL

HUBS (2)
REAR AXLE MY8880

ASSEMBLY
REAR AXLE WHEEL

HUBS (2)
5-2 G5-18A, 2505H, 25.5

5.2 SAFETY INFORMATION 5.4.4 Axle Maintenance

CLEANING: Clean parts with machined or ground
surfaces (such as gears, bearings and shafts) with
WARNING emulsion cleaners or petroleum-based cleaners. DO
NOT steam clean internal components and the interior of
the planetary hub and axle housing. Water can cause
corrosion of critical parts. Rust contamination in the
lubricant can cause gear and bearing failure. Remove old
gasket material from all surfaces.
5.3 GENERAL INFORMATION DRYING: Use clean, lintless towels to dry components
after cleaning. DO NOT dry bearings by spinning them
Before performing any inspection, maintenance or
with compressed air; this can damage mating surfaces
service operation, thoroughly clean the unit. The axles
due to lack of lubrication. After drying, coat components
and drive shafts should be checked and repaired only by
with oil or a rust-preventive chemical to help protect them
experienced service technicians who are aware of all
from corrosion. If storing components for a prolonged
safety instructions and particular component features.
period, wrap them in wax paper.
Use suitable products to thoroughly clean all
PERIODIC OPERATION REQUIREMENT: Every two
disassembled mechanical parts to help prevent personal
weeks, drive the machine far enough to cause the drive-
injury to the worker and prevent damage to the parts.
train components to make several complete revolutions.
Carefully inspect the integrity of all moving parts
This will help ensure that internal components receive
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
lubrication to minimize deterioration caused by
(nuts, bolts, washers, etc.) as they are subject to major
environmental factors such as high humidity.
stress and wear.
SUBMERSION: If the machine has been exposed to
5.4 AXLE ASSEMBLIES water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
5.4.1 Axle Serial Number Plate water, especially if the water level was above the vent
The front and rear axle serial number plate is located on tube (breather), drain the axle and inspect internal parts
the inside of each axle on the right side of the center for water damage and contamination. Before assembling
section. Information on the serial number plate is required and refilling the unit with the specified lubricant(s), clean,
in correspondence regarding the axle. examine and replace damaged parts as necessary.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle
components.
5.4.2 Axle Specifications

General axle specifications are found in Section 2,
“General Information and Specifications.”
5.4.3 Axle Internal Service

Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and
troubleshooting information) are provided in the following
publications:
• Front Axle Manual P/N 31200419
• Rear Axle Manual P/N 31200981
G5-18A, 2505H, 25.5 5-3

5.4.5 Axle Removal
3
WARNING 2
An improperly supported machine can fall, causing

death or severe personal injury. Safely raise and
adequately support the machine so that it will remain
stable and in place before attempting to remove an axle.
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a drop box, hydraulic 5
MY8890
drive pump, parking brake mechanism and a limited-slip
feature; the rear axle has none of these. The following 4 4
steps outline a typical axle removal procedure, suitable
8. If axle will be disassembled after removal, place a
for either the front or the rear axle assembly.
suitable receptacle under axle (1), drop box (2) and
Cleanliness is extremely important. Before attempting to wheel hubs (3) drain plugs (4). Remove drain plugs
remove the axle, thoroughly clean the machine. Avoid and allow axle oil to drain into receptacle. Transfer
spraying water or cleaning solution on the stabilizer used axle oil into a suitable covered container, and
solenoids and other electrical components. If using a label container as "Used Oil." Dispose of used oil at
steam cleaner, seal all openings before steam cleaning. an approved recycling facility.
Note: Clear the work area of all debris, unnecessary 9. Label, disconnect and cap steering and brake lines
personnel, etc. Allow sufficient space to raise the at axle. Wipe up any spilled oil.
machine and to remove the axle. 10. Block front and rear of both tires on axle that is not
1. Park machine on a hard, level surface. being removed. Ensure that machine will remain in
place during axle removal before proceeding.
control lever in (N) NEUTRAL. 11. Raise machine using a suitable jack or hoist. Place
suitable supports under both sides of frame and
lower machine onto supports. Ensure that machine
4. Place a Do Not Operate Tag on both ignition key will remain in place during axle removal.
12. Support axle that is being removed with a suitable
5. Properly disconnect battery. jack, hoist or overhead crane and sling. DO NOT
6. Open engine cover. Allow system fluids to cool. raise axle or machine.
7. If the axle will be disassembled after removal, the oil 13. Mark and remove both wheel and tire assemblies
will have to be drained. Loosen the breather to from the axle that is being removed. (Refer to
release possible internal pressure, then tighten Section 5.6.1, “Removing Wheel and Tire Assembly
breather with a torque wrench to 9 lb-ft (12 Nm). from Machine.”)
1 Note: The wheel and tire assemblies must be re-installed
5 later with the directional tread pattern “arrows” facing in
the direction of forward travel.
14. Remove drive shaft assembly. (Refer to Section 5.5.3,
“Drive Shaft Removal.”)
15. Remove capscrews, locknuts and axle plates
securing axle to frame.
16. Remove axle from machine using jack, hoist or
overhead crane and sling supporting axle. DO NOT
raise or otherwise disturb machine while removing
MY2091 axle. Balance axle and prevent it from tipping,
4
turning or falling while removing it from beneath
machine. Place the axle on a suitable support or
holding stand.
5-4 G5-18A, 2505H, 25.5

5.4.6 Axle Installation 11. Carefully raise machine using a suitable jack or
hoist. Remove supports from beneath frame and
1. Before proceeding, ensure that the machine will
lower machine to ground.
remain in place during axle installation. Block the
front and rear of both tires on the axle that is already 12. Remove blocks from front and rear of both tires on
installed on the machine. other axle.
2. If applicable, raise the machine using a suitable jack 13. Uncap and reconnect steering and brake lines at
or hoist. Place suitable supports beneath the frame their axle fittings. Refer to Section 8.11.2, “Service
and lower the machine onto the supports, allowing Brake Valve,” for brake bleeding procedures.
enough room for axle installation. Ensure that the 14. Check hydraulic reservoir oil level.
machine will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and
16. Close and secure the engine covers.
sling, remove the axle from its support or holding
stand. Balance the axle and prevent it from tipping, 17. Start engine. Turn steering wheel several times lock
turning or falling while positioning it beneath the to lock and check function of brakes. Check for
machine. DO NOT raise or otherwise disturb the hydraulic leaks, and tighten or repair as necessary.
machine while installing the axle. Keep the axle 18. Remove a Do Not Operate Tag on both ignition key
supported and balanced on the jack, hoist or switch and steering wheel.
overhead crane and sling throughout the installation
procedure.
4. Position the axle under the frame, and align with the
holes in the frame.
5. Install the axle with capscrews, locknuts and the axle
plates. Torque the front and rear axles to 420 lb-ft
(569 Nm).
6. Install the drive shaft assemblies. (Refer to Section
5.5.5, “Drive Shaft Installation.”)
7. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transmission.
8. Tighten the axle oil drain plug (4), loosen and
remove the axle oil fill plug (5). Tighten the drop box
oil drain plug (4), loosen and remove the drop box oil
fill plug (5). Fill axle with the appropriate oil. Refer to
Section 2.4, “Fluids, Lubricants and Capacities,” for
proper oil and capacities.Rotate wheel hubs 90
degrees so the drain plug (4) becomes the fill plug.
Fill wheel hubs with the appropriate oil. Refer to
Section 2.4, “Fluids, Lubricants and Capacities,” for
proper oil and capacities.
9. Install the wheel and tire assemblies. (Refer to
Section 5.6.2, “Installing Wheel and Tire Assembly
onto Machine.”)
10. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
G5-18A, 2505H, 25.5 5-5

5.4.7 Axle Assembly and Drive Shaft Troubleshooting

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. (Refer to
driving. Section 2.4, “Fluids, Lubricants
and Capacities.”)
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
low. (Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”)
3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level.
(Refer to Section 2.4, “Fluids,
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal

traveling. damaged. joints as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
3. Vibration or intermittent noise 1. Drive shaft universal joint(s) 1. Tighten capscrews to correct
when traveling. assembly incorrectly tightened. torque.
2. Drive shaft universal joint(s) 2. Repair or replace universal

worn or damaged. joints as needed.
3. Drive shaft damaged/ 3. Replace drive shaft as needed.

unbalanced.
5-6 G5-18A, 2505H, 25.5

5.4.7 Axle Assembly and Drive Shaft Troubleshooting (Continued)

4. Oil leaking from axle 1. Drain plugs loose and/or o-rings 1. Replace o-rings as needed and
(differential housing and/or damaged or missing. tighten plugs 59 lb-ft (80 Nm).
axle housings).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint

missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or

damaged or missing and/or input shaft. Adjust ring and
worn or damaged pinion (input) pinion alignment and bearing
shaft sealing surfaces. preload as described in the Axle
Repair Manuals.
5. Axle casing to brake housing 5. Replace o-rings and seals.

and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews to
236 lb-ft (320 Nm).
7. Differential and/or axle 7. Replace housing(s) as needed.

housing(s) damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 59 lb-ft (80 Nm).
2. O-ring between hub and 2. Replace o-ring.

housing (planet carrier)
damaged or missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to

41 lb-ft (55 Nm).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.

seals worn or damaged.
3. Piston rod seal worn or 3. Replace piston rod seal.

damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.
G5-18A, 2505H, 25.5 5-7

5.4.7 Axle Assembly and Drive Shaft Troubleshooting (Continued)

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. (Refer to
Section 2.4, “Fluids, Lubricants
and Capacities.”)
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil housing and fill to correct level.
contaminated or oil level low. (Refer to Section 2.4, “Fluids,
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to the appropriate Axle
operating properly. Repair Manual.
2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to the appropriate Axle
2. Steering cylinder leaking 2. Repair or replace steering

internally. cylinder as needed.
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to appropriate Axle Repair
Manual.
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to the appropriate Axle
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to the appropriate Axle
reduced. Repair Manual.
2. Brake (hydraulic) system not 2. Refer to the appropriate Axle

3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).
5-8 G5-18A, 2505H, 25.5

5.5 DRIVE SHAFTS

TO REAR AXLE
5.5.1 Drive Shaft Inspection

Whenever servicing the machine, conduct a visual
inspection of the drive shaft and cross and bearing 4
assembly (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and
2
down time later.
Inspect area where the drive shaft flange yoke and slip 2
yoke mount to the drive shaft. Attempt to turn drive shaft
in both directions. Look for excessive looseness, missing
parts, cracks or other damage. Worn or damaged drive
1
shaft and cross and bearing assembly may cause an 3
excessive amount of vibration or noise. MY8900
TO FRONT AXLE
Note: Any bolt removed from the drive shaft assembly
MUST be replaced. Do Not re-torque 10. Remove hardware (1) securing drive shaft to rear
axle flange.
5.5.2 Drive Shaft Maintenance 11. Remove hardware (2) securing drive shaft to front
Refer to Section 2.6, “Lubrication Schedule,” for axle flange.
information regarding the lubrication of the grease fittings 12. Remove drive shaft assembly (3).
on the drive shafts.
5.5.4 Drive Shaft Cleaning and Drying
5.5.3 Drive Shaft Removal
1. Disassemble and clean all parts. Allow to dry.
2. Remove any burrs or rough spots from all machined
2. Fully retract boom, lower boom, place transmission surfaces. Re-clean and dry as required.
5.5.5 Drive Shaft Installation
1. Raise drive shaft assembly (3) into position. The
slip-yoke (4) end of drive shaft mounts toward rear
axle. If reinstalling a drive shaft previously removed,
5. Properly disconnect battery. align flange yokes according to alignment marks
6. Open engine cover. Allow system fluids to cool. made during removal.
7. Block the wheels. 2. Apply locking compound to all mounting bolts.
8. The drive shaft assembly is a balanced assembly. 3. Install hardware securing drive shaft to front axle.
Mark yoke and axle, transmission and shaft and slip Torque capscrews to 102 lb-ft (139 Nm).
yoke so that these components can be returned to 4. Install hardware securing slip-yoke to rear axle.
their original positions when reinstalled. Torque capscrews to 102 lb-ft (139 Nm).
9. Yokes at both ends of drive shaft must be in same 5. Properly connect the battery.
plane to help prevent excessive vibration.
6. Unblock the wheels.
8. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
G5-18A, 2505H, 25.5 5-9

5.6 WHEELS AND TIRES 1
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
It is recommended that a replacement tire to be the same

size, ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using an approved replacement tire, It is recommended
that replacement tires have the following characteristics:
MZ6020
• Equal or greater ply/load rating and size of original.
The wheel and tire assemblies must be installed with the
• Tire tread contact width equal or greater than
directional tread pattern “arrows” (1) facing in the
original.
direction of forward travel.
• Wheel diameter, width and offset dimensions equal
to the original. 5.6.1 Removing Wheel and Tire Assembly
• Approved for the application by the tire manufacturer from Machine
(including inflation pressure and maximum tire load). 1. Park the machine on a firm, level surface, fully
The rims installed have been designed for stability retract the boom, lower the boom, place the
requirements which consist of track width, tire pressure transmission control lever in (N) NEUTRAL, engage
and load capacity. Size changes such as rim width, the park brake and shut the engine OFF.
center piece location, larger or smaller diameter, etc., 2. Place a Do Not Operate Tag on both the ignition key
without written factory recommendations, may result in switch and steering wheel, stating that the machine
unsafe condition regarding stability. should not be operated.
Foam filled tires have a positive effect on the weight, 3. Loosen but DO NOT remove the lug nuts on the
stability and handling characteristics of the machine, wheel and tire assembly to be removed.
especially under load. The use of hydrofill as a tire-fill
substance is not recommended because of possible 4. Place a suitable jack under the axle pad closest to
environmental impact. the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
Large-bore valve stems are used to help expedite tire sufficient room to lower the machine onto the
inflation and deflation. An inner tube may be used if a tire support and to remove the wheel and tire assembly.
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire 5. Lower the machine onto the support.
on the wheel, the tire must be mounted on the wheel 6. Remove lug nuts and washers in an alternating
respective of the directional tread pattern of the tire; this pattern.
produces a left or right tire and wheel assembly. 7. Remove the wheel and tire assembly from the
machine.
5-10 G5-18A, 2505H, 25.5

5.6.2 Installing Wheel and Tire Assembly 5.7 STEERING ANGLE ADJUSTMENT
onto Machine
Detailed axle service instructions are provided in the Axle
Note: The wheel and tire assemblies must be installed
Disassembly & Assembly Manual (P/N 31200451).
with the directional tread pattern “arrows” facing in the
direction of forward travel.
5.8 BRAKES
TREAD “ARROWS” MUST 5.8.1 Brake Disc Inspection

POINT FORWARD
Detailed axle service instructions are provided in the
Front Axle Disassembly & Assembly Manual
(P/N 31200419).
INSTALL TIRES ONTO

WHEELS TO ROTATE IN
PROPER DIRECTION
MAH0460
1. Position wheel onto studs on wheel end of axle.

2. Install washers on the wheel studs.
3. Start all lug nuts by hand to prevent cross threading.
DO NOT use a lubricant on threads or nuts.
3
1 5
8 7
6 2
4
OAH0990
4. Tighten lug nuts in an alternating pattern as

indicated in figure. Torque to 221 lb-ft (300 Nm).
5. Remove machine from supports.
G5-18A, 2505H, 25.5 5-11

5.9 TOWING A DISABLED MACHINE 5.9.1 Equipment and Supplies Required
Towing a disabled machine should only be attempted

after exhausting all other options. Make every effort to NOTICE
repair the machine, and move it under its own power.
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Towing is only possible by using the “towing” feature built
Supply hydraulic oil must be compatible with hydraulic
into hydrostatic pump and disengaging park brake on the
oil shown in Section 2.4, “Fluids, Lubricants and
front axle.
Capacities.”
• Maximum towing distance is 200 ft (60 m).
Auxiliary Hydraulic Power Supply:
• Maximum towing speed is 5 mph (8 kmh).
• Portable hydraulic unit with capability of
• Maximum towing grade is 25%. producing 300 psi (20,7 bar) minimum
DO NOT attempt to tow a machine that is loaded or pressure to release park brake.
boom/attachment is raised above 1,2 m (4 ft). Hose:
• One Hydraulic Hose–Approximately 5 ft
WARNING (1,5 m), with a minimum I.D. of 0.25 in (6,3 mm)
and a minimum rating of 250 psi (17 bar).
MACHINE HAS NO TOWING BRAKES. Towing Fittings:
vehicle must be able to control machine at all times.
On highway towing is NOT permitted. • One 9/16-18 UNF (-6) ORFS Cap
• One 9/16-18 UNF (-6) ORFS Plug
WARNING Note: Machine axle fittings are 9/16–18 UNF (-6)

ORFS. The adaptor size may vary depending on the
BLOCK ALL FOUR WHEELS TO PREVENT hose end of the auxiliary hydraulic power supply.
MACHINE FROM MACHINE ROLL AWAY. Failure
to follow instructions could cause death or serious
injury.
5-12 G5-18A, 2505H, 25.5

5.9.2 Towing Procedure 9. Tighten relief valve (1) on hydrostatic transmission to

32-41 lb-ft (44-56 Nm).
1. Securely block all four wheels.
10. Connect an auxiliary hydraulic power supply to the
P1 port (2) on the front axle and apply 220-435 psi
(15-30 bar) to release the park brake.
Note: DO NOT apply more than 450 psi (31 bar) to
release the park brake. Excessive pressure could
damage the axle brake system.
11. Loosen unlocking bolts (4) and install stop washers.
12. Tighten unlocking bolts 70-85 lb-ft (95-115 Nm).
13. Release pressure from auxiliary hydraulic power
MY8910 supply and remove auxiliary hydraulic power supply.
2
1 14. The parking brake should now be reactivated and
front wheels locked.
2. Loosen shuttle valve (1) on hydrostatic transmission 15. Remove blocks from four tires.
until it hits against stop (2).
16. Verify that parking brake works.
Note: This procedure does not alter any relief settings. 17. If parking brake does not work, check all activation
operations step by step.
4 (Not Shown)
MY2050
3 4
3. Connect an auxiliary hydraulic power supply to

P1 port (3) on front axle and apply 220-435 psi
(15-30 bar) to release the park brake.
Note: DO NOT apply more than 450 psi (31 bar) to
release the park brake. Excessive pressure could
damage the axle brake system.
4. Loosen unlocking bolts (4) located at front and back
side of axle housing and remove stop washers.
5. Tighten unlocking bolts against axle housing.
6. Release pressure from auxiliary hydraulic power
supply and remove auxiliary hydraulic power supply
7. Carefully remove blocking from each tire and tow
machine to a secure location.
8. After machine has been towed to a secure location,
block all four wheels.
G5-18A, 2505H, 25.5 5-13

5-14 G5-18A, 2505H, 25.5

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5.2 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
G5-18A, 2505H, 25.5 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

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 transmission. The following
illustration identifies the components that are referred to throughout this section.
TOP FILL PORT
HYDROSTATIC
TRANSMISSION
FORWARD
RELIEF
VALVE
SHUTTLE VALVE
REVERSE
RELIEF
VALVE
DIRECTIONAL
CONTROL VALVE
VIEW FROM BOTTOM WITH MY8920

PLATE REMOVED
6-2 G5-18A, 2505H, 25.5

Transmission
6.2 SAFETY INFORMATION 6.5 TRANSMISSION REPLACEMENT

Note: Contact the local JLG Dealer if internal
WARNING transmission repair is required during warranty period.
Cleanliness is of extreme importance. Before attempting
to remove the transmission, thoroughly clean the exterior
of the transmission to help prevent dirt from entering
during the replacement process. Avoid spraying water or
cleaning solution onto or near the transmission shift
6.3 TRANSMISSION DESCRIPTION solenoids and other electrical components.
Instructions in this section pertain mainly to general 6.5.1 Transmission Removal

specifications, towing, maintenance information, and
transmission removal and installation procedures. For 1. Park machine on a hard, level surface.
internal transmission service instructions and detailed 2. Fully retract boom, lower boom, place transmission
specifications contact an authorized Rexroth Repair control lever in (N) NEUTRAL.
center.
More information can be obtained from the serial number
plate directly mounted on the transmission. Information
specified on the serial number plate includes the
transmission model number, the transmission serial 5. Properly disconnect battery.
number and other data. Information on the serial number 6. Open engine cover. Allow system fluids to cool.
plate is required in correspondence regarding the
7. Remove the air cleaner assembly.
transmission.
8. Remove cooling system, Refer to Section 7.2,
6.4 TRANSMISSION SPECIFICATIONS “Engine Cooling System.”
9. Drain the hydraulic oil reservoir. Refer to Section
8.8.2, “Hydraulic Oil Reservoir Draining.”
6.4.1 Transmission Maintenance
10. Label, disconnect and cap all hydraulic hoses
The transmission is a hydraulic component and requires
attached to transmission and implement pump.
the same maintenance as the hydraulic system. Refer to
Section 2.5, “Maintenance Schedule.” 11. Cap all fittings and openings to keep dirt and debris
from entering hydraulic system.
Performance criteria is based on full throttle engine
speed unless otherwise specified or not applicable. 12. Remove front fender support bar.
13. Label and disconnect all electrical connections
attached to transmission.
14. Wipe up any spilled hydraulic oil.
G5-18A, 2505H, 25.5 6-3

Transmission
15. Vertically secure transmission and implement pump 7. Install cooling system. Refer to Section 7.2, “Engine
with a lifting strap or chain. Use a suitable hoist or Cooling System.”
overhead crane. Operate hoist or crane to remove 8. Fill hydraulic reservoir with clean, fresh oil and bleed
slack from chain, but DO NOT raise transmission at system. DO NOT overfill.
this time.
16. Remove two bolts that attach transmission to engine.
10. Check hydraulic oil level and add oil as required.
WARNING NOTICE
The transmission may move while hoisting it out of
the chassis. Carefully move the transmission and DO NOT use flushing compounds for cleaning
adjust the sling as needed. Keep fingers, hands, legs purposes.
and other body parts clear of the transmission.
11. Run engine for two minutes at idle to help bleed any air
17. Carefully remove transmission and pump from the from hydraulic system.
machine. Avoid causing damage to transmission or
12. Operate all boom functions to ensure any air is
surrounding parts.
removed from hydraulic system.
18. Lift transmission and pump clear of machine, and
13. Retract and level boom, recheck level of the fluid in
lower it onto suitable supports or secure it to a stand
the reservoir.
built especially for transmission or engine service.
Secure transmission and pump so that it will not 14. Add oil as necessary to bring fluid level up until it
move or fall. reaches FULL mark on reservoir. Recheck oil level
when it reaches operating temperature 180–200° F
6.5.2 Transmission Disassembly (83–94° C).
Contact an authorized Rexroth Repair center for 15. Recheck all drain plugs, lines, connections, etc., for
transmission disassembly, internal inspection, service, leaks, and tighten where necessary.
repair and assembly procedures. 16. Close and secure the engine covers.
6.5.3 Transmission Installation ignition key and the steering wheel.
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling. Failure to follow the safety practices
could result in death or serious injury.
1. Use a lifting strap or chain attached to a hoist or
overhead crane to position transmission and pump
within the chassis.
2. Insert the two bolts that attach transmission to
engine. Torque to 154 lb-ft (210 Nm).
3. Remove hoist or overhead crane and sling.
4. Uncap and reconnect previously labeled hoses and
electrical connections to their appropriate locations.
5. Remove fill port screw and pre-fill transmission to
top of fill port. Install screw and torque to 398 lb-ft
(540 Nm).
6. Install front fender support bar.
6-4 G5-18A, 2505H, 25.5

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.4 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.1 Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.2 Radiator/Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
G5-18A, 2505H, 25.5 7-1

Engine
7.1 INTRODUCTION 7.1.2 Engine Serial Number

The engine serial number is located on a tag on top of the
7.1.1 Disclaimer and Scope engine. Information contained in the serial number is
required in correspondence with the engine
These instructions are written for worldwide use. In
manufacturer.
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
7.1.3 Specifications and Maintenance
data and dimensions provided herein in such a way that
Information
after maintenance, service and repair of the engine,
engine operation does not violate local regulations. For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General
Note: Detailed engine service instructions (covering
Information and Specifications.”
disassembly, inspection, internal repair, assembly,
adjustment and troubleshooting information) are
provided in appropriate engine service manual.
A gradual running-in (break-in) of a new engine is not
necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
temperature is at least 140° F (60° C). Extended light-
load operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-load
speeds. DO NOT apply an overload to the engine.
7-2 G5-18A, 2505H, 25.5

Engine
7.1.4 Component Terminology

To understand safety, operation and maintenance
operator/mechanic be familiar with names and locations
of engine components. The following illustration identifies
THERMOSTAT
FUEL PUMP
FUEL FILTER
OIL FILTER
ALTERNATOR
TURBOCHARGER
STARTER
MY8930
G5-18A, 2505H, 25.5 7-3

Engine
7 4
6 1
10
10
3 9 8
2 MY8970
7.2 ENGINE COOLING SYSTEM 3. Open the engine cover. Allow the system fluids to
cool.
7.2.1 Surge Tank Cap 4. Thoroughly clean the engine and surrounding area,
including all hoses and fittings before proceeding.
A 14.5 psi (1,0 Bar) cap is used on the surge tank. An
incorrect or malfunctioning cap can result in the loss of 5. Open the battery cover.
coolant and a hot-running engine. 6. Properly disconnect the battery.
7. Support or secure the hood assembly.
7.2.2 Radiator/Oil Cooler Replacement
8. Remove the mounting nuts from the rod end of each
Before considering radiator or oil cooler replacement for hood gas strut.
other than obvious damage, conduct a cooling system
9. Remove the two bolts and washers securing each
pressure test check the coolant specific gravity, coolant
hinge from the hood side of the hood. Mark each bolt
level, fan belt tension and dash panel temperature
location before removing to aid in aligning the hood
indicator.
during reassembly.
• If the engine runs hot, check the temperature of
10. Remove the hood assembly.
the upper radiator hose.
11. Remove the inside firewall plate (1) to access the
• If the hose is not hot, the thermostat may be
back side of the cooling package.
stuck in the closed position.
12. Remove the engine pod side skirt (2) and belly pan.
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking 13. Disconnect the ECM connectors and remove any
cylinder head gasket, cracked cylinder head or nylon ties that may be securing the wire harness
block, and/or other internal engine damage. mounted to the right front fender.
14. Remove the right front fender (3).
a. Radiator/Oil Cooler Removal
Note: It may be required to remove the right front tire to
1. Park the machine on a firm, level surface, fully access hydraulic hose fittings.
retract the boom, raise and support the boom, place
the transmission control lever in (N) NEUTRAL, 15. Slowly turn the coolant surge tank cap and allow any
engage the park brake and shut the engine OFF. pressure to escape (4).
2. Place a Do Not Operate Tag on both the ignition key 16. Place a suitable container beneath the radiator
switch and the steering wheel, stating that the petcock (5).
machine should not be operated.
7-4 G5-18A, 2505H, 25.5
Engine
17. Place a funnel at the base of the radiator to channel 29. Loosen and remove the lower hydraulic oil cooler
the drained coolant into the container. Open the hose. Cap all fittings and openings to keep dirt &
radiator petcock and drain the coolant into the debris from entering the hydraulic system.
funnel. Transfer the fluid into a properly labeled 30. Remove the bottom radiator hose (13). Cap all
container. Dispose of properly if coolant needs to be fittings and openings to keep dirt & debris from
replaced. Close the radiator petcock. entering the cooling system.
18. Remove air dam (6) to gain access to the cooling 31. Slowly remove the radiator/oil cooler from the
package lifting eye mounts. machine.
19. Loosen the mounting bolts and move the surge tank
(4) to access the cooling package lifting eye mounts. b. Cooler/Fan Motor Removal
20. Remove the top radiator hose (7) and hose from the
14
surge tank attached to the radiator. Cap all fittings
and openings to keep dirt & debris from entering the
cooling system.
21. Place a suitable container beneath the hydraulic oil
cooler fittings. Transfer any hydraulic oil into a
properly labeled container. Dispose of properly.
22. Disconnect and cap the hydraulic hose (8) attached 14
14
to the radiator/oil cooler assembly. Allow hydraulic oil
to drain from the hydraulic oil cooler. Cap all fittings
hydraulic system.
23. Disconnect the hydraulic cooler temperature sensor
(9).
24. Loosen and remove the four mounting nuts and 14
MY8940
rebound washers (9) from the radiator assembly.
25. Connect a lifting strap to the radiator/oil cooler 1. Turn the radiator/cooler assembly over and place on
assembly lifting eyes. a secure location.
26. Slowly lift the radiator assembly to gain access to the 2. Remove the four bolts (14) securing the fan motor/
fan side, hydraulic oil cooler out hose connections guard to the radiator/cooler shroud.
and the bottom radiator hose.
15
13 11 MY9000
12
27. Disconnect the connector on the fan solenoid(s).
Loosen and remove the fan solenoid(s) (11).
MY8950
28. Label, disconnect and cap the three hydraulic hoses
attached to the fan motor (12). Cap all fittings and 3. Turn the fan motor/guard over to access the fan
openings to keep dirt and debris from entering the assembly.
hydraulic system. 4. Loosen and remove the center bolt and washer (15)
securing the fan to the motor shaft.
G5-18A, 2505H, 25.5 7-5

Engine
Note: Retain the key located on the fan motor shaft. 6. Remove any caps and/or plugs and install the
previously removed hydraulic cooler outlet hose.
7. Install previously removed bottom radiator hose.
16 8. Connect the electrical connector to the fan
solenoid(s).
9. Connect the electrical connector to the hydraulic
temperature sensor.
10. Install the previously removed rebound washers and
nuts securing the radiator assembly. Torque the
16 mounting nuts to 31-34 lb-ft (23-25 Nm).
11. Install the previously removed surge tank.
12. Install the previously removed top radiator hose.
MY8960
13. Connect the previously removed surge tank hose to
5. Turn the fan motor/guard over to access the two fan the radiator.
motor mounting bolts (16). 14. Re-fill the surge tank/radiator with approximately
6. Loosen and remove both mounting bolts securing 2.7 gal (9.9 L) of a 50/50 mixture of ethylene glycol
the fan motor to the fan guard. and water.
7. Remove the fan motor as necessary. 15. Install the previously removed air dam.
16. Install the previously removed inside firewall plate.
c. Cooler/Fan Motor Installation
17. Install the previously removed right front fender. Do
1. Apply Loctite® 242TM to all mounting bolts not tighten mounting bolts at this time.
2. Install the fan motor to the fan guard. The fan motor 18. Connect the ECM connectors and secure the wire
can only be installed one way. harness.
3. Install the two previously removed mounting bolts 19. Properly connect the battery.
and torque to 31-35 lb-ft (41-47 Nm). 20. Remove any boom support.
4. Verify the key is in place on the fan motor shaft and 21. Run the engine to operating temperature. Visually
install the previously removed fan. Install the fan check for leaks with the engine running. Check the
mounting washer and bolt. Torque to 10.75 lb-ft coolant level in the surge tank and fill, or drain, as
(15 Nm). necessary. Check the hydraulic oil level in the tank
5. Install the fan motor assembly to the fan shroud. and add hydraulic oil as required.
Install and torque the mounting bolts to 27 lb-ft
Note: Refer to Section 8.11.11, “Variable Speed Fan
(37 Nm).
Valve,”for detailed testing information.
d. Radiator/Oil Cooler Installation 22. Retract and raise boom. Install previously removed
boom support. Shut engine OFF.
1. Connect a lifting strap to the radiator/oil cooler lifting
eyes. Note: If previously removed, install the right front tire
2. Slowly lower the radiator assembly to connect the and torque lug nuts to 220 lb-ft (300 Nm).
previously removed hydraulic fan hoses, hydraulic oil 23. Install the previously removed engine pod side skirt
cooler out hoses and the bottom radiator hose. and belly pan. Tighten all mounting bolts, including
3. Remove any caps and/or plugs and install the the right front fender mounting bolts.
previously removed hoses. 24. Install the hood and secure with the previously
4. Install the previously removed fan solenoid(s). removed mounting bolts.
Note: Verify the fan solenoid(s) retaining nut is installed 25. Install each gas strut and secure with the previously
with the recess FACING the solenoid. removed mounting nuts.
26. Adjust hood as needed.
5. Lower the radiator/oil cooler assembly into place.
7-6 G5-18A, 2505H, 25.5

Engine
28. Install and secure the battery cover. 7.4 FUEL SYSTEM
29. Remove previously installed boom support.
30. Remove the Do Not Operate Tags from both the 7.4.1 Diesel Fuel
ignition key and the steering wheel. Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
7.3 ENGINE ELECTRICAL SYSTEM use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
The engine electrical system, including the starter, expensive engine repair.
alternator and primary wiring, is described in Section 9,
“Electrical System.” Note: Use only diesel fuel designed for diesel engines.
Some heating fuels contain harmful chemicals that can
seriously affect engine efficiency and performance.
Note: Due to the precise tolerances of diesel injection
systems, keep the fuel clean, and free of dirt and water.
Dirt and water in the fuel system can cause severe
damage to both the injection pump and the injection
nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
rating of 40. #2 diesel fuel gives the best economy and
performance under most operating conditions. Fuels
with Cetane numbers higher than 40 may be needed in
high altitudes or extremely low ambient temperatures to
help prevent misfiring and excessive smoking.
Inform the owner/operator of the machine to use #2
diesel fuel, unless ambient temperatures are below 32° F
(0° C). When temperatures are below 32° F (0° C), a
blend of #1 diesel and #2 diesel fuels (known as
“winterized” #2 diesel) may be used.
Note: #1 diesel fuel may be used, however, fuel
economy will be reduced.
If equipped for ULS, use ultra low-sulfur content fuel
with a cloud point (temperature at which wax crystals
form in diesel fuel) at least 10° below lowest expected
fuel temperature. Viscosity of fuel must be kept above 1.3
centistrokes to provide adequate fuel system lubrication.
If equipped for LS, use low-sulfur content fuel with a
cloud point (temperature at which wax crystals form in
diesel fuel) at least 10° below lowest expected fuel
temperature. Viscosity of fuel must be kept above 1.3
centistrokes to provide adequate fuel system lubrication.
7.4.2 Fuel/Hydraulic Oil Tank
a. Cleaning and Drying

If contaminated fuel, hydraulic oil or foreign material is in
the tank, the tank can usually be cleaned.
b. If a leak is suspected between the fuel and hydraulic oil

tank, contact the local JLG dealer.
To clean the fuel/hydraulic oil tank:
G5-18A, 2505H, 25.5 7-7

Engine
1. Have a dry chemical (Class B) fire extinguisher near 7.5 ENGINE EXHAUST SYSTEM
the work area.
2. Depending on which side of the tank is contaminated 7.5.1 Exhaust System Removal
(fuel or hydraulic oil), remove the fuel or oil tank
1. Park the machine on a firm, level surface, level the
drain plug, and safely drain any fuel or hydraulic oil
machine, fully retract the boom, lower the boom,
into a suitable container. Dispose of fuel or hydraulic
place the travel select lever in the (N) NEUTRAL
oil properly.
position, engage the parking brake, and shut the
3. Clean the fuel/hydraulic oil tank with a high-pressure engine OFF.
washer, or flush the tank with hot water for five
minutes and drain the water. Dispose of
switch and steering wheel, stating that the machine
contaminated water properly.
should not be operated.
4. For the fuel tank side, add a diesel fuel emulsifying
3. Open the engine cover. Allow the system fluids to
agent to the tank. Refer to the manufacturer’s
cool.
instructions for the correct emulsifying agent-to-
water mixture ratio. Refill the tank with water, and 4. Properly disconnect the battery.
agitate the mixture for 10 minutes. Drain the tank
completely. Dispose of contaminated water properly.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.
ULS
c. Inspection
Note: If a leak is suspected between the fuel and hydraulic
oil tank, contact the local JLG dealer.
1. Inspect the fuel/hydraulic oil tank thoroughly for any
cracks, slices, leaks or other damage.
2. Plug all openings except one elbow fitting. Install the
1
elbow fitting, and apply approximately 1-1.5 psi
(0.07-0.10 bar) of air pressure through the elbow.
Check the tank for leaks by applying a soap solution LS
to the exterior and look for bubbles to appear at the
cracked or damaged area.
2
d. Disassembly and Assembly
The fuel/hydraulic oil reservoir is a one piece-unit integral
to the chassis frame and cannot be disassembled.
7.4.3 After Fuel System Service 1

1. Drain and flush the fuel tank if it was contaminated.
2. Fill the fuel tank with fresh, clean diesel fuel as required.
Note: If bleeding of the fuel system is required, contact
the local JLG dealer. MY8980
2
5. Loosen and remove the bolts (1) connecting the

muffler bracket to the frame brackets on the side of
the frame.
6. Loosen and remove the exhaust pipe flange nuts (2)
at the turbocharger.
7. Remove the exhaust system as an assembly.
7-8 G5-18A, 2505H, 25.5

Engine
7.5.2 Exhaust System Installation

Note: Keep all clamps loosened until entire exhaust
system is in place.
Note: Replace the nuts and the exhaust studs on the
turbocharger if damaged.
1. Install the exhaust assembly in place at the
turbocharger with the previously used hardware.
Torque the flange nuts (2) on the turbo charger to
22 ±5 lb-ft (30 ±7 Nm).
2. Install the muffler brackets (1) to the frame brackets
with the previously used hardware.
3. Adjust the muffler, exhaust and tail pipes for proper
clearance then tighten all clamps.
4. Properly connect the battery.
5. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
G5-18A, 2505H, 25.5 7-9

Engine
7.6 AIR CLEANER ASSEMBLY 5. Loosen the clamp (3) securing the air intake elbow to
the air cleaner assembly. Pull the air intake elbow off
the air cleaner.
CAUTION 6. Remove the hardware securing the air cleaner to the
air cleaner mounting plate (4). Remove the air
NEVER run the engine with only the inner safety cleaner assembly (5).
element installed.
Note: Refer to the machine Operation & Safety Manual 7.6.2 Air Cleaner Assembly Installation
for the correct element change procedure. 1. Install the air cleaner assembly (5) to the air cleaner
mounting plate with the previously used hardware
7.6.1 Air Cleaner Assembly Removal (4). Hand torque mounting bolts to 10-12 lb-ft
1. Park the machine on a firm, level surface, level the (13,5-16,3 Nm).
machine, fully retract the boom, lower the boom, 2. Place the loosened clamp (3) over the air intake
place the travel select lever in the (N) NEUTRAL elbow and install elbow on the air cleaner assembly.
position, engage the parking brake, and shut the 3. Adjust and tighten clamps before starting the
engine OFF. machine.
2. Place a Do Not Operate Tag on both the ignition key 4. Properly connect the battery.
switch and steering wheel, stating that the machine
should not be operated. 5. Close and secure the engine cover.
3. Open the engine cover. Allow the system fluids to 6. Remove the Do Not Operate Tags from both the
cool. ignition key and the steering wheel.
4. Properly disconnect the battery.
4
5
MY9010
7-10 G5-18A, 2505H, 25.5

Engine
7.7 ENGINE REPLACEMENT
2
MY8970
2
7.7.1 Engine Removal 11. Label, disconnect and cap all hydraulic hoses
attached to engine and transmission, cap all fittings
1. Park the machine on a firm, level surface, fully
and plug hoses to keep dirt & debris from entering
retract the boom, lower the boom, place the
hydraulic system.
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF. 12. Label, disconnect and cap all fuel lines. Install a plug
in the end of each line.
switch and the steering wheel, stating that the 13. Remove hydraulic and fuel filters, and radiator/oil
machine should not be operated. cooler assembly bracket assembly (2).
3. Open the engine cover. Allow the system fluids to 14. Label and disconnect all wire connections on the
cool. engine and transmission.
4. Thoroughly clean the engine and surrounding area, 15. Secure the engine (3) with a lifting strap or chain
including all hoses and fittings before proceeding. from the appropriate lifting points. Use a suitable
hoist or overhead crane.
16. Remove the four motor mount bolts that attach the
6. Remove the radiator/oil cooler assembly. Refer to
engine to the frame.
Section 7.2.2, “Radiator/Oil Cooler Replacement.” for
detailed removal instructions. 17. Carefully lift the engine from the machine. Avoid
causing damage to the surrounding parts.
7. Drain hydraulic reservoir. Refer to Section 8.8.2,
“Hydraulic Oil Reservoir Draining.” 18. Lift the engine clear of the machine, and lower it onto
suitable supports or stand. Secure the engine so
8. Remove the air cleaner assembly. Refer to Section
that it will not move or fall.
7.6.1, “Air Cleaner Assembly Removal,” for detailed
removal instructions.
9. Remove the exhaust system. Refer to Section 7.5.1,
“Exhaust System Removal,” for detailed removal
instructions.
10. Loosen and remove the rear fender (1).
G5-18A, 2505H, 25.5 7-11

Engine
7.7.2 Engine Disassembly, Inspection and 12. Check that all hydraulic, electrical, cooling, fuel and
Service exhaust system connections are correct and
connected tightly.
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Deutz 13. Run engine to normal operating temperature then shut
Engine manual. Several special engine service tools are off the engine. While the engine is cooling, check for
required to properly service the Deutz engine. Contact the leaks.
local JLG dealer for further information. 14. Allow the engine to cool. Check the radiator coolant
Note: If the engine is being replaced, there may be external level, and top off with a 50/50 mixture of ethylene
components that will be required to be transferred from the glycol and water. Replace the radiator cap.
original engine to the replacement engine depending upon
who you purchase the new engine from and the
configuration of your replacement engine. Refer to the NOTICE
appropriate JLG user manual for detailed procedures that
During the full throttle check:
cover the transfer of original engine components to the
replacement engine. • DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the
7.7.3 Engine Installation steering wheel.
Note: Refer to Section 2.2, “Torque Charts,” for specific • Keep the transmission in NEUTRAL (N).
fastener torque specifications.
15. Check for leaks from the engine, main hydraulic pump
1. Position engine (3) in engine compartment being and lines, transmission, hydraulic reservoir and fuel
sure to line up the four motor mount holes. Replace tank. Check the levels of all fluids and lubricants. Fill
bolts and torque to 185 lb-ft (251 Nm). as required.
2. Reattach any previously labeled wire connections on 16. Purge the hydraulic system of air by operating all
the engine and transmission. boom functions through their entire range of motion
3. Install the hydraulic and fuel filters, and radiator/oil several times. Check the hydraulic oil level.
cooler assembly bracket assembly (2). 17. Check for proper operation of all components.
4. Install the previously removed rear fender (1). 18. Turn the engine OFF.
5. Remove the plugs and connect all previously labeled 19. Install the belly pan.
fuel lines.
20. Install the engine cover. Close and secure the cover.
6. Install the exhaust assembly. Refer to Section 7.5.2,
“Exhaust System Installation.” for detailed installation
instructions.
7. Install the air cleaner assembly. Refer to Section
7.6.2, “Air Cleaner Assembly Installation.” for
detailed installation instructions.
8. Install the radiator/oil cooler assembly. Refer to
Section 7.2.2, “Radiator/Oil Cooler Replacement.” for
detailed installation instructions.
9. Uncap and reconnect all hydraulic hoses and fittings
to the engine and transmission. Keep hoses free of
dirt & debris.
10. Refill the hydraulic reservoir (Refer to the
appropriate Operation & Safety Manual for
information concerning the hydraulic oil and filter
change).
7-12 G5-18A, 2505H, 25.5

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.2 Hose, Tube, Line and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.2 Main Control Valve Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.3 Charge Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.4 Boom Function Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.5 Steering Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.6 Fan Speed Pressure and Direction Checking . . . . . . . . . . . . . . . . . . . . . . 8-6
8.7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.8.1 Pressurized Hydraulic Oil Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.8.2 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.8.3 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.9 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.9.1 Implement Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.9.2 Implement Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.9.3 Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.10.1 Front Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.10.2 Front Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.11.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.11.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.11.3 Park Brake Valve (G5-18A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.11.4 Hand Brake Valve (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.11.5 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.11.6 Pilot Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.11.7 Inching Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.11.8 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.11.9 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.11.10 Quick Attach Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.11.11 Variable Speed Fan Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
G5-18A, 2505H, 25.5 8-1

Hydraulic System
8.12 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8.12.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.12.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.12.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.12.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.12.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.12.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.12.7 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.12.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8-2 G5-18A, 2505H, 25.5

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
COMPENSATING
CYLINDER
HYDRAULIC RESERVOIR AND

LIFT/LOWER CYLINDER
(UNDER BOOM)
MAIN CONTROL
VALVE
EXTEND/RETRACT
CYLINDER
TILT CYLINDER
HYDRAULIC
FILTER
HYDROSTATIC
DRIVE PUMP
IMPLEMENT
PUMP
FRONT AXLE
DRIVE MOTOR
MY8690
STEERING
CYLINDER
G5-18A, 2505H, 25.5 8-3

Hydraulic System
8.2 SAFETY INFORMATION 8.4 SPECIFICATIONS

Refer to Section 4, “After connection has been properly
WARNING tightened, mark a straight line across the connecting
parts, not covering dots indicating that connection has
DO NOT service the machine without following all been properly tightened.,” for hydraulic system
safety precautions as outlined in the “Safety Practices” specifications.
8.5 HOSES, TUBE LINES, FITTINGS, ETC.
8.3 GENERAL INFORMATION
There are numerous hydraulic hoses, tubes, fittings, etc.
Petroleum-based hydraulic fluids are used in this used on this machine. Periodically inspect all of these
machine. The temperature of hydraulic fluid increases and carefully examine any signs of wear, abrasion and/or
during the operation of various hydraulic functions. A deterioration. Determine whether any further use of the
heated petroleum-based hydraulic fluid presents a fire component would constitute a hazard. If in doubt, replace
hazard, especially when an ignition source is present. the component.
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully 8.5.1 Replacement Considerations
examine any deterioration and determine whether any Conditions including, but not limited to, the following are
further use of the component would constitute a hazard. sufficient for considering component replacement:
If in doubt, replace the component. 1. Any evidence of hydraulic fluid leakage at the
Whenever you disconnect a hydraulic line, coupler, fitting surface of a flexible hose or its junction with the
or other component, slowly and cautiously loosen the part metal and couplings.
involved. A hissing sound or slow seepage of hydraulic 2. Any blistering or abnormal deformation to the outer
fluid may occur in most cases. After the hissing sound covering of a hydraulic hose.
has ceased, continue removing the part. Any escaping oil
should be directed into an appropriate container. Cap or 3. Hydraulic oil leakage at any threaded or clamped
otherwise block off the part to prevent further fluid joint that cannot be eliminated by normal tightening
seepage. or other recommended procedures.
Hydraulic system maintenance will, at times, require that 4. Evidence of excessive abrasion or scrubbing on the
the engine be operated. Always follow safety precautions. outer surface of a hose, rigid tube, or hydraulic
fitting. Modification must be made to eliminate the
A major cause of hydraulic component failure is interference of the elements in contact with one
contamination. Keeping the hydraulic fluid as clean as another, or to otherwise protect the components
possible will help avoid downtime and repairs. Sand, grit from contact with one another. Slightly moving a
and other contaminants can damage the finely machined hose or adjusting a plastic tie wrap may often be all
surfaces within hydraulic components. If operating in an that is necessary to eliminate interference; evaluate
exceptionally dirty environment, change filters and each situation and proceed as required by the
inspect the fluid more often. When servicing the system, individual circumstances.
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir,
8.5.2 Hose, Tube, Line and Fitting
and pump openings until installation occurs. Protect
Replacement
threads from contamination and damage.
Before removing a hydraulic hose or component, always
Some hydraulic functions are actuated by interfacing with
mark or otherwise label the related parts and the exact
electrical system components (switches, solenoids and
location of the hose or component to aid in proper
sensors). When the hydraulic system is not functioning
reinstallation. Hydraulic fluid is a good cleaner and can
properly, check the electrical aspect of the malfunctioning
remove most liquid-ink type markings, so make sure the
circuit also.
mark or label will remain intact. Alternative methods to
using markers include color-coded tie wraps, number-tag
sets, alpha-numeric stampings or markings, and suitably
labeled pieces of tape. Select an appropriate marking
method for the conditions and proceed accordingly.
8-4 G5-18A, 2505H, 25.5

Hydraulic System
NEVER replace a hydraulic hose or other component 6. As a last resort, adjust the appropriate relief valve, if
with a part not specifically designed for this machine. Use applicable. Turning the adjustment screw clockwise
only factory approved parts for best performance and will increase the pressure; turning the screw
safety. counterclockwise will decrease the pressure.
Removal and replacement of hoses, tube lines, fittings,
etc. usually involves straightforward procedures. When 8.6.2 Main Control Valve Pressure Checking
removing a hydraulic hose or other component, be aware
that o-rings are used throughout the hydraulic system.
ALWAYS replace a used o-ring with a new part.
Check all routing of hoses, wiring and tubing for sharp
bends or interference with any rotating members. Install 1
appropriate protective devices such as tie wraps and
conduit to help shield hoses from damage. All tube and
hose clamps must be tight.
8.6 HYDRAULIC PRESSURE DIAGNOSIS
8.6.1 Pressure Checks and Adjustments

MY8640
In general, follow the steps below whenever conducting
pressure checks and performing adjustments:
1. Attach 5000 psi (345 bar) gauge to the test port (1)
1. Park the machine on a firm, level surface. Engage at the rear of the implement pump to check the
the park brake, place the transmission control lever system pressure. Make sure the gauge is visible
in (N) NEUTRAL, place the neutral lock lever in the (N) from inside the cab.
NEUTRAL LOCK position, level the boom and turn
2. See Section 8.6, “Hydraulic Pressure Diagnosis,” for
the engine OFF.
start up procedure. Check the main control pressure
2. Pressure tee fittings are conveniently located in each with the park brake on and the service brake off at
hydraulic circuit. Install a pressure gauge capable of full throttle. Retract a boom circuit function until the
measuring at least 10% more pressure than that cylinder bottoms. The main control valve pressure
which the circuit being checked operates under. should be 3585-3665 psi (247-252,7 bar) at full
3. Start the engine. Operate machine functions several throttle. Repeat for each boom circuit to verify the
times to allow hydraulic oil to reach operating correct main control valve pressure.
temperature. The hydraulic oil temperature should
be between 100-120° F (38-49° C). If a temperature
gauge or thermometer is unavailable, the hydraulic oil
reservoir should be warm to the touch.
4. Fully depress the accelerator pedal as required.
Place and hold the joystick in the position needed to
operate the particular machine function being
checked. Continue holding the joystick in position
until pressure readings are taken.
5. Check the pressure gauge reading. It should read as 2
described in the appropriate section. If the reading is MY2110
not as specified, turn the engine OFF and check
other components in the system. Verify that all 3. If a pressure adjustment is required, adjust the main
related hydraulic components and electrical relief cartridge (2) on the main control valve.
switches, sensors, solenoids, etc. are operating Recheck pressure after any adjustment has been
correctly. made.
G5-18A, 2505H, 25.5 8-5

Hydraulic System
8.6.3 Charge Pressure Checking 8.6.5 Steering Pressure Checking
4
3
5
6
MY8640
MY8650
1. Attach a pressure gauge to the test fitting (5) at the
1. Attach a pressure gauge to the test port (3) on the rear of the implement pump. The pressure reading
hydrostatic transmission (4) to check the system should be 2490-2590 psi (171,7-178,6 bar) with the
pressure. The pressure should be 350-410 psi steering wheel fully turned to the steering stop in
(24,1- 28,2 bar) with the engine at low idle. one direction.
2. The charge pressure relief valve is preset at the 2. There is no adjustment for steering pressure.
factory and is not adjustable.
8.6.6 Fan Speed Pressure and Direction
8.6.4 Boom Function Pressure Checking Checking
1. Attach 5000 psi (345 bar) gauge to the test port (5) 1. Place a piece of paper over the face of the radiator
at the rear of the implement pump to check the core. If the paper is held in place, the fan is rotating
system pressure. Make sure the gauge is visible in the right direction.
from inside the cab. 2. Attach a pressure gauge to the test fitting (6) at the
2. See Section 8.6, “Hydraulic Pressure Diagnosis,” for rear of the implement pump.
start up procedure. Check the boom function 3. If the machine is equipped with either the variable
pressure with the park brake on and the service fan option or the variable, reversing fan option; run
brake off at full throttle. Retract each boom circuit the engine at high idle and measure the fan speed
function until the cylinder bottoms. Each circuit using a suitable portable stroboscope adjustable to
function pressure should be 3585-3665 psi fractional RPM, and with the ability to distinguish
(247-252,7 bar) at full throttle. actual RPM from harmonic frequencies. The fan
speed must be a minimum of 2800 RPM at high idle.
Note: With the machine at operating temperature, the
3585-3665 psi (247-252,7 bar) pressure reading at the 4. Connect the JLG Analyzer and activate the Test
main control valve is 125 psi (13,3 bar) HIGHER than the Mode to drive the fan to the maximum fan RPM.
3450-3550 psi (237,8-244,7 bar) of each individual valve Note: Refer to
section function. DO NOT adjust the main control valve
relief pressure below 3585-3665 psi (247-252,7 bar). 5. The pressure reading should be 2400 psi (166 bar)
To check individual valve section pressures, install a tee at high idle.
and test port between the cylinder being checked and
the corresponding valve section on the main control
valve.
The individual valve section relief valves are preset at the
factory and are not adjustable.
8-6 G5-18A, 2505H, 25.5

8 7 6 5 4 3 2 1
8.7
CYLINDER, TILT CYLINDER, CROWD
CYLINDER, LIFT
H H
G5-18A, 2505H, 25.5

JOYSTICK
T P
FRONT AUX
G G
1 2 3 4
FRONT AXLE
PARK BRAKE
VALVE, MAIN CONTROL 1b 1B 1A 2b 2B 2A 3b 3B 3A 4b 4B 4A

T VALVE, PILOT SELECT
T
JS4
VALVE, PARK
241 BAR
P T2 BRAKE RELEASE
JS2
F TELE AUX TILT F
HYDRAULIC SCHEMATIC
1a 2a 3a 4a
3A 3B P2 P1 P3 P4 P5 P6
FRONT AXLE
MASTER CYLINDER SERVICE BRAKE
R
LS CF EF B
E E
VALVE, PRIORITY
P INCHING VALVE
T P
FILTER, CHARGE
D 3.45 BAR D
b a
STANDARD-VARIABLE PS Yst MH Fa
T1 R
STEERING SPEED FAN DRIVE
ORBITAL A X1
VALVE, STEER L R 11 CC
X2 G
MB
SELECT
DR T1 U
B
B
DRIVE
A MOTOR
B Vg min
C C
11 CC 31.8 14.3
IMPLEMENT
CC CC
PUMP Vg max
2.41 BAR
DR A
LS
B
CYLINDER
CYLINDER
26.2 BAR A T2
OPTION-VAR SPEED &
REAR STEERING
FRONT STEERING
REVERSING FAN DRIVE
P T A
T2 G S MA
11 CC
DRIVE
PUMP
FILTER, RETURN M1 Sa
B DR
B B
3.45 BAR
A A
Hydraulic System
8 7 6 5 4 3 2 1
MAL2710B
8-7
8-8
G5-18A
8 7 6 5 4 3 2 1
H H
AUXILIARY OPTIONS
FRONT AUX
REAR AUX FRONT AUX 1ST 2ND
G G
REAR AUX
Hydraulic System
F F
3B 3A
3B 3A
OPTIONAL REAR OPTIONAL REAR AUX/WITH

E E
AUXILIARY ELECTRIC SECOND FRONT AUX
FRONT AUX
D D
1ST 2ND
C C
3B 3A
OPTIONAL SECOND
B FRONT AUXILIARY B
-ELECTRIC-
A A
8 7 6 5 4 3 2 1
MAL2720B
G5-18A, 2505H, 25.5

8 7 6 5 4 3 2 1
2505H & 25.5
H H
G5-18A, 2505H, 25.5

FRONT AUX AUXILIARY OPTIONS
1ST 2ND
REAR AUX FRONT AUX

REAR AUX
G G
TRAILER BRAKE CONNECTION
F F
B
3B 3A
3B 3A
FROM SERVICE BRAKE
OPTIONAL REAR
AUXILIARY X
E E
OPTIONAL REAR AUX/WITH L
ELECTRIC SECOND FRONT AUX
TO IMPLEMENT VALVE
P
P1
D D
STEERING
FRONT AUX
1ST 2ND
C LS CF EF C
OPTIONAL TRAILER BRAKE

3B 3A
B B
OPTIONAL SECOND
FRONT AUXILIARY
-ELECTRIC-
A A
Hydraulic System
8 7 6 5 4 3 2 1
MAL2730B
8-9
Hydraulic System
8.8 HYDRAULIC RESERVOIR 8.8.3 Hydraulic Oil Reservoir Filling

1. Be sure the reservoir is clean and free of all debris.
The hydraulic reservoir and fuel tank are part of the
frame. For this reason, neither tank can be removed. For 2. Install new hydraulic oil filters.
cleaning instructions, see Section 7.4.2, “Fuel/Hydraulic 3. Fill the reservoir with Cat HDO oil. Refer to Section
Oil Tank.” 2.4, “Fluids, Lubricants and Capacities.”
Occasionally, fluid may seep, leak or be more forcefully 4. Properly connect the battery.
expelled from the filter head when system pressure
5. Close and secure the battery and engine covers.
exceeds the rating of the filter head or filler cap. If the
return filter becomes plugged, return hydraulic oil will 6. Remove the Do Not Operate Tags from both the
bypass the filter when pressure reaches 22 psi (1,5 bar) ignition key and the steering wheel.
and return to the reservoir unfiltered. 7. Start the machine. Run engine to normal operating
Carefully examine fluid seepage or leaks from the temperature. Operate all hydraulic functions.
hydraulic reservoir to determine the exact cause. Clean
the reservoir and note where any seepage occurs.
Leaks from a cracked or damaged reservoir require that
the reservoir be flushed completely with water and
repaired by a certified welder using approved techniques.
If these conditions cannot be met, the reservoir must be
replaced in its entirety. Contact the local JLG dealer
should reservoir welding be required.
8.8.1 Pressurized Hydraulic Oil Fill Cap

The fill cap will allow the hydraulic oil reservoir to
pressurize to 2 psi (0,14 bar). Inspect the condition of the
cap seal to maintain proper reservoir pressure.
8.8.2 Hydraulic Oil Reservoir Draining

retract the boom, support the boom, place the
the park brake and shut the engine OFF.
switch and the steering wheel, stating that the
3. Open the battery and engine covers. Allow the
system fluids to cool.
5. Remove the drain plug at the bottom of the hydraulic
oil reservoir.
6. Transfer the used hydraulic oil into a suitable,
covered container, and label as "Used Oil". Dispose
of used oil at an approved recycling facility. Clean
and reinstall the drain plug.
7. Wipe up any spilled hydraulic oil.
8-10 G5-18A, 2505H, 25.5

Hydraulic System
8.9 HYDRAULIC SYSTEM PUMP 3. Uncap and reconnect previously labeled hydraulic
hoses to their proper locations.
8.9.1 Implement Pump Removal 4. Fill the hydraulic reservoir with clean, filtered
hydraulic oil.
1. Park the machine on a firm, level surface, fully retract
the boom, support the boom, place the transmission 5. Prime the pump by filling the case drain port with fresh,
control lever in (N) NEUTRAL, engage the park brake filtered hydraulic oil from a clean container before
and shut the engine OFF. installing the case drain connector and hose.
2. Place a Do Not Operate Tag on both the ignition key 6. Check all routing of hoses and tubing for sharp
switch and the steering wheel, stating that the bends or interference with any rotating members. All
machine should not be operated. tube and hose clamps must be tight.
3. Open the battery and engine covers. Allow the 7. Properly connect the battery.
system fluids to cool. 8. Start the engine and run at approximately one-third
4. Properly disconnect the battery. to one-half throttle for about one minute without
moving the machine or operating any hydraulic
5. Loosen and remove the belly pan and front fender. functions.
6. Drain the hydraulic oil reservoir. Refer to Section 9. Inspect for leaks and check all fluid levels.
8.8.2, “Hydraulic Oil Reservoir Draining.”
10. Install the front fender and belly pan.
2 ignition key and the steering wheel.
Note: Check for leaks and repair as required before
continuing.
8.9.3 Pump Test

MY8640
1. Perform a flow meter test on the pump.
2 1 2. Check the system functions.
7. Thoroughly clean the pump (1) and surrounding
area, including all hoses and fittings before
proceeding.
8. From under the machine, label, disconnect and cap
all hydraulic hoses attached to the pump, cap all
fittings and plug hoses to keep dirt & debris from
entering the hydraulic system.
9. Remove the two bolts and washers (2) securing the
pump in place.
8.9.2 Implement Pump Installation

1. Position pump in the mounting position.
Note: Use new o-rings where required. Never reuse o-
rings.
2. Use the two previously removed bolts and washers
to secure the pump into place. Torque to
64 lb-ft (87 Nm).
G5-18A, 2505H, 25.5 8-11

Hydraulic System
8.10 FRONT DRIVE MOTOR 8.10.2 Front Drive Motor Installation

1. Install the motor onto the front axle and secure with
For internal service instructions and detailed
the four previously removed bolts (4). Torque to
specifications, contact the local JLG Dealer.
72 lb-ft (97 Nm). Use only new seals.
8.10.1 Front Drive Motor Removal 2. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
retract the boom, lower the boom, place the 3. Fill the motor with hydraulic fluid through the fill plug
transmission control lever in (N) NEUTRAL, engage (5) before starting the machine.
the park brake and shut the engine OFF. 4. Refill the hydraulic reservoir and inspect for leaks
2. Place a Do Not Operate Tag on both the ignition key around the machine.
switch and the steering wheel, stating that the 5. Properly connect the battery.
machine should not be operated. 6. Start the engine and run at approximately one-third
3. Open the battery and engine covers. Allow the to one-half throttle for about one minute without
system fluids to cool. moving the machine or operating any hydraulic
functions.
7. Inspect for leaks and check all fluid levels.
5. Drain the hydraulic reservoir or attach a vacuum
adapter fitting to the reservoir fill tube to reduce oil 8. Close and secure the battery and engine covers.
spillage. 9. Remove the Do Not Operate Tags from both the
6. Label and disconnect all hydraulic hoses attached to ignition key and the steering wheel.
the pump, cap all fittings and plug hoses to keep dirt
& debris from entering hydraulic system.
7. Disconnect the electrical connector (3) on the
proportional valve.
4
5
3
MY8660
8. Support the motor and remove the four bolts (4)

securing the motor to the front axle.
8-12 G5-18A, 2505H, 25.5

Hydraulic System
8.11 CONTROL VALVES 9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
8.11.1 Main Control Valve 10. Remove the four bolts securing the main control
valve to the frame bracket.
The main control valve is mounted on the rear of the
machine behind the rear access panel. b. Main Control Valve Disassembly
1. To disassemble the individual sections of the main
control valve, remove the nuts from the end of the tie
rods. Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
6 Some sections include a pre-adjusted relief valve that

regulates pressure in a specific circuit.
1
NOTICE
MY2110 DO NOT adjust any of the relief valve assemblies!
Tampering with a relief valve will irrevocably alter
FRONT OF MACHINE 2 3 4 5 pressure in the affected circuit, requiring re-calibration or
a new relief valve.
The main control valve assembly consists of various
working sections with their own valve assemblies, each
providing a specific hydraulic function. The section Disassemble each Valve Section
assemblies are the left-hand end cover (1), lift/lower (2), 1. Carefully separate the end cover section from the lift/
tilt (3), auxiliary (4), crowd (5) and right-hand end cover lower section.
(6) sections.
2. Remove the o-rings from between the two sections.
a. Main Control Valve Removal 3. Carefully separate each remaining section and
remove all o-rings and seals.
retract the boom, lower the boom, place the 4. Remove any plugs, check valves, compensator
transmission control lever in (N) NEUTRAL, engage valves, anti-cavitation valves, shock valves or the
the park brake and shut the engine OFF. rectangular hydraulic remote positioners from each
individual valve section if equipped.
switch and the steering wheel, stating that the 5. Keep all parts being removed from individual valve
machine should not be operated. sections tagged and kept together.
3. Open the battery and engine covers. Allow the c. Main Control Valve Parts Cleaning
Clean all components with a suitable cleaner, such as
trichlorethylene, before continuing. Blow dry.
5. Remove the rear panel. Allow the hydraulic fluid to
cool. d. Main Control Valve Parts Inspection
6. Thoroughly clean the main control valve and Inspect all parts and internal passageways for wear,
surrounding area, including all hoses and fittings, damage, etc. If inner surfaces of any component DO NOT
before proceeding. display an ultra-smooth, polished finish, or are damaged
7. Place a suitable container to catch hydraulic fluid in any way, replace the damaged part. Often, dirty
drainage beneath the frame. hydraulic fluid causes failure of internal seals, damage to
8. Label, disconnect and cap all the hydraulic hoses the polished surfaces within the component, and wear of
attached to the main control valve. Cap all fittings and/or harm to other parts.
hydraulic system.
G5-18A, 2505H, 25.5 8-13

Hydraulic System
e. Main Control Valve Assembly 7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
functions.
operation. Lubricate seals and o-rings with clean
hydraulic oil. 8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Assemble each Valve Section
9. Wipe up any hydraulic fluid spillage in, on, near and
1. Reassemble any plugs, check valves, compensator around the machine, work area and tools.
valves, anti-cavitation valves, shock valves or
hydraulic remote positioners from individual valve 10. Install the rear panel.
sections if equipped. 11. Close and secure the battery and engine covers.
2. Install the end covers onto Lift/Lower and Crowd 12. Remove the Do Not Operate Tags from both the
sections. ignition key and the steering wheel.
Assemble the Main Control Valve g. Main Control Valve Test

1. Place all three tie rods with the washers and nuts Conduct a pressure check of the hydraulic system in its
through the end main control valve section. entirety. Adjust pressure(s) as required. Refer to Section
2. Stand the end main control valve section on end. 8.6.2, “Main Control Valve Pressure Checking.”
3. Install proper o-rings on the inner face of the end 8.11.2 Service Brake Valve
main control valve section. Align the Crowd section
over the three tie rods and slide onto the end main The service brake valve is at the base of the steering
control valve section. column support, concealed by the lower dash cover.
4. Using proper o-rings and load sense shuttle, repeat The service brakes themselves are part of the front axle.
step three for the remaining sections. Refer to Section 5.8, “Brakes,” for further information.
5. Install the washers and nuts on the tie rods and
a. Service Brake Valve Removal
torque to 18.5 lb-ft (25 Nm).
f. Main Control Valve Installation retract the boom, lower the boom, place the
1. Loosely install the four main control valve mounting
bolts through bracket on the rear of the machine.
2. Install the main control valve onto the bracket,
aligning the bolts with the holes in the end sections
of the main control valve. Slide the main control
valve into position, and tighten the bolts. 3. Open the battery and engine covers. Allow the
3. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a 4. Properly disconnect the battery.
clean container, before attaching the hoses. 5. Remove the necessary dash panels.
4. Use new oiled o-rings as required. Uncap and
reattach and secure all hoses, clamps, etc. to the
main control valve.
5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
8-14 G5-18A, 2505H, 25.5

Hydraulic System
7. Start the engine and run at approximately one-third

to one-half throttle for about one minute, without
functions.
1 8. Inspect the service brake valve and connections for
leaks, and check the brake oil level. Shut the engine
3 OFF.
9. Replace the necessary dash panels.
10. Wipe up any hydraulic oil spillage in, on, near and
around the machine, work area and tools.
2
MY2161
6. Label, disconnect and cap the hydraulic hoses c. Service Brake Bleeding Procedure
connected to the service brake valve (1). Cap all 1
fittings and openings to keep dirt & debris from
entering the brake system.
7. Remove the pin and clip (2) securing the service
brake rod to the brake pedal assembly.
8. Remove the two bolts and washers (3) securing the
service brake valve to the steering column support.
Note: DO NOT disassemble the service brake valve.
The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
MY2050
b. Service Brake Valve Installation
Carefully bleed the brake lines as soon as the brake valve
1. Install the service brake valve to the steering column is installed on the machine. Air in the system will not allow
support with the previously removed hardware (3). the brakes to apply properly. There are two brake bleeder
Torque as required. locations (1) on the front axle. The outside bleeder is
Note: ALWAYS replace seals, o-rings, gaskets, etc., used for the park brake circuit. The inside bleeder is used
with new parts to help ensure proper sealing and for the service brake circuit. Work with an assistant to
operation. Lubricate seals and o-rings with clean perform this procedure.
hydraulic oil. 1. Place the transmission control lever in
2. Use new oiled o-rings as required. Uncap and (N) NEUTRAL, engage the park brake, and start the
reconnect the previously labeled hydraulic hoses to engine.Raise the boom to access the brake
the appropriate locations. bleeders. Support boom and turn off engine.
3. Install the pin and clip (2) securing the service brake 2. Remove the plastic cap from the brake bleeder.
rod to the brake pedal assembly. Attach one end of a length of transparent tubing over
the brake bleeder. Place the other end of this tubing
4. Check the routing of all hoses, and tubing for sharp in a suitable transparent container that is partially
bends or interference with any rotating members, filled with hydraulic oil. The end of the tubing must be
and install tie wraps and/or protective conduit as below the oil level in the container.
required. Tighten all tube and hose clamps.
5. Fill the brake reservoir with Mobil 424 10W-30
hydraulic oil.
G5-18A, 2505H, 25.5 8-15

Hydraulic System
3. DO NOT open the brake bleeder without holding the b. Park Brake Valve Disassembly, Cleaning,
tubing firmly on the bleeder. There is pressure at the Inspection and Assembly
brakes. Have an assistant depress the brake pedal.
1. Place the park brake valve on a suitable work
Carefully open the bleeder with a 12 mm wrench.
surface.
Close the brake bleeder when air bubbles no longer
appear in the oil. Release the brake pedal. Remove
the tubing from the brake bleeder.
1
4. If bleeding the service brake circuit, install a vacuum
pump on the brake reservoir and remove the
remainder of the trapped air from the brake system. 2
5. The inching valve may also require bleeding, refer to
Section 8.11.7, “Inching Valve.”
6. Check brake fluid level and add fluid if necessary. MY2150
Refer to Section 2.4, “Fluids, Lubricants and
Capacities.” 2. Remove the solenoid valve (1) and cartridge (2) from
the park brake housing.
d. Brake Performance Test 3. Clean all components with a suitable cleaner before
inspection.
1. Press down on the service brake pedal. The pedal
should NOT travel to the cab floor. Start the 4. Inspect the solenoid cartridges for proper operation.
machine, shift into forward, release the park brake Check by shifting the spool to ensure that it is
and slowly accelerate. Apply the service brake functioning properly. Check that the spring is intact.
carefully noting the performance of the service brake Inspect the cartridge interior for contamination.
system. If the service brakes do not safely stop the 5. Inspect internal passageways of the park brake
machine, repeat the service brake bleeding manifold and valve for wear, damage, etc. If inner
procedure. surfaces of the manifold DO NOT display an ultra-
smooth, polished finish, or components are
8.11.3 Park Brake Valve (G5-18A) damaged in any way, replace the manifold or
The park brake valve is located in the cab, below the seat. appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
a. Park Brake Valve Removal surfaces within the unit.
1. Park the machine on a firm, level surface, fully Note: ALWAYS replace seals, o-rings, gaskets, etc.,
retract the boom, lower the boom, place the with new parts to help ensure proper sealing and
transmission control lever in (N) NEUTRAL, engage operation. Lubricate seals and o-rings with clean
the park brake and shut the engine OFF. hydraulic oil.
2. Place a Do Not Operate Tag on both the ignition key 6. Install the solenoid valves and cartridges in the park
switch and the steering wheel, stating that the brake housing.
c. Park Brake Valve Installation
system fluids to cool. 1. Install the park brake valve with the two lockwashers
4. Properly disconnect the battery. and two capscrews to the cover.
5. Remove the four capscrews holding the cover below Note: ALWAYS replace seals, o-rings, gaskets, etc.,
the seat. The park brake valve is mounted on the with new parts to help ensure proper sealing and
backside of the cover. operation. Lubricate seals and o-rings with clean
hydraulic oil.
6. Label, disconnect and cap the hydraulic hoses on
each side and bottom of the park brake valve. 2. Use new oiled o-rings as required. Uncap, reattach
Disconnect and cap all hoses, fittings, etc. and secure the three hoses.
7. Remove the two capscrews, and two lockwashers 3. Check the routing of all hoses for sharp bends or
mounting the park brake valve to the cover. interference with any rotating members, and install
tie wraps and/or protective conduit as required.
8-16 G5-18A, 2505H, 25.5

Hydraulic System
4. Properly connect the battery. b. Hand Brake Valve Disassembly, Cleaning,

5. Start the engine and run at approximately one-third Inspection and Assembly
to one-half throttle for about one minute, without 1. Place the hand brake valve on a suitable work
moving the machine or operating any hydraulic surface.
functions.
6. Inspect the park brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
7. Install the park brake/cover with the four capscrews.
MU7710
d. Park Brake Valve Test.
2. Clean all components with a suitable cleaner before
1. Start the machine and engage the shift lever to the inspection.
forward position. Slowly depress the throttle to mid 3. Inspect internal passageways of the hand brake
idle. The parking brake will not allow the machine to manifold and valve for wear, damage, etc. If inner
move. surfaces of the manifold DO NOT display an ultra-
2. If further troubleshooting is required, refer to the smooth, polished finish, or components are
Section 8.7, “Hydraulic Schematic,” or Section 9.4, damaged in any way, replace the manifold or
“Electrical System Schematics.” appropriate part. Often, dirty hydraulic fluid causes
8.11.4 Hand Brake Valve (2505H & 25.5) surfaces within the unit.
The hand brake valve is located in the cab, beside the Note: ALWAYS replace seals, o-rings, gaskets, etc.,
seat. with new parts to help ensure proper sealing and
a. Hand Brake Valve Removal hydraulic oil.
c. Hand Brake Valve Installation
transmission control lever in (N) NEUTRAL, engage 1. Install the Hand brake valve with the four
the hand brake and shut the engine OFF. lockwashers and capscrews to the mounting plate.
2. Place a Do Not Operate Tag on both the ignition key Note: ALWAYS replace seals, o-rings, gaskets, etc.,
switch and the steering wheel, stating that the with new parts to help ensure proper sealing and
machine should not be operated. operation. Lubricate seals and o-rings with clean
3. Open the battery and engine covers. Allow the hydraulic oil.
system fluids to cool. 2. Use new oiled o-rings as required. Uncap, reattach
4. Properly disconnect the battery. and secure the three hoses.
5. Remove the two capscrews holding the cover below 3. Check the routing of all hoses for sharp bends or
the seat. The hand brake valve is mounted on the interference with any rotating members, and install
mounting plate attached to the seat base. tie wraps and/or protective conduit as required.
6. Label, disconnect and cap the hydraulic hoses on 4. Properly connect the battery.
each side and bottom of the hand brake valve. 5. Start the engine and run at approximately one-third
Disconnect and cap all hoses, fittings, etc. to one-half throttle for about one minute, without
7. Remove the four capscrews and lockwashers moving the machine or operating any hydraulic
mounting the hand brake valve to the mounting functions.
plate.
G5-18A, 2505H, 25.5 8-17

Hydraulic System
6. Inspect the hand brake valve and connections for a. Pilot Select Valve Removal
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
7. Install the hand brake cover with the two capscrews. transmission control lever in (N) NEUTRAL, engage
8. Wipe up any hydraulic fluid spillage in, on, near and the park brake and shut the engine OFF.
around the machine, work area and tools. 2. Place a Do Not Operate Tag on both the ignition key
9. Close and secure the battery and engine covers. switch and the steering wheel, stating that the
ignition key and the steering wheel. 3. Open the battery and engine covers. Allow the
d. Hand Brake Valve Test. 4. Properly disconnect the battery.
1. Start the machine and engage the shift lever to the 5. Label or otherwise mark the hydraulic hoses in
forward position. Slowly depress the throttle to mid relation to the pilot select valve. Disconnect and cap
idle. The hand brake will not allow the machine to all hoses, fittings, solenoid wire terminal leads, etc.
move. 6. Remove the capscrews that attach the valve to the
2. If further troubleshooting is required, refer to the frame.
Section 8.7, “Hydraulic Schematic,” or Section 9.4, 7. Remove the pilot select valve from the machine.
“Electrical System Schematics.” Wipe up any hydraulic fluid spillage in, on, near and
around the machine.
8.11.5 Steering Orbitrol Valve
Refer to Section 4.4.2, “Steering Column/Valve b. Pilot Select Valve Disassembly, Cleaning,
Replacement,” for details. Inspection and Assembly
1. Place the pilot select assembly on a suitable work
8.11.6 Pilot Select Valve surface.
The pilot select valve is attached to a manifold mounted 2. Remove the solenoid valves and cartridges (3, 4 &5)
on a mounting plate inside the frame in front of the comp from the steer select housing.
cylinder.
6 7
5 inspection.
4 4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultra-
smooth, polished finish, or components are
5
damaged in any way, replace the manifold or
7 4 appropriate part. Often, dirty hydraulic fluid causes
3 6 MU7720
3
CE & AUS
ANSI
surfaces within the unit.
Verify the correct operation of the pilot select valve
solenoids: boom lift/lower (3), auxiliary (4), tilt (5), boom
extend/retract (6) and front auxiliary (7) before
considering replacement of the valve. The housing of the
hydraulic oil.
pilot select valve is not serviceable and must be replaced
if defective. 6. Install the solenoid valves and cartridges in the pilot
select housing.
8-18 G5-18A, 2505H, 25.5

Hydraulic System
c. Pilot Select Valve Installation 8.11.7 Inching Valve

1. Attach the pilot select manifold valve to the mounting The inching valve is attached at the front of the frame
plate on the frame using the socket head capscrews. directly above the steer select valve.
2. Connect the hydraulic hoses, fittings, solenoid wire Verify the correct operation of the inching valve before
terminal leads, etc., to the pilot select valve. considering replacement of the valve. The housing of the
3. Check the routing of all hoses, wiring and tubing for inching valve is not serviceable and must be replaced if
sharp bends or interference with any rotating defective.
conduit as required. Tighten all tube and hose clamps. a. Inching Valve Removal
4. Properly connect the battery. 1. Park the machine on a firm, level surface, fully
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
5. Label or otherwise mark the hydraulic hoses in
relation to the inching valve. Disconnect and cap all
hoses, fittings, etc.
d. Pilot Select Valve Test
6. Remove the capscrews that attach the valve to the
1. Check boom lift/lower, auxiliary and tilt for proper frame.
function.
7. Remove the inching valve from the machine. Wipe
2. If further troubleshooting is required, refer to Section up any hydraulic fluid spillage in, on, near and
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical around the machine.
System Schematics,” for details.
b. Inching Valve Disassembly, Cleaning, Inspection
and Assembly
1. Place the inching valve assembly on a suitable work
surface.
MY2330
2. Remove the cartridge (1) from the inching valve

housing.
inspection.
G5-18A, 2505H, 25.5 8-19

Hydraulic System
4. Inspect the cartridge for proper operation. Check by 1. Place the transmission control lever in
shifting the spool to ensure that it is functioning (N) NEUTRAL, engage the park brake, start the
properly. Check that the spring is intact. Inspect the engine and lower the boom. Turn off engine.
cartridge interior for contamination.
5. Inspect internal passageways of the inching valve for 2
wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
manifold or appropriate part. Often, dirty hydraulic
fluid causes failure of internal seals and damage to
the polished surfaces within the unit.
Note: ALWAYS replace seals, o-rings, gaskets, etc., MY2330
operation. Lubricate seals and o-rings with clean 2. Remove the plastic cap (2) from the inching brake
hydraulic oil. bleeder. Attach one end of a length of transparent
tubing over the bleeder. Place the other end of this
6. Install the cartridge in the inching valve housing.
tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
c. Inching Valve Installation
must be below the oil level in the container.
1. Attach the inching valve to the mounting plate on the 3. DO NOT open the bleeder without holding the tubing
frame using the socket head capscrews. firmly on the bleeder. Have an assistant depress the
2. Connect the hydraulic hoses, fittings, etc., to the brake pedal. Carefully open the bleeder with a 10
inching valve. mm wrench. Close the bleeder when air bubbles no
3. Check the routing of all hoses and wiring for sharp longer appear in the oil. Release the brake pedal.
bends or interference with any rotating members, Remove the tubing from the bleeder.
and install tie wraps and/or protective conduit as 4. If brake system bleeding is required, refer to Section
required. Tighten all hose clamps. 8.11.2, “Service Brake Valve.”
4. Properly connect the battery. 5. Check brake fluid level and add fluid if necessary.
5. Start the engine and run at approximately 1/3-1/2 Refer to Section 2.4, “Fluids, Lubricants and
throttle for about one minute, without moving the Capacities.”
e. Inching Test
fluid in the reservoir. Shut the engine OFF. 1. Start the machine, engage the shift lever to the
forward position and release the parking brake.
Note: Check for leaks and repair as required before Slowly depress the throttle to 1/2 throttle. Slowly
continuing. Add hydraulic fluid to the reservoir as needed. apply the service brake. The machine will slow, but
7. Wipe up any hydraulic fluid spillage in, on, near and still maintain forward movement. Continuing to
around the machine, work area and tools. depress the service brake will disengage the inching
brake and engage the service brakes.
2. If further troubleshooting is required, refer to Section
8.7, “Hydraulic Schematic.”
d. Inching Valve Bleeding Procedure

Carefully bleed the inching valve as soon as the inching
valve is installed on the machine. Air in the system will not
allow the brakes to apply properly. There is one bleeder
location on the inching valve. Work with an assistant to
perform this procedure.
8-20 G5-18A, 2505H, 25.5

Hydraulic System
8.11.8 Priority Valve 3. Clean all components with a suitable cleaner before
inspection.
.The priority valve is attached at the engine pod frame
directly beside the engine. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
Verify the correct operation of the priority valve before with new parts to help ensure proper sealing and
considering replacement of the valve. The priority valve operation. Lubricate seals and o-rings with clean
must be replaced if defective. hydraulic oil.
4. Install the previously labeled fittings in the priority valve
a. Priority Valve Removal housing.
retract the boom, lower the boom, place the c. Priority Valve Installation
transmission control lever in (N) NEUTRAL, engage 1. Attach the priority valve to the mounting plate on the
the park brake and shut the engine OFF. frame using the socket head capscrews.
2. Place a Do Not Operate Tag on both the ignition key 2. Connect the hydraulic hoses, fittings, etc., to the
switch and the steering wheel, stating that the priority valve.
3. Check the routing of all hoses for sharp bends or
3. Open the battery and engine covers. Allow the interference with any rotating members, and install
system fluids to cool. tie wraps and/or protective conduit as required.
4. Properly disconnect the battery. Tighten all hose clamps.
3 4. Properly connect the battery.
continuing. Add hydraulic fluid to the reservoir as needed.
3
MY2971
relation to the priority valve. Disconnect and cap all d. Priority Valve Test
hoses, fittings, etc.
1. Start the machine and slowly depress the throttle to
6. Remove the capscrews that attach the valve to the 1/2 throttle. Turn the steering and engage a boom
frame. function. The steering will continue to respond along
7. Remove the priority valve from the machine. Wipe up with the engaged boom function.
any hydraulic fluid spillage in, on, near and around 2. If further troubleshooting is required, refer to Section
the machine. 8.7, “Hydraulic Schematic.”
b. Priority Valve Disassembly, Cleaning, Inspection

and Assembly
1. Place the priority valve assembly on a suitable work
surface.
2. Label and remove the fittings (3) from the priority
valve housing.
G5-18A, 2505H, 25.5 8-21

Hydraulic System
8.11.9 Steer Select Valve 2. Separate the steer select valve from the manifold by
removing the capscrews. Discard the old o-rings.
The steer select valve is attached to inside the frame near
the front drive motor. 3. Remove the solenoid valves and cartridges (1) from
the steer select housing.
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve. 4. Clean all components with a suitable cleaner before
The housing of the steer select valve is not serviceable inspection.
and must be replaced if defective. 5. Inspect the solenoid cartridges for proper operation.
a. Steer Select Manifold and Valve Removal functioning properly. Check that the spring is intact.
1. Park the machine on a firm, level surface, fully Inspect the cartridge interior for contamination.
retract the boom, lower the boom, place the 6. Inspect internal passageways of the steer select
transmission control lever in (N) NEUTRAL, engage manifold and valve for wear, damage, etc. If inner
the park brake and shut the engine OFF. surfaces of the manifold DO NOT display an ultra-
2. Place a Do Not Operate Tag on both the ignition key smooth, polished finish, or components are
switch and the steering wheel, stating that the damaged in any way, replace the manifold or
machine should not be operated. appropriate part. Often, dirty hydraulic fluid causes
3. Open the battery and engine covers. Allow the surfaces within the unit.
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
1
new, oiled o-rings and socket head capscrews.
c. Steer Select Manifold and Valve Installation

1
1. Attach the steer select manifold and valve to the
mounting plate on the frame using the socket head
capscrews.
MY2180 2. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the steer select valve and
manifold.
relation to the steer select manifold. Disconnect and
cap all hoses, fittings, solenoid wire terminal leads, 3. Check the routing of all hoses, wiring and tubing for
etc. sharp bends or interference with any rotating
6. Remove the capscrews that attach the manifold to
conduit as required. Tighten all tube and hose clamps.
the frame.
7. Remove the steer select manifold with attached steer
select valve from the machine. Wipe up any 5. Start the engine and run at approximately 1/3-1/2
hydraulic fluid spillage in, on, near and around the throttle for about one minute, without moving the
machine. machine or operating any hydraulic functions.
b. Steer Select Valve and Manifold Disassembly, fluid in the reservoir. Shut the engine OFF.
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work continuing. Add hydraulic fluid to the reservoir as needed.
surface.
8-22 G5-18A, 2505H, 25.5

Hydraulic System

d. Steering Test
1
1. Start the machine and select either the 4-wheel
steer or the crab steer mode.
2. Turn the steering wheel until the left rear wheel is
aligned with the side of the frame.
3. Select the 2-wheel steer mode and turn the steering
wheel until the left front wheel is aligned with the
frame.
4. With the wheel now aligned, select the desired steer
2
mode.
8.6.5, “Steering Pressure Checking,” Section 8.7,
“Hydraulic Schematic,” or Section 9.4, “Electrical MY8670
System Schematics.”
8.11.10 Quick Attach Valve relation to the quick attach valve (1). Disconnect and
cap all hoses, fittings, solenoid wire terminal leads,
The quick attach valve is located on the left side of the etc.
boom head.
6. Remove the quick attach valve from the machine.
Verify the correct operation of the quick attach valve Wipe up any hydraulic fluid spillage in, on, near and
solenoid before considering replacement of the valve. around the machine.
The housing of the quick attach valve is not serviceable
and must be replaced if defective. b. Quick Attach Valve Disassembly, Cleaning,
Inspection and Assembly
a. Quick Attach Valve Removal
1. Place the quick attach valve assembly on a suitable
1. Park the machine on a firm, level surface, fully work surface.
retract the boom, raise the boom, place the
2. Remove the solenoid valve and cartridge (2) from
the quick attach valve housing.
inspection.
machine should not be operated. 4. Inspect the solenoid cartridge for proper operation.
5. Inspect internal passageways of the decompression
valve for wear, damage, etc. If inner surfaces of the
manifold DO NOT display an ultra-smooth, polished
finish, or components are damaged in any way,
replace the manifold or appropriate part. Often, dirty
hydraulic fluid causes failure of internal seals and
damage to the polished surfaces within the unit.
hydraulic oil.
G5-18A, 2505H, 25.5 8-23

Hydraulic System
6. Install the solenoid valve and cartridge in the quick 3. Place a Do Not Operate Tag on both the ignition key
attach valve housing. switch and the steering wheel, stating that the
c. Quick Attach Installation 4. Open the battery and engine covers. Allow the
1. Attach the quick attach valve to the fittings on the system fluids to cool.
boom head. 5. Properly disconnect the battery.
2. Connect the hydraulic hoses, fittings, solenoid wire 6. Refer to Section 7.2.2, “Radiator/Oil Cooler
terminal leads, etc., to the quick attach. Replacement,” for detailed removal instructions.
4. Start the engine and run at approximately 1/3-1/2 VARIABLE SPEED FAN
(if equipped)
continuing. Add hydraulic fluid to the reservoir as needed. 1

2
VARIABLE SPEED
8. Remove the Do Not Operate Tags from both the REVERSING FAN
ignition key and the steering wheel. (if equipped)
d. Quick Attach Valve Test

1. Turn the ignition switch to the ON position, activate
the quick attach switch to switch the auxiliary
position or the quick attach position.
2
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical 1
2 MY8680
8.11.11 Variable Speed Fan Valve 7. Label or otherwise mark the hydraulic hoses in
The variable speed fan valve is located on the bottom relation to the variable speed fan valve (1).
side of the Radiator assembly. Disconnect and cap all hoses, fittings, solenoid wire
terminal leads, etc.
Place a piece of paper over the face of the radiator core.
If the paper is held in place, the fan is rotating in the right 8. Remove the variable speed fan valve from the
direction. machine. Wipe up any hydraulic fluid spillage in, on,
near and around the machine.
The housing of the variable fan valve is not serviceable
and must be replaced if defective.
b. Variable Speed Fan Valve Disassembly, Cleaning,
Inspection and Assembly
a. Variable Speed Fan Valve Removal
1. Place the variable speed fan valve assembly on a
suitable work surface.
retract the boom, raise the boom, place the
transmission control lever in (N) NEUTRAL, engage 2. Remove the solenoid valve and cartridge (2) from
the park brake and shut the engine OFF. the variable speed fan valve housing.
2. Properly support the boom. 3. Clean all components with a suitable cleaner before
inspection.
8-24 G5-18A, 2505H, 25.5

Hydraulic System
4. Inspect the solenoid cartridge for proper operation.

5. Inspect internal passageways of the variable speed
fan valve for wear, damage, etc. If inner surfaces of
the manifold DO NOT display an ultra-smooth,
polished finish, or components are damaged in any
way, replace the manifold or appropriate part. Often,
dirty hydraulic fluid causes failure of internal seals
and damage to the polished surfaces within the unit.
hydraulic oil.
6. Install the solenoid valve and cartridge in the variable
speed fan valve housing.
c. Variable Speed Fan Valve Installation

1. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the variable fan valve.
2. Refer to Section 7.2.2, “Radiator/Oil Cooler
Replacement,” for detailed installation instructions.
continuing. Add hydraulic fluid to the reservoir as needed.
d. Variable Speed Fan Valve Test

1. Turn the ignition switch to the ON position, activate
the variable speed fan switch to the ON position.
2. Place a piece of paper over the face of the radiator
core. If the paper is held in place, the fan is rotating
in the right direction.
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical
G5-18A, 2505H, 25.5 8-25

Hydraulic System
8.12 HYDRAULIC CYLINDERS 1

2
8.12.1 General Cylinder Removal
Instructions 3
1. Park the machine on a firm, level surface, fully 4
2. Chock the wheels.
4. Open the battery and engine covers. Allow the 1
6. Label, disconnect and cap hydraulic hoses in 5
2
relation to the cylinder.
6
7. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can MAH0160
actually support the cylinder.

8. Remove the lock bolt and/or any retaining clips
securing the cylinder pins. Remove the cylinder pins.
9. Remove the cylinder. NOTICE
10. Wipe up any hydraulic fluid spillage in, on, near or
DO NOT tamper with or attempt to adjust the
around the machine.
counterbalance valve cartridge. If adjustment is
necessary, replace the counterbalance valve with a
8.12.2 General Cylinder Disassembly new part.
1. Clean the cylinder with a suitable cleaner before
disassembly. Remove all dirt, debris and grease 4. Extend the rod (5) to allow access to the base of the
from the cylinder. cylinder.
2. Clamp the barrel end of the cylinder in a soft-jawed
vise or other acceptable holding equipment if NOTICE
possible.
Protect the finish on the rod at all times. Damage to the
NOTICE surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head

Avoid using excessive force when clamping the gland (6) from the barrel (1). A considerable amount
cylinder in a vise. Apply only enough force to hold the of force will be necessary to remove the head gland.
cylinder securely. Excessive force can damage the Carefully slide the head gland down along the rod
cylinder tube. toward the rod eye end, away from the cylinder
barrel.
3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
8-26 G5-18A, 2505H, 25.5

Hydraulic System
2. Clean all metal parts with an approved cleaning

solvent such as trichlorethylene. Carefully clean
NOTICE cavities, grooves, threads, etc.
Note: If a white powdery residue is present on threads
When sliding the rod and piston assembly out of the and parts, it can be removed. Clean the residue away
tube, prevent the threaded end of the tube from with a soft brass wire brush prior to reassembly, and
damaging the piston. Keep the rod centered within the wipe clean before reinstallation.
tube to help prevent binding.
8.12.4 Cylinder Inspection
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel. 1. Inspect internal surfaces and all parts for wear,
damage, etc. If the inner surface of the tube does not
7. Fasten the rod end in a soft-jawed vise, and put a
display a smooth finish, or is scored or damaged in
padded support under and near the threaded end of
any way, replace the tube.
the rod to help prevent damage to the rod.
2. Remove light scratches on the piston, rod or inner
8. Remove the set screw (3) from the piston (4).
surface of the tube with a 400-600 grit emery cloth.
Note: It may be necessary to apply heat to break the Use the emery cloth in a rotary motion to polish out
bond of the sealant between the piston and the rod and blend the scratch(es) into the surrounding
before the piston can be removed. surface.
Some cylinder parts are sealed with a special organic 3. Check the piston rod assembly for run-out. If the rod
sealant and locking compound. Before attempting to is bent, it must be replaced.
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic 8.12.5 General Cylinder Assembly
oil, then heat the part(s) uniformly to break the bond. A 1. Use the proper tools for specific installation tasks.
temperature of 300-400° F (149-204° C) will destroy the Clean tools are required for assembly.
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal 1
2
while the parts are still hot. The sealant often leaves a
white, powdery residue on threads and other parts, which
3
must be removed by brushing with a soft brass wire brush
prior to reassembly. 4
9. Remove the piston head (4) from the rod (5) and
carefully slide the head gland (6) off the end of the
rod.
10. Remove all seals, back-up rings and o-rings (2) from
the piston head and all seals, back-up rings and o-
rings from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary. 1
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
2 5
manual for ordering information.
6
8.12.3 Cylinder Cleaning Instructions MAH0160
1. Discard all seals, back-up rings and o-rings. Replace

with new items from complete seal kits to help
2. Install new seals, back-up rings and o-rings (2) on
ensure proper cylinder function.
the piston (4) and the head gland (6).
G5-18A, 2505H, 25.5 8-27

Hydraulic System
Note: The Crowd cylinder has a spacer that MUST be 8.12.6 General Cylinder Installation
installed over the rod AFTER the head gland and
1. Grease the bushings at the ends of the hydraulic
BEFORE the piston head.
cylinder. Using an appropriate sling, lift the cylinder
3. Fasten the rod eye in a soft-jawed vise, and place a into it’s mounting position.
padded support under and near the threaded end of 2. Align cylinder bushing and install pin, lock bolt or
the rod (5) to prevent any damage to the rod. retaining clip.
3. Uncap and connect the hydraulic hoses in relation to
NOTICE the labels or markings made during removal.
4. Before starting the machine, check fluid level of the
Protect the finish on the rod at all times. Damage to the hydraulic fluid reservoir and if necessary, fill to full
surface of the rod can cause seal failure. mark.
4. Lubricate and slide the head gland (6) over the 5. Properly connect the battery.
cylinder rod (5). Install the piston head (4) on to the 6. Start the machine and run at low idle for about one
end of the cylinder rod. Loctite® 243TM and install the minute. Slowly activate hydraulic cylinder function in
setscrew (3) in the piston head. Refer to Section both directions allowing cylinder to fill with hydraulic
8.12.8, “Hydraulic Cylinder Torque Specifications,” oil.
for tightening guidelines for the piston head and the
7. Inspect for leaks and check level of hydraulic fluid in
set screw.
reservoir. Add hydraulic fluid if needed.
8. If no leaks are present, operate the hydraulic
function at least twenty times at full throttle to bleed
NOTICE any air from the cylinder and hoses.
Note: To bleed air from the tilt cylinder, operate the tilt
Avoid using excessive force when clamping the
function along with the lift cylinder as described above.
cylinder barrel in a vise. Apply only enough force to
More operation cycles may be required to clear all air
hold the cylinder barrel securely. Excessive force can
from the system.
damage the cylinder barrel.
5. Place the cylinder barrel (1) in a soft-jawed vise or around the machine, work area and tools.
other acceptable holding equipment if possible.
NOTICE ignition key and the steering wheel.
When sliding the rod and piston assembly into the 8.12.7 Steering Cylinders
cylinder barrel, prevent the threaded end of the
cylinder barrel from damaging the piston head. Keep The steering cylinders are attached to each axle center
the cylinder rod centered within the barrel to prevent housing. Detailed axle service instructions are provided
binding. in the Axle Disassembly & Assembly Manual
(P/N 31200451).
6. Carefully insert the cylinder rod assembly into the
tube.
7. Screw the head gland (6) into the cylinder barrel (1)
and tighten with a spanner wrench. Refer to Section
8.12.8, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the head gland.
8. If applicable, thread the new counterbalance valve
into the block on the cylinder barrel.
8-28 G5-18A, 2505H, 25.5

Hydraulic System
8.12.8 Hydraulic Cylinder Torque

Specifications
a. Lift Lower Cylinder
Head Piston CB Valve Valve Screw FC Valve Set Screw

300-400 lb-ft 1800-2000 lb-ft 45-50 lb-ft 20-25 lb-ft 30-35 lb-ft
11 lb-ft (15 Nm)
(406-542 Nm) (2440-2712 Nm) (61-67,7 Nm) (27-33,8 Nm) (40,6-47,5 Nm)
b. Extend/Retract Cylinder
Head Piston Valve Valve Screw Set Screw

200-250 lb-ft 200-240 lb-ft 44 lb-ft 10-12 lb-ft 60-69 lb-ft
(271-339 Nm) (271-325 Nm) (60 Nm) (14-16 Nm) (81-94 Nm)
c. Tilt Cylinder

300-400 lb-ft 1400-1500 lb-ft 44 lb-ft 10-12 lb-ft
11 lb-ft (15 Nm)
(406-542 Nm) (1898-2034 Nm) (60 Nm) (14-16 Nm)
d. Compensating Cylinder

300-400 lb-ft 1400-1500 lb-ft 44 lb-ft 10-12 lb-ft
11 lb-ft (15 Nm)
(406-542 Nm) (1898-2034 Nm) (60 Nm) (14-16 Nm)
Use Loctite® 262TM on all Piston Applications

Use Loctite® 242TM on all Set Screws
G5-18A, 2505H, 25.5 8-29

Hydraulic System
8-30 G5-18A, 2505H, 25.5

Section 9
Electrical System

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.1 Engine Compartment Relays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.2 Cab Compartment Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.3 Power Distribution Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3.4 Cab Fuses / Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.5.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.6 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.6.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.7 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.7.1 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.7.2 Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.8 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.2 Rear Window or Roof Wiper Motor (if equipped) . . . . . . . . . . . . . . . . . . . 9-20
9.8.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.9 Cab Heater/AC and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.9.1 Cab Heater/AC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.10 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.3 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.4 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.10.5 Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.10.6 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.11 Load Stability Indicator System (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.11.1 LSI Axle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.11.2 LSI Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.11.3 LSI Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.11.4 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.11.5 LSI-CAN Check PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.11.6 500 Hour - LSI UGM Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
G5-18A, 2505H, 25.5 9-1

Electrical System
9.12 Hand Held Analyzer (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

9.12.1 Analyzer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.12.2 Analyzer Software - Version 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.13 Diagnostic Trouble Codes (DTC) on Ground Module . . . . . . . . . . . . . . . . . . . . . 9-34
9.13.1 Gauge Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.13.2 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.14 Engine Diagnostic Trouble Code EMR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.14.1 Gauge Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9-2 G5-18A, 2505H, 25.5

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
DIAGNOSTIC
CONNECTION
CAB FUSE BOX
INSTURMENT
CLUSTER
BACK-UP ALARM
FRAME HARNESS
HORN
RELAYS
FRAME HARNESS
FUSE BOX
ENGINE DIAGNOSTIC
CONNECTION
ENGINE HARNESS BATTERY
MY8700
G5-18A, 2505H, 25.5 9-3

Electrical System
9.2 SAFETY INFORMATION
WARNING
safety precautions as outlined in the “Safety
Practices” section of this manual.
9.3 FUSES AND RELAYS
9.3.1 Engine Compartment Relays and

Fuses
4 5 6 7
3
MY8710
2 1
There are seven relays and one buss bar located on the
frame, mounted on a bracket behind the battery. The
relays control the auxiliary (1), ignition (2), fuel pump (3),
Cut Out (4), Auxiliary (5) and Joystick (6 & 7).
9.3.2 Cab Compartment Fuses and Relays
MY2480 8
The cab fuse block (8) is located behind an access panel

at the right side of the dash.
9-4 G5-18A, 2505H, 25.5

Electrical System
9.3.3 Power Distribution Module
MAP0030
Fuse/Relay Function Amp Rating

F1 Drive Cut-Out 15
F2 Auxiliary Circuit 15
F3 Display 5
F4 Joystick 5
F5 System Module 15
F6 ClearSky 5
F7 Back-Up Alarm, Reverse Light 15
F8 Beacon 10
F9 LSI System 10
F10 ECM 15
F11 Key 10
F12 ClearSky 5
F13 Rear Power & Horn 15
F14 Front Worklights 10
F15 Boom Worklights 10
F16 Rear Worklights 10
R1 Worklights 35
R2 Back-Up Alarm, Reverse Light 35
G5-18A, 2505H, 25.5 9-5

Electrical System
9.3.4 Cab Fuses / Relays
MY2470
Fuse/Relay Function Amp Rating

F21 Hazard 10
F22 LSI Over Ride 5
F23 Dome Light 10
F24 Analyzer 5
F25 Front Washer & Fan 15
F26 Rear Roof Wiper 20
F27 Front Wiper 20
F28 HVAC Switch 30
F29 Spare
F30 Spare
F31 Right Headlight - High Beam 7.5
F32 Left Headlight - High Beam 7.5
F33 Right Headlight - Low Beam 7.5
F34 Left Headlight - Low Beam 7.5
F35 Right Marker Lights - Trailer Light Connection 7.5
F36 Left Marker Lights - License Light - Trailer Connection 7.5
F37 Turn Signal Switch 15
F38 Brake Pedal Switch 15
F39 Radio 15
F40 HVAC Switch - AC 10
R11 Relay - Start Enable 35
R12 Park Brake Switch (CE) 35
X1 Flasher 10
9-6 G5-18A, 2505H, 25.5

9-7 G5-18A, 2505H, 25.5
MY8720B
A
B
C
D
NA MACHINES
INDICATOR, TURN, HIGH BEAM
PARK BRAKE QUICK COUPLER LMI OVERRIDE
RS-232
PWR MGT
DIAGNOSTIC
1A
1B
2A
2B
1
2
3
4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
X159
SW08
SW09
SW01
LB02-1
LB02-2
1
1
YEL 062-12 IGN
YEL 062-14 IGN

YEL 062-12-2 IGN
YEL 062-2-1 IGN

YEL 062-3-1 IGN
BLK 000-8-8 GND

BLK 000-7-6 GND
BLK 000-8-9 GND

BLK 000-8-9 GND
BLK 000-8-6 GND
X41
BLK 000-8-11 GND
BLK 000-8-11 GND
BLK 000-8-13 GND

BLK 000-8-10 GND
BLK 000-8-10 GND
BLK 000-8-12 GND
BLK 000-8-13 GND
BLK 000-8-12 GND

BLK 000-8-13 GND
BLK 000-8-14 GND
WHT 071-14 L TRN

WHT 071-17 R TRN
RED CAN HI
WHT 076-9 LSI O/R
WHT 071-3-3 HDLP HI
A
WHT 070-1-6 LIGHTING
BLK CAN LO
B

WHT 077-2-2 PK BRK IND

WHT 076-4 SW QK CPLR
WHT 077-2-1 ST ENABLE

WHT 077-1 VALVE PK BRK
C
WHT 084-3 PWR MGT XMIT
WHT 084-4 PWR MGT RECEIVE
WHT 107-1 SEAT SW 2

4 Sheet3-[8,B]
&
YEL 062-13-2 IGN

TO
3
IP68
WHT 106-1 SEAT SW 1

2 Sheet3-[8,B]
YEL 062-13-3 IGN
1
SEAT SW 2
SEAT SW 1
X166
Sheet3-[8,B]
Sheet3-[8,A]
Sheet3-[1,A]
Sheet3-[1,B]
Sheet3-[8,B]
Sheet3-[6,C]
Sheet3-[7,D]
Sheet3-[8,D]
Sheet3-[2,C]
YEL 062-4-3 IGN

Sheet3-[6,C] 1 IGN RUN
RED CAN HI
2 CAN HI
BLK CAN LO
GAUGE
3 CAN LO
2
BLK 000-8-5 GND

Sheet3-[2,C] 4 GND
WHT 007-1 FNR-F WHT 048-9 FUEL SENSE
WHT 071-5-6 L TRN
1 Sheet3-[8,D] Sheet3-[8,C] 5 FUEL SENSE

WHT 077-1-3 FNR LVR RED CABLE 1 CAN HI
2
2 6 CAN HI
WHT 008-1 FNR-R BLK CABLE 1 CAN LO
3 Sheet3-[8,D] 7 CAN LO
4 8 PARK BRAKE
WHT 048-2 PK BRK RLY WHT 078-3 STR PRES
5 Sheet3-[8,B] 9 STEERING PRES
WHT 048-1 START WHT 065-4-1 2W STR
FNR LEVER
6 Sheet3-[1,C] 10 2W STEER
WHT 065-3-2 4W STR
SW10 Sheet3-[6,C] 11 4W STEER
WHT 065-2-2 CRB STR
Sheet3-[6,C] 12 4W CRAB STEER
13
14
RED 061-8-2 B+ SHIELD CABLE 1 CAN S
2 NC CAN SHLD
1 GD167
4
WHT 071-16 BU LP
3 Sheet3-[8,B]
WHT 071-15 FLASHER
SN11 1A
BLK 000-8-14 GND
1B
SWITCH, BRAKE PEDAL
S208
BLK 000-8-15 GND

LB03-1
WHT 077-3 RH STOP
Sheet3-[8,B] 2A
WHT 074-6 FR WASH BLK 000-8-15 GND
1 Sheet3-[6,D] 2B
BLK 000-6-2 GND BLK 000-8-16 GND
2 LB03-2
3
M
INDICATOR, TRAILER
BLK 000-6-5 GND

FRONT
WH13-F
IP69
1
WHT 074-7 R WPR WHT 052-1 HORN
1 Sheet3-[8,D] Sheet3-[8,C] 2
BLK 000-6-5 GND RED 061-2-2 HORN SW
3
M 2 Sheet3-[2,D] 3
REAR
WH13-R 4
5
HORN
TANK, DUAL WASHER, PUMPS
6
WHT 077-1-2 PK BRK
WHT 077-1-1 PK BRK
BLK 000-8-16 GND

7
WHT 071-17 R TRN
G BLK 000-6-3 GND 14AWG WHT 070-1-6 LIGHTING

5 8
4 Sheet3-[4,A] SW05
H WHT 074-3 WPR H 14AWG BLK 000-8-17 GND
M 2 Sheet3-[6,D]
L WHT 074-2 WPR L 14AWG
1 Sheet3-[6,D]
P WHT 074-5 WPR P 14AWG
3 Sheet3-[7,D]
WH12
IGNITION SWITCH
WIPER, FRONT MOTOR

S270
X211 X291 SW06-F

YEL 062-1 IGN RLY YEL F
Sheet3-[8,C] 1 1 1
Sheet3-[6,B]
Sheet3-[6,B]
2 2 SW06-I
WHT 048-1 START GRY I
3 3 1
RED 061-5 KEY RED
4
Sheet3-[8,C] 4 4 SW06-B
B
5 5 1
SIDE LT WHT 070-1-18 LIGHTING WHT 070-1 LIGHTING
1 6 6 SW06-S
LIGHT PWR RED 061-7 B+ S280 S
2 1
LOW HD WHT 071-2 HDLP LO
3
HIGH HD WHT 071-3 HDLP HI
4
FLASH PWR RED 061-8-1 B+
5
LEFT WHT 071-5-5 L TRN WHT 071-5-6 L TRN
6
4
TURN PWR WHT 071-4 TRN PWR S209
7 X215
FC73-L1
RIGHT WHT 071-5 L TRN YEL 062-10 IGN 8AWG

SHEET 5
8 Sheet3-[2,A] 1
ON FRAME
WHT 071-6-5 R TRN WHT 071-17 R TRN

SW14
SWITCH, TURN SIGNAL LEVER

S210 WHT 071-6 R TRN Sheet3-[3,A]
YEL 062-10-2 IGN
TO IGNITION RELAY
YEL 062-10-4 IGN

SHIELD CABLE 1 CAN S
C
RED CABLE 1 CAN HI YEL 062-11 IGN
MS290-1 B Sheet3-[1,B] F21_A
BLK CABLE 2 CAN LO BLK CABLE 1 CAN LO YEL 062-10-1 IGN
Sheet3-[8,C] A A F21_B
Sheet3-[8,C] B MS290-2 F22_A
SHIELD CABLE 2 CAN S SHIELD CABLE 3 CAN S YEL 062-10-2 IGN
Sheet3-[8,C] C C F22_B
B F23_A
5
5
BLK CABLE 3 CAN LO YEL 062-10-3 IGN
A F23_B
YEL 062-14 IGN
MS290-3 F24_A
YEL 062-10-4 IGN
F24_B
YEL 062-15 IGN
Sheet3-[7,D] F25_A
S214 YEL 062-10-5 IGN
F25_B
YEL 062-16 IGN 14AWG
Sheet3-[8,D] F26_A
YEL 062-10-6 IGN 14AWG
F26_B
Sheet3-[6,D] F27_A
F27_B
Sheet3-[1,A] F28_A
F28_B
F29_A
WHT 071-3-1 HDLP HI
F29_B
WHT 071-3-1 HDLP HI
F30_A
WHT 071-2-1 HDLP LO
F30_B
WHT 071-7 RH HDLP HI
Sheet3-[8,B] F31_A
WHT 071-3 HDLP HI
F31_B
WHT 071-8 LH HDLP HI
Sheet3-[8,B] F32_A
WHT 071-3-3 HDLP HI
F32_B
BLK CABLE 3 CAN LO WHT 071-9 RH HDLP LO
12 Sheet3-[8,B] F33_A
RED CABLE 3 CAN HI WHT 071-2 HDLP LO
6
6
11 F33_B
SHIELD CABLE 3 CAN S WHT 071-10 LH HDLP LO
10 Sheet3-[8,A] F34_A
WHT 085-1 LSI LP WHT 071-2-1 HDLP LO
9 Sheet3-[8,B] F34_B
BLU LSI PWR WHT 071-11 RH SD LP
8 Sheet3-[8,B] Sheet3-[8,A] F35_A
BLK LSI 2 S213 WHT 071-1-3 LIGHTING
RED LSI 1 WHT 071-12 LH SD LP
6 Sheet3-[8,B] Sheet3-[8,A] F36_A
SHIELD LSI S WHT 071-1-4 LIGHTING
TO CAB ROOF
HOLDER, FUSE/RELAY, CAB
RED 061-7 B+
4 F37_A
BLK 000-7-2 GND RED 061-6-1 B+
3 F37_B
WHT 076-8 LSI C/O RED 061-8 B+
2 Sheet3-[8,B] F38_A
OPTION HARNESS X298

YEL 062-12-2 IGN S67 RED 061-6-2 B+
1 F38_B
S212 RED 061-9 B+
X15 F39_A
RED 061-6-3 B+
F39_B
WHT 073-5 AC
Sheet3-[1,A] F40_A
WHT 073-4 AC
8 Sheet3-[1,A] F40_B
WHT 077-2 PK BRK
7 Sheet3-[5,B] R11_85
BLK 000-6-4 GND 14AWG BLK 000-7-5 GND
6 R11_86
WHT 074-8 R WPR 14AWG WHT 048-3 IGN S
5 Sheet3-[8,D] Sheet3-[8,C] R11_87
WHT 074-9 R WPR WHT 048-2 PK BRK RLY
4 Sheet3-[8,D] R11_30
RED 061-9 B+ WHT 077-2-1 ST ENABLE
3 R11_87a
YEL 062-13-1 IGN WHT 077-2-3 PK BRK
TO CAB ROOF
2 Sheet3-[5,B] R12_85
7
BLK 000-7-3 GND BLK 000-8-17 GND

1 R12_86
X16 R12_87
BLK 000-8-13 GND
R12_30
7
OPTION HARNESS X223
BLK 000-7-5 GND
R12_87a
YEL 062-4-4 IGN BLK 000-7-4 GND
4 Sheet3-[6,C] X1_31 31
WHT 070-1-2 LIGHTING WHT 071-13 FLASHER
3 Sheet3-[1,B] X1_49 49
YEL 062-2-2 IGN WHT 071-4 TRN PWR
2 Sheet3-[6,C] X1_49a 49a
WHT 065-1-2 STR SEL WHT 071-4-1 FLASHER
1 Sheet3-[3,D] Sheet3-[1,B] X1_C1 C1
FLASHER
X17 WHT 071-15 FLASHER

X1_C2 C2
FC07
X65
1
062-2-2 YEL 16AWG
Sheet3-[8,B]
Sheet3-[8,B]
Sheet3-[8,B]
X1
2
NAME
F40
F39
F38
F37
F36
F35
F34
F33
F32
F31
F30
F29
F28
F27
F26
F25
F24
F23
F22
F21
R11
R12
3
S220
TO X17
S288
TO X66.
S221
TO X65.
4
EMPTY
EMPTY
8
FUSE, AC
FUSE, LSI
FUSE, HVAC
FUSE, RADIO
X66
3. FOR EUROPEAN CABS

FUSE, HAZARDS
1
FUSE,ANALYZER
RELAY, FLASHER

062-2-2 YEL 16AWG
WHT 048-22 APS SIG
WHT 057-1 APS 5V

BLK 000-6-8 GND
WHT 048-23 IVS2

BLK 000-7-1 GND 14AWG
NO CONNECTOR REQUIRED
RED 061-8-3 FLASHER
BLK 000-6 GND 10AWG

BLK 000-7 GND 10AWG
RED 061-6 BATTERY 10AWG
FUSE, DOME LIGHT
WHT 058-8-1 APS GND

WHT 058-8 APS GND
DESCRIPTION
WHT 058-8-2 APS GND

FUSE, LIGHT POWER
FUSE, LEFT MARKER
FUSE, FRONT WIPER
NO HEADLIGHTS CONNECT X17
2. FOR NORTH AMERICAN CABS

3
FUSE, RIGHT MARKER
RELAY, START ENABLE

FUSE, LEFT HIGH BEAM
062-4-4 YEL 16AWG
WITH HEADLIGHTS CONNECT X17

FUSE, FLASHER POWER
FUSE, LEFT HEAD LIGHT
FUSE, REAR WIPE WASH
4 FUSE, RIGHT HIGH BEAM
RELAY, PRK BRK IND (CE)
X206
X216
FUSE, RIGHT HEAD LIGHT
F
E
B
A
D
C
FUSE, FRONT WASH & FAN
1. FOR NORTH AMERICAN CABS WITH
8
-
-
5A
5A
Sheet3-[8,B]
Sheet3-[2,A]
Sheet3-[5,A]
Sheet3-[2,A]
TO
Sheet3-[1,C]
Sheet3-[1,C]
Sheet3-[8,C]
10A
35A
35A
10A
15A
15A
15A
30A
20A
20A
15A
10A
10A
RL72-R
TPS
7.5A
7.5A
7.5A
7.5A
7.5A
7.5A
RATING
SHEET 5
TO FRAME
A
B
C
D
a. Cab Schematic "A"
ELECTRICAL SYSTEM SCHEMATICS 9.4
Electrical System
9-8
1 2 3 4 5 6 7 8
FAN REVERSE STEER SELECT SWITCH BOOM WORK LIGHTS FRONT WORK LIGHTS REAR WORK LIGHTS FRONT WIPER FRONT WASHER
SWITCH, JOYSTICK LOCKOUT
POWER SOCKET

WHT 074-9 R WPR
Sheet2-[7,B] 1
Sheet2-[5,D] 2
1
2
3
4
5
6
7
8
Sheet2-[3,D]
1
2
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
WHT 074-8 R WPR 14AWG
Sheet2-[7,B] 3
1
2
3
4
5
6
7
8
4
SW26
SW145
MS18
SW21
SW23
SW29
SW30
13
14
3
15
16
6
12
11
9
10
5
SW19
WHT 074-7 R WPR
Sheet2-[3,A] 6
SW20
TO
BLK 000-8-26 GND
7
b. Cab Schematic "B"
FRAME BLK 000-11 GND 6AWG WHT 070-1-17 LIGHTING

ROOF/REAR WIPER
1 8
GROUND X81 SW31
D STUD D
YEL 062-15 IGN
BLK 000-8-4 GND
YEL 062-15-2 IGN

YEL 062-15-2 IGN
BLK 000-8-22 GND
BLK 000-8-19 GND
BLK 000-8-18 GND

BLK 000-8-25 GND
BLK 000-8-21 GND
YEL 062-2-5 IGN

YEL 062-2-4 IGN
YEL 062-2-3 IGN
YEL 062-15-1 IGN
YEL 062-15-1 IGN

BLK 000-8-23 GND
BLK 000-8-24 GND
BLK 000-8-22 GND

BLK 000-8-25 GND
BLK 000-8-24 GND
BLK 000-8-23 GND

BLK 000-8-26 GND
YEL 051-2 FR WK LP
YEL 051-4 RR WK LP
YEL 051-3 BM WK LP
WHT 051-5 BOOM LP
RED 061-2-1 R PWR

BLK 000-8-19 GND
BLK 000-8-20 GND
WHT 051-6 FR WK LP
WHT 051-7 RR WK LP
WHT 074-6 FR WASH
TO
WHT 076-7 JS C/O
WHT 101-1 FAN CYCLE

BLK 000-8-20 GND
BLK 000-8-21 GND
WHT 065-4-2 2W STR
RED 061-2-2 HORN SW

WHT 074-1 WPR 14AWG
WHT 074-1 WPR 14AWG

31
WHT 065-1 LOCK OUT

WHT 065-3 4W STR
WHT 065-4 2W STR
WHT 101-2 FAN DEMAND



CAB
WHT 074-4 WPR P 14AWG

RED 061-2 RR PWR
WHT 065-2 CRB STR

WHT 074-2 WPR L 14AWG

WHT 074-3 WPR H 14AWG

30
WHT 074-2-1 WPR L 14AWG
WHT 065-1 LOCK OUT

WHT 074-2-1 WPR L 14AWG
WHT 073-9 AC PRES SW
WHT 065-1-2 STR SEL

S186
Electrical System
WHT 065-1-1 LOCK OUT

WHT 065-1-1 LOCK OUT
GROUND 1 29
WHT 008-2-2 BU LP
STUD X82 28
Sheet2-[2,C] 27
Sheet2-[2,C] 26
WHT 008-1 FNR-R
Sheet2-[7,B]
Sheet2-[4,A]
Sheet2-[4,A]
Sheet2-[3,A]
Sheet2-[4,A]
Sheet2-[5,D]
Sheet2-[5,D]
Sheet2-[2,A] 25
WHT 007-1 FNR-F
Sheet2-[2,A] 24
TO X22 23
WHT 051-6 FR WK LP WHT 101-1 FAN CYCLE
1 22
CAB BLK 000-8-3 GND SHIELD CABLE 2 CAN S
2 Sheet2-[5,A] 21
ROOF WHT 051-7 RR WK LP RED CABLE 2 CAN HI
3 Sheet2-[5,A] 20 TO
BLK 000-8-2 GND WHT 048-9 FUEL SENSE
WORKLIGHT 4 Sheet2-[2,D] 19
WHT 072-1 BEACON LP BLK CABLE 2 CAN LO BASE
HARNESS 5 Sheet2-[5,A] 18
BLK 000-8-1 GND S205 WHT 048-3 IGN S FRAME
6 Sheet2-[7,D] 17
X22 WHT 052-1 HORN
Sheet2-[3,D] 16 HARNESS
WHT 065-4-1 2W STR WHT 065-3-2 4W STR WHT 065-3-1 4W STR
Sheet2-[2,D] Sheet2-[2,D] 15 X119
WHT 065-2-2 CRB STR S112 WHT 065-2-1 CRB STR
Sheet2-[2,D] 14
S113 WHT 076-3 F/R AUX
TO 13
BLK 000-5 GND 6AWG WHT 070-1-1 LIGHTING
1 Sheet2-[8,C] 12
FRAME YEL 062-9 BEACON
X217 11
GROUND YEL 051-4 RR WK LP
10
YEL 051-2 FR WK LP
STUD 9
WHT 051-5 BOOM LP
C 8 C
BLK 000-7 GND 10AWG YEL 051-3 BM WK LP
Sheet2-[8,C] 7
BLK 000-6 GND 10AWG YEL 062-4-3 IGN YEL 062-4-1 IGN
Sheet2-[8,C] Sheet2-[2,D] 6
S115 YEL 062-3 IGN
5
YEL 062-2-1 IGN YEL 062-2 IGN
Sheet2-[2,B] 4
BLK 000-8 GND 8AWG YEL 062-2-2 IGN S143
Sheet2-[7,B] 3
S219 RED 061-5 KEY
S218 Sheet2-[4,D] 2
YEL 062-4-4 IGN YEL 062-1 IGN RLY
Sheet2-[7,B] Sheet2-[4,D] 1
BLK 000-8-5 GND
Sheet2-[2,D] X27
BLK 000-8-6 GND
Sheet2-[2,B]
BLK LSI 2
Sheet2-[6,B] 31
RED LSI 1
Sheet2-[6,B] 30
29
WHT 078-3 STR PRES
Sheet2-[2,D] 28
WHT 107-1 SEAT SW 2
Sheet2-[2,A] 27
WHT 106-1 SEAT SW 1
Sheet2-[2,A] 26
25
24 TO
WHT 085-1 LSI LP
Sheet2-[6,B] 23
WHT 076-7 JS C/O OPTION
22
WHT 048-23 IVS2 FRAME
Sheet2-[8,B] 21
Sheet2-[4,B]
Sheet2-[4,B]
WHT 048-22 APS SIG

Sheet2-[8,B] 20 HARNESS
B BLU LSI PWR B
Sheet2-[6,B] 19 X188
YEL 062-3-1 IGN SHIELD LSI S
Sheet2-[2,C] Sheet2-[6,B] 18
S204
WHT 076-9 LSI O/R

Sheet2-[2,C] 17
WHT 076-8 LSI C/O
Sheet2-[6,B] 16
WHT 057-1 APS 5V
Sheet2-[8,B] 15
WHT 058-8 APS GND
Sheet2-[8,C] 14
Sheet2-[2,B] 13
WHT 071-4-1 FLASHER WHT 008-2-2 BU LP
Sheet2-[7,D] 12
WHT 071-13 FLASHER WHT 071-16 BU LP
Sheet2-[7,D] Sheet2-[3,A] 11
WHT 077-3 RH STOP
Sheet2-[3,D] 10
YEL 062-11 IGN WHT 071-7 RH HDLP HI
Sheet2-[5,D] Sheet2-[6,D] 9
WHT 077-1-1 PK BRK
WHT 077-1-2 PK BRK

BLK 000-8-30 GND
WHT 077-2-4 PK BRK
WHT 077-2 PK BRK

WHT 077-2-3 PK BRK
YEL 062-2-4 IGN
Sheet2-[6,D] 8
WHT 071-9 RH HDLP LO
Sheet2-[6,D] 7
WHT 073-4 AC WHT 071-10 LH HDLP LO
1
2
3
2
1
SN35
HV36
WHT 071-11 RH SD LP
Sheet2-[6,D] 5
YEL 062-18 IGN 12AWG WHT 071-12 LH SD LP
Sheet2-[8,C]
Sheet2-[8,C]
Sheet2-[4,B]
Sheet2-[5,B]
Sheet2-[4,D]
Sheet2-[8,C]
WHT 071-5-1 LH TRN
3
WHT 073-5 AC WHT 071-6-1 RH TRN
Sheet2-[7,D]
Sheet2-[7,D]
Sheet2-[7,D] 2
Sheet2-[2,B] 1
X28
PARK BRAKE
VALVE, MANUAL PARK BRAKE NA MACHINES ONLY

CE + AUS MACHINES
A A
YEL 062-3-1 IGN

WHT 071-5-1 LH TRN
BLK 000-8-8 GND

BLK 000-8-29 GND
BLK 000-8-28 GND

YEL 062-3 IGN
BLK 000-8-29 GND
BLK 000-8-28 GND
BLK 000-8-27 GND
BLK 000-8-8 GND

BLK 000-6-8 GND
BLK 000-7-1 GND
WHT 071-6-1 RH TRN

WHT 073-3 FAN L 14AWG
WHT 071-5 L TRN

RED 061-8-3 FLASHER
WHT 071-6 R TRN
WHT 073-1 FAN H 14AWG
WHT 073-2 FAN M 14AWG
WHT 073-9 AC PRES SW
WHT 073-5 AC
WHT 073-6 AC
WHT 073-6 AC
YEL 062-9 BEACON

WHT 076-3 F/R AUX
WHT 073-4 AC
WHT 072-1 BEACON LP
WHT 073-3 FAN L 14AWG

WHT 073-1 FAN H 14AWG
WHT 073-2 FAN M 14AWG
WHT 071-13 FLASHER
BLK 000-8-30 GND

WHT 071-4-1 FLASHER
YEL 062-11 IGN
X266
1
L
1
2
3
4
5
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
1
2
B
A
B
SW33
SW25
SW24
H
C
C
M
SW32-F
WH34-F
17
18
10
SW32-AC
WH34-AC
HI
AC
HI
Sheet2-[2,B]
TO
LOW
PWR
MED.
GND
MED
LOW
CAB FAN
SWITCH, HAZARD BEACON
M
GROUND F/R AUX HYD AC

STUD AC
SWITCH, HVAC CONTROL WITH A/C HVAC FAN
1 2 3 4 5 6 7 8
MY8730B
G5-18A, 2505H, 25.5

9-9 G5-18A, 2505H, 25.5
MY8740B
A
B
C
D
X16
X15
TO CAB
TO CAB
SHEET 2
SHEET 2
HARNESS
HARNESS
11
8
7
6
5
4
3
2
1
12
10
9
8
7
6
5
4
3
2
1
X223
X298
SN123-2
WHT 073-8-4 AC COMP
1
S128
SN123-1
WHT 073-9 AC PRES
1
1
1
PRESSURE SW
SHIELD LSI S
RED LSI CABLE
RED 061-9 PWR

YEL 062-13 IGN
BLK LSI CABLE 2
BLK 000-7-2 GND
BLK 000-7-3 GND

YEL 062-12-2 IGN
WHT 085-1 LSI LP

WHT 076-8 LSI C/O
BLU LSI CABLE PWR
5
RED CABLE 12 CAN HI
BLK CABLE 12 CAN LO
WHT 073-9 AC PRES

4
BLK 000-1 GND 12AWG

3
WHT 073-8-2 AC COMP
TO
2
X264
WHT 061-10 COND FAN 12AWG

1
FRAME
S245
SHEET 5
X268
HARNESS
RL267
WHT 073-8-3 AC COMP
5
86 BLK 000-1-3 GND
2 GD237
85 YEL 062-12-2 IGN
3 1 PWR
87a WHT 061-10 COND FAN 12AWG BLK 000-7-6 GND
1 1 2 GND
30 WHT 108-1 COND FAN 12AWG WHT 076-8 LSI C/O
4 2 3 SWITCHED OUT
2
87 RED LSI CABLE 1

CONDENSER FAN
3 4 SENSOR 1 -VE
S247
RED 061-9 PWR BLK LSI CABLE 2

4 5 SENSOR 2 -VE
S246
S285
BLU LSI CABLE PWR

LSI DISPLAY
5 6 SENSOR VE+
RED CABLE 12 CAN HI
6 7 CAN H
YEL 062-13-1 IGN BLK CABLE 12 CAN LO
7 8 CAN L
BLK 000-1-2 GND 14AWG BLK 000-7-9 GND SHIELD CABLE 12 CAN S
2 8 NC
WHT 108-1-1 COND FAN 14AWG
TO
1 MS242-GRY
S287
FAN 1
COND
X269 1
2
BLK 058-2 SPEAKER-
RADIO (EUROPE)
3 LB238+
WHT 052-4 SPEAKER+ WHT 085-1 LSI LP
CUSTOMER SUPPLIED
X284 4 1
WHT 108-1-2 COND FAN 14AWG BLK 058-1 SPEAKER-
1 5
BLK 000-1-1 GND 14AWG WHT 052-3 SPEAKER+ BLK 000-7-10 GND
TO
2 6 1
FAN 2
COND
LSI PASSIVE
7 LB238-
8
MS242-BRN
LB239
1
YEL 062-13-2 IGN
2
3
LIGHT, DOME
BLK 000-7-8 GND

1
WHT 052-3 SPEAKER+
1 LB239-G
MS243+
3 BLK 058-1 SPEAKER-
1
MS243-
CUSTOMER SUPPLIED
SPEARKERS(EUROPE)
WHT 074-8-2 ROOF WPR 14AWG W

1
S248 WH240-W
P
M
1
WHT 052-4 SPEAKER+
1 WH240-P
BLK 000-6-7 GND 14AWG G
MS244+ 1
BLK 058-2 SPEAKER- S249 WH240-G
1
WIPER, ROOF MOTOR
MS244-
CUSTOMER SUPPLIED
SPEARKERS(EUROPE)
WHT 074-8-1 REAR WPR 14AWG W

1
WH241-W M
WHT 074-9 R WPR 14AWG P
4
1
WH241-P
BLK 000-6-6 GND 14AWG G
1
WH241-G
WIPER, REAR MOTOR
4
025-2 GRN S148 025-2-1 GRN
1 1
026-4 GRN 026-4 GRN
2 2
070-1-22 BLU 014-1-2 GRN
3 3
014-1 GRN S149 014-1-1 GRN
4 4
026-5 GRN 026-5 GRN
5 5
062-3-3 YEL 025-2-2 GRN
6 6
000-4-13 BLK S146 000-4-14 BLK
7 7
5
5
055-2 GRN
8 8
X27 9
10
SWITCH, FRAMER LOADER
SW120
X98
TO CAB
SHEET 5
HARNESS
1
062-3-3 YEL
2
055-2 GRN
3
4
5
6
000-4-15 BLK
7
070-1-22 BLU
8
SWITCH, AUX DECOMP
SW145
072-1 BLU
1 1
000-8-1 BLK
2 2
6
6
MS109
LIGHT BEACON
057-7-2 BLU BLUE

1 1 1
000-8-30 BLK BLACK
2 2 2
X103 X LB
REAR LEFT
WORKLIGHT
S113 051-7-1 BLU BLUE

1 1 1
000-8-29 BLK BLACK
2 2 2
S112 X104 X104 LB104
WORKLIGHT
REAR RIGHT
7
051-6-2 BLU BLUE

1 1 1
000-8-28 BLK BLACK
2 2 2
X106 X106 LB106
7
WORKLIGHT
FRONT LEFT
S111 051-6-1 BLU BLUE

1 1 1
000-8-27 BLK BLACK
2 2 2
S110 X105 X105 LB105
WORKLIGHT
FRONT RIGHT
000-8-2 BLK
072-1 BLU
051-6 BLU
000-8-1 BLK
000-8-3 BLK
051-7 BLU
X22
8
6
5
4
3
2
1
X22
TO CAB
SHEET 3
HARNESS
8
A
B
C
D
c. Cab Roof, AC and Miscellaneous Schematic
Electrical System
9-10
1 2 3 4 5 6 7 8
NAME DESCRIPTION RATING
F1 FUSE, DRIVE CUTOUT 15A
PWR MOD, FUEL PMP, GREEN PWR MOD, IGNITION, YELLOW PWR MOD, AUX, RED F2 FUSE, AUX CIRCUIT 15A
ELEC ASSY, MAIN FUSE BOX RELAY, CUTOUT FUEL SENDER
R1 R2
CONT. HYD JOYSTICK VALVE, STEER SELECT VALVE, DIVERTER, AUX F3 FUSE, DISPLAY 5A
FUEL
HORN F4 FUSE, JOYSTICK 5A
LEVEL
F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F12 F13 F14 F15 F16 F5 FUSE, SYSTEM MODULE 15A
PWR
OUT
GND
F6 FUSE, CLEARSKY 5A
87
30
87a
85
86
F7 FUSE, REVERSE CIRCUIT 15A
TO RL71-R
TO RL71-B+
F8 FUSE, BEACON 10A
1
1
2
1
1
1
1
1
2
1
1
1
1
1
2
1
1
Sheet9-[2,B]
L1
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
C1
D1
C2
D2
C3
D3
C4
D4
C5
D5
C6
D6
B8
D7
D8
B7
C8
B10
D9
D10
B9
C10
Sheet6-[3,B]
1
1
4
1
3
2
5
1
2
3
4
1
2
3
1
2
1
2
1
2
F9 FUSE, LSI SYSTEM 10A
F10 FUSE, ECM 15A
JS76
X120
X279
RL71
RL72
RL75
FC73
AH74
SN77
HV78
HV79
HV80
RL139
RL71-Y
RL72-Y
RL71-R
RL72-R
AH74-G
FC73-L1
RL139-Y
RL71-B+
RL72-B+
RL139-R
F11 FUSE, KEYSWITCH 10A
RL139-B+
D F12 FUSE, CLEARSKY (IN BAG) 5A D
F13 FUSE, REAR POWER & HORN 15A
F14 FUSE, FRONT WL 10A
F15 FUSE, BOOM WL 10A
BUSS BAR 1
BUSS BAR 1
BUSS BAR 1
BUSS BAR 2
BUSS BAR 2
GRN 079-2 FT
GRN 079-3 FT
F16 FUSE, REAR WL 10A
GRN 025-1 AUX
YEL 062-6 IGN

YEL 062-7 IGN
RED 061-5 KEY
YEL 062-8 BK UP
WHT 52-3 HORN
WHT 52-2 HORN
YEL 062-8 BK UP
BLK 000-5-2 GND
BLK 000-5-3 GND
BLK 000-5-4 GND
BLK 000-5-9 GND

YEL 062-1-1 KEY I
R1 RELAY, WORKLIGHTS 35A
YEL 062-3-4 IGN
YEL 062-1-2 KEY 1

BLU 008-2 BU LPS
YEL 062-4 GAUGE

YEL 062-2 PK BRK
Electrical System
BLK 000-3-20 GND

BLK 000-3-6 GND
BLK 000-5-1 GND

BLK 000-4-1 GND
BLK 000-4-6 GND
BLK 000-3-9 GND
YEL 080-1 FCN L/O
YEL 062-19 LSI IGN

YEL 062-9 BEACON
WHT 076-3 F/R AUX
BLK 000-3-17 GND

WHT 008-1-2 FNR-R
BLK 000-3-12 GND
WHT 026-1 TOGGLE
RED 061-4 CLRSKY
YEL 62-9-5 ECM IGN

YEL 051-2 FR WK LP
R2 RELAY, REVERSE CIRCUIT 35A
YEL 051-4 RR WK LP
YEL 062-3-2 F/R AUX

YEL 051-3 BM WK LP
YEL 062-5 JOY STK

WHT 065-3-1 4W STR
RED 061-2-3 RR PWR

RED 061-1 B+ 10AWG
RED 061-1 B+ 10AWG
061 FUSIBLE LINK 16 GA

WHT 065-2-1 CRB STR
WHT 048-9 FUEL SENS
RED 001-2 BATT 6AWG
RED 001-2 BATT 6AWG

RED 061-1-1 B+ 10AWG
RED 061-1-3 B+ 10AWG
RED 061-1-2 B+ 10AWG
S278
RED 061-1-3 B+ 10AWG
RED 061-1-2 B+ 10AWG
RED 061-1-1 B+ 10AWG
WHT 070-1-21 LIGHTNG
RED 061-14 PWR 10AWG

YEL 051-1 WK LP 12AWG
d. Base Frame Schematic "A"
YEL 051-1-2 WK LP 12AWG
Sheet6-[6,B]
Sheet6-[3,B]
WHT 090-1 FUEL PUMP 14AWG

1. BASE NORTH AMERICAN
Sheet6-[6,B]
2. LSI & OPTION EQUIPED
WHT 148-26 FUEL PUMP CONT

MACHINES HAVE X163A MACHINES X83
Sheet6-[1,B]
Sheet6-[1,B]
JUMPER PLUGS INTO X184
S118
S138
OPTION FRAME
S126
ON SHEET 8
X119
YEL 062-1 KEY 1
1 X83 X163A
RED 061-5 KEY S146 YEL 080-1 FCN L/O YEL
2 1 1
S132
YEL 062-19 LSI IGN
3 2 2
YEL 062-2 PK BRK
4
YEL 062-3 F/R AUX
5
YEL 062-4 GAUGE
TO 6
YEL 051-3 BM WK LP
S130
7 X89 TO
WHT 051-5 BOOM LP WHT 051-5 BOOM LP
BASE 8 1 WORK LP X90
YEL 051-2 FR WK LP BLK 000-3-11 GND
9 2
YEL 051-4 RR WK LP SHEET 9
CAB 10 X94
YEL 062-9 BEACON WHT 076-4 SW QK CPLR
C 11 1 TO C
WHT 070-1-1 LIGHTNG WHT 076-5 SW QK CPLR
HARNESS 12 2
WHT 076-3 F/R AUX QK CPLR X93
13 3
WHT 065-2-1 CRB STR SHEET 9
X27 14 4
WHT 065-3-1 4W STR
15
WHT 052-1 HORN
SHEET 3 16 HV85
WHT 48-3 IGN S GRN 055-2 AUX DCMP
17 1
BLK CABLE 4 CAN LO BLK 000-3-5 GND
18 2
WHT 048-9 FUEL SENS
19
RED CABLE 4 CAN HI
20
S296
VALVE, AUX DECOMP
21 RL95
WHT 101-1 FAN CYCLE BLK 000-5-5 GND
22 Sheet6-[4,B] 5
WHT 101-2 FAN DEMAND WHT 026-1-2 JOY STK 86
23 Sheet6-[4,B] S127 2
WHT 007-1 FNR-F GRN 055-1 AUX 85
24 3
WHT 008-1 FNR-R S125 GRN 026-3 FT 87a
25 1
WHT 076-4 SW QK CPLR 30
RELAY AUX
26 4
WHT 076-5 SW QK CPLR 87
27
BLU 008-2-2 BU LPS
28
WHT 073-9 AC PRES
29
RED 061-2 RR PWR
30 X98
S316 WHT 025-2 TELE
31 1
WHT 026-4 FRM LDR SW TO
S129 2
WHT 058-8 APS GND WHT 070-1-22 LIGHTNG
16 Sheet6-[2,C] 3 FRAMER/
YEL 62-9-5 ECM IGN BLK 000-3-13 GND WHT 014-1 TILT
S131
15 4
WHT 057-1 APS 5V WHT 026-5 FRM LDR SW LOADER SW
14 Sheet6-[2,C] S121 5
WHT 048-22 APS SIG YEL 062-3-3 F/R AUX SHEET 4
13 Sheet6-[2,C] 6
WHT 048-23 IVS2 BLK 000-3-10 GND
12 Sheet6-[2,C] 7 X27
B TO GRN 055-2 AUX DCMP B
11 8
WHT 148-26 FUEL PUMP CONT
10
ENGINE WHT 073-8-2 AC COMP BLK 000-3-2 GND
9
WHT 48-3 IGN S S110
8
HARNESS RED CABLE 4 CAN HI
7
BLK CABLE 4 CAN LO
6
X56 SHIELD CABLE 4 CAN S
5
S136
BLK 000-3-1 GND

4
S137
SHEET 7 SHIELD CABLE 8 CAN S WHT 026-5 FRM LDR SW 87
3 Sheet6-[5,D] 4
S122
BLK CABLE 8 CAN LO GRN 026-2 FT 30
2 Sheet6-[4,D] 1
RED CABLE 8 CAN HI WHT 026-4 FRM LDR SW 87a
1 Sheet6-[4,D] 3
BLK 000-3-14 GND
BLK 000-3-7 GND

BLK 000-3-19 GND
BLK 000-3-8 GND

GRN 026-2 FT
GRN 079-4 FT
WHT 026-1-1 JOY STK 85

WHT 025-2 TELE
GRN 025-1 AUX
BLK 000-5-7 GND
WHT 014-1 TILT

BLK 000-3-18 GND
GRN 055-1 AUX
GRN 026-3 FT
BLK 000-3-4 GND

BLU 008-2-1 BU WRN
X124 2
Sheet6-[1,B]
BLK 000-5-6 GND 86
5
RL96
RL97
2
1
2
1
2
1
1
2
5
2
3
1
4
AH99
S135
HV102
HV101
HV100
RELAY, SPDT, 12V, 20/40 AMP
86
85
30
87
87a
Sheet6-[6,B]
Sheet6-[3,B]
ALARM, REVERSE
VALVE, FUNCTION SELECT
RELAY, SPDT, 12V, 20/40 AMP
1.MORTH AMERICAN
BLK 000-3-15 GND
MACHINES HAVE
BLK 000-3-3 GND

WHT 008-1-4 FNR-REV
WHT 008-1-1 FNR-R
WHT 008-1-4 FNR-REV
RED 061-2-4 RR PWR

BLK 000-3 GND 10AWG
BLK 000-5 GND 12AWG

BLK 000-4 GND 12AWG
WHT 061-10 COND FAN 12AWG

RED 061-14 PWR 10AWG
WHT 008-1-3 FNR-R
WHT 073-9 AC PRES

WHT 007-3 FNR-F
WHT 007-2 FNR-F
BLK 000-3-23 GND

BLK 000-3-16 GND
WHT 073-8-2 AC COMP

BLK 000-6 GND 12AWG
BLK 000-6 GND 12AWG

X104 CAP
A 2. FOR OTHER MACHINES
A
X264
X274
X182
X149
X116
X226
X305
X103
1
2
3
4
5
1
2
1
1
1
1
2
1
2
1
2
2
1
X103 PLUGS INTO X183

B
A
HV108
HV107
1. BASE NORTH AMERICAN OPTION FRAME

1
2
C
B
A
ON PAGE 8
MACHINES HAVE X163A
2
1
X104
X163A
JUMPER
Sheet6-[3,B]
X306
TO AC FRAME TO TO FRAME
GROUND ENGINE ENGINE GROUND

HARNESS
STUD X180 X151 STUD 2. LSI & OPTION EQUIPED VALVE, F/R DRIVE
YEL
SHEET 4 IP307
MACHINES X226
X268
ALL WIRES ARE 16 GA. UNLESS NOTED OTHERWISE.
PLUGS INTO X222
ON SHEET 8
1 2 3 4 5 6 7 8
MY8750B
G5-18A, 2505H, 25.5

9-11 G5-18A, 2505H, 25.5
MY8760B
A
B
C
D
31
1
1
30
29
28
27
1/2W 1%
26
25
METAL FILM
24
23
Sheet5-[7,D]
Sheet5-[7,D]
Sheet5-[3,A]
22
WHT 102-3 HYD TMP WHT 048-23 IVS2
21
WHT 048-22 APS SIG
SN144 20
WHT 102-2 HYD TMP 499 OHM WHT 102-1 HYD TMP
1 19
BLK 102-4 HYP TMP GND IP155
2 18
TO
WHT 057-1 APS 5V
WHT 058-8 APS GND
WHT 048-22 APS SIG

WHT 048-23 IVS2

X187
17
FRAME
OPTION
16
WHT 057-1 APS 5V
X154
15
1
2
3
4
5
6
7
8
9
11
10
12
WHT 058-8 APS GND

HYD TEMP SENSOR
BLK 000-4-6 GND
BLK 000-4-1 GND
14
11
1
2
3
4
5
6
7
8
9
10
12

13
BLK 000-4 GND 12AWG
X152
12
11
BLK 000-4-5 GND
B 10
2
WHT 101-4 FAN REV

A 9
HV140 8
INTO X152
PLUG X154
2
IS NOT USED
7
6
VALVE, FAN REVERSE
IF OPTION FRAME
WHT 048-23 IVS2
5
WHT 057-1 APS 5V
WHT 058-8 APS GND
4
WHT 048-22 APS SIG
RED CABLE 10 CAN HI
BLK CABLE 10 CAN LO
3
2
BLK 000-4-3 GND WHT 084-3 PWR MGT XMIT

2 1
WHT 101-3 FAN SPD
1 X153
HV141
FAN SPEED
S04
TO
X28
CAB
Sheet5-[1,B]
Sheet5-[1,B]
Sheet5-[1,B]
Sheet5-[1,B]
RL315
BLK 000-4-9 GND
5
86 WHT 52-3-1 HORN A
2
85
3
87a RED 061-2-4 RR PWR
1 Sheet5-[2,A]
30 WHT 52-3 HORN
4 Sheet5-[5,D]
87
3
3
ALARM - OPERATOR PRESENCE
YEL 062-6 IGN

IGN PWR (7-33V) 1 Sheet5-[3,D]
BLK 000-3-7 GND
GROUND 2 Sheet5-[6,A]
WHT 101-1 FAN CYCLE
FAN CYCLE 3 Sheet5-[1,C]
FAN DEMAND 4 Sheet5-[1,C]
NC 5
WHT 052-2 VEH SPD SEN 18AWG
VEH SPEED SENSOR 6
NC 7
WHT 101-3 FAN SPD
FAN CONTROL 8
WHT 101-4 FAN REV
FAN REVERSE 9
WHT 104-1 VAR SP CON
VEH SPEED CONTROL 10
NC 11
WHT 52-3-1 HORN A
ALARM 12
4
4
CO299-J1
WHT 102-1 HYD TMP
+5V OUT 1
WHT 102-3 HYD TMP
HYDRAULIC TEMP 2
BLK 102-4 HYP TMP GND
ANALOG GROUND 3
WHT 052-3 VEH SPD 5V 18AWG
+5V OUT 4 MS265
RED CABLE 8 CAN HI
NC 5 Sheet5-[1,B] 1
POWER MANAGEMENT MODULE

BLK 102-9 VEH SPD GND 18AWG RED CABLE 10 CAN HI
ANALOG GROUND 6 2
RED CABLE 9 CAN HI
NC 7 11
RED CABLE 11 CAN HI
NC 8 12
RED CABLE 9 CAN HI BLK CABLE 8 CAN LO
CANBUS HIGH 9 Sheet5-[1,B] 3
BLK CABLE 9 CAN LO BLK CABLE 10 CAN LO
CANBUS LOW 10 4
WHT 084-3 PWR MGT XMIT BLK CABLE 9 CAN LO
ANALYZER TRANSMIT 11 9
WHT 084-4 PWR MGT RECEIVE BLK CABLE 11 CAN LO
ANALYZER RECEIVE 12 10
3 x 4 Buss Bar
SHIELD CABLE 9 CAN S SHIELD CABLE 8 CAN S

N/C Sheet5-[1,B] 5
CO299-J2 6
7
8
BLK 000-4-2 GND
2
WHT 104-1 VAR SP CON
1
5
5
HV157
VARIABLE SPEED CONTROL

SN207
BLK 102-9 VEH SPD GND 18AWG
GND 3
WHT 052-2 VEH SPD SEN 18AWG
Vout 2
WHT 052-3 VEH SPD 5V 18AWG
SPEED
Vcc 1
SENSOR
SENSOR, SPEED
MS295-3
A
B
BLK 000-3-8 GND SHIELD CABLE 11 CAN S
A Sheet5-[6,A] C C
RED 061-4 CLRSKY BLK CABLE 11 CAN LO
B Sheet5-[4,D] MS295-2 B
RED CABLE 14 CAN HI RED CABLE 14 CAN HI RED CABLE 11 CAN HI
6
6
C A A
BLK CABLE 14 CAN LO BLK CABLE 14 CAN LO
TO
D B MS295-1
SHIELD CABLE 14 CAN S SHIELD CABLE 14 CAN S
E C
F
CLEARSKY
G
YEL 062-7 IGN
H Sheet5-[3,D]
J
X185
ATTACH
DUST CAP
1001106736
7
7
8
8
A
B
C
D
e. Base Frame Schematic "B"
Electrical System
f.
9-12
1 2 3 4 5 6 7 8
TO ALTERNATOR
RELAY, GLOW PLUG
TO AC COMPRESSOR
EC57-B+
ATO FUSE
SHEET 9 GLOW PLUG
7.5A
1
X281
2
1
1
1
1
2
1
2
1
RL60
X111
X37 X39
FC61
RL60-2
RL60-1
MS302
WHT TWISTED PAIR 3 INJ 1 1.5mm²
33 62
Engine Schematic
BLK TWISTED PAIR 3 INJ 1 1.5mm²

16 35 RL148-1
WHT TWISTED PAIR 4 INJ 4 1.5mm²
48 42 RL148-1 PRE WIRED ON ENGINETO EC58-B+ SHEET 9 1
18 37 RL148-2
D WHT TWISTED PAIR 5 INJ 3 1.5mm² D
32 38 RL148-2 PRE WIRED ON ENGINE TO EC58 SHEET 9 1
2 61 RL148
YEL 69-9-5-4 IGN

WHT TWISTED PAIR 6 INJ 2 1.5mm² WHT 048-73 ST SOL 0.75mm²
46 40 1
BLK TWISTED PAIR 6 INJ 2 1.5mm² GRY 048-28 ST RLY (-) 0.75mm²
3 41 2
WHT 078-8-2 AC COMP

WHT TWISTED PAIR 7-1 MPROP 1.5mm²
5 20
ST RELAY PIA ENGINE
BLK TWISTED PAIR 7 MPROP 1.5mm²

4 19
Electrical System
WHT TWISTED PAIR 8 CAMSHAFT 0.75mm²

37 14
WHT 048-22 GLOW PLG 8AWG

BLK TWISTED PAIR 8 CAMSHAFT 0.75mm²
RED 001-11 GLOW PLUG 8AWG

WHT 048-22-4 GLOW PLG 8AWG
WHT 048-22-3 GLOW PLG 8AWG
52 13
BLK 000-40-2 GP RLY 0.75mm²

GRY 048-22-1 GP SENSE 0.75mm²
WHT TWISTED PAIR 9 CRANKSHAFT 0.75mm²
WHT 048-22-2 GP SENSE 12AWG

WHT 048-22-2 GP SENSE 12AWG
001-11-1 FUSIBLE LINK 12 GA

39 15
BLK TWISTED PAIR 9 CRANKSHAFT 0.75mm²
TO 54 21
WHT 100-1 FUEL RAIL PRES 0.75mm²
ECM 7 32 TO
WHT TWISTED PAIR 10 EGR + 1.5mm²
19 47
BLK TWISTED PAIR 10 EGR - 1.5mm² ENGINE
20 48
WHT 100-2 V REF 0.75mm² RED 001-11 GLOW PLUG 8AWG S117 TO
24 22
WHT 100-3 FUEL RAIL PRES 0.75mm² S312 RED 061-14 PWR 10AWG
25 31 1 FRAME X149
WHT 100-4 FUEL RAIL PRES 0.75mm²
26 25 X151
WHT 100-5 BOOST PRESS/TEMP 0.75mm² SHEET 5
27 29
WHT 100-6 COOLING TEMP 0.75mm² BLK 058-8 APS GND 0.75mm²
28 24 16
WHT 101-2 SIG RTN 0.75mm² YEL 62-9-5 IGN
29 27 15
WHT 100-7 BOOST PRESS/TEMP 0.75mm² S51 YEL 057-1 APS 5V 0.75mm²
40 28 14
WHT 106-3-1 BOOST PRESS/TEMP 0.75mm² GRY 048-22 APS SIG 0.75mm²
43 23 13
WHT 106-4-1 OIL PRESS 0.75mm² WHT 048-23 IVS2 0.75mm²
44 26 12
WHT 106-1 FUEL LOW PRESS 0.75mm²
59 17 11
WHT 106-5 EGR SIG 0.75mm² WHT 148-26 FUEL PUMP CONTROL 0.75mm²
60 46 10 TO
GRY 048-22-1 GP SENSE 0.75mm² WHT 102-2 EGR 5V 0.75mm² WHT 078-8-2 AC COMP
23 50 9
BLK 000-40-2 GP RLY 0.75mm² WHT 104-2 EGR GND 0.75mm² GRY 048-10 IGN S 0.75mm² FRAME X124
35 51 8
RED CABLE 5 CAN HI 18AWG SHEET 5
C 57 7 C
BLK CABLE 5 CAN LO 18AWG
58 6
SHIELD CABLE 5 CAN S 18AWG
59 5
60 4
3
2
RED CABLE 7 CAN HI 18AWG
1
X56
TO
2 FRAME X182
1 SHEET 5
X180
PLUG EC169
X38 1
RED 061-14-1 PWR 2.5mm² BLK 000-63 GND 14AWG M TO X319
1 2
BLK 000-52-1 GND 2.5mm² S48 SHEET 7
GENERIC
2 EC169
FUEL PUMP
RED 061-14-3 PWR 2.5mm²

5
BLK 000-52-3 GND 2.5mm² SHIELD CABLE 15 CAN S
6 NC
WHT 105-2 COOLANT LVL 0.75mm² S49 YEL 62-9-5-3 IGN
13 A
WHT 048-23 IVS2 0.75mm² BLK 000-86 GND 16AWG
16 B
GRY 048-28 ST RLY (-) 0.75mm²
28 C
WHT 148-29 COOLANT 0.75mm²
29 D
GRY 048-10 IGN S 0.75mm²
35 E
WHT 102-2 EGR 5V 0.75mm² BLK CAN LO DIAGNOSTIC
44 F
BLK CAN 2 LO
45 G
YEL 057-1 APS 5V 0.75mm² S54 RED CAN 2 HI
46 H
52 S55 J
B BLK CABLE 15 CAN LO B
53 K
54 L
WHT 103-2 WATER/FUEL 0.75mm² RED CAN HI
57 M
WHT 106-1 FUEL LOW PRESS 0.75mm²
61 X46
BLK 058-8 APS GND 0.75mm²
TO 62 X62
GRY 048-22 APS SIG 0.75mm² RED CAN 3 HI
63 A A
ECM WHT 103-1 WATER/FUEL 0.75mm² BLK CAN 3 LO
64 B B
RED CABLE 15 CAN HI
75 C C
76 X45
78 X156 X158
WHT 104-2 EGR GND 0.75mm² RED CAN 4 HI
82 A A
WHT 106-5 EGR SIG 0.75mm² BLK CAN 4 LO
85 B B
86 C C
WHT 105-1 SIG RTN 0.75mm² S292
87
62-9-5-1 YEL 0.75mm²
88
93
BLK 000-65 GND 12AWG
94 TO
RED 061-14-2 PWR 2.5mm²
3 X43
BLK 000-52-2 GND 2.5mm² ENGINE
4 1
WHT 148-15-68 CLUTCH 0.75mm² BLK 000-52 GND 10AWG GROUND
68
WHT 148-15-68 CLUTCH 0.75mm²
15
WHT 148-26 FUEL PUMP CONTROL 0.75mm²
26
WHT 048-73 ST SOL 0.75mm²
BLK 000-64 GND

BLK CAN LO
RED CAN HI


73
NC
8
7
6
5
9
4
3
2
1
MS283
10
12
11
A A
WHT 105-1 SIG RTN 0.75mm²

3 x 4 Buss Bar
WHT 148-29 COOLANT 0.75mm²


WHT 103-1 WATER/FUEL 0.75mm²
WHT 105-2 COOLANT LVL 0.75mm²
WHT 103-2 WATER/FUEL 0.75mm²
X40
X319
X192
1
1
1
2
1
2
1
2
3
4
EC322-
EC322+
PLUG X319
WATER/FUEL COOLANT LEVEL ALL WIRES ARE 16 GA. UNLESS NOTED OTHERWISE.
TO EC169
M
SHEET 7
FUEL PUMP
1 2 3 4 5 6 7 8
MY8770B
G5-18A, 2505H, 25.5

9-13 G5-18A, 2505H, 25.5
MY8780B
A
B
C
D
TO
TO
X28
CAB
X152
MAIN
BASE
FRAME
11
11
12
10
9
8
7
6
5
4
3
2
1
21
20
15
31
30
29
28
27
26
23
22
19
18
17
16
2
14
12
25
24
1
13
10
5
9
7
4
8
3
6
RL193
WHT 105-1 FNR L/O
X187
X188
5
86 BLK 000-9-13 GND
2
85
3
87a BLK 000-3-3 GND
1
30 BLK 000-3-23 GND
1
1
4
87
BLK LSI 2 LSI
BLU LSI PWR
SHIELD LSI S
RED LSI 1 LSI
F/R SAFETY LOCK OUT

WHT 048-23 IVS2
WHT 048-23 IVS2
WHT 057-1 APS 5V

WHT 057-1 APS 5V
WHT 071-16 BU LP
WHT 008-2-2 BU LP
BLK 000-3-23 GND

WHT 048-22 APS SIG
WHT 058-8 APS GND

WHT 077-3 RH STOP
WHT 058-8 APS GND

WHT 071-5-1 LH TRN
WHT 048-22 APS SIG
2
WHT 071-6-1 RH TRN
WHT 071-12 LH SD LP
RED CABLE 13 CAN HI

WHT 071-11 RH SD LP
BLK CABLE 13 CAN LO

WHT 107-1 SEAT SW 2
WHT 106-1 SEAT SW 1
BLK 000-3-3 GND

WHT 071-7 RH HDLP HI
1
WHT 071-9 RH HDLP LO

WHT 071-10 LH HDLP LO
WHT 085-1 LSI LP 18AWG
WHT 078-3 STR PRES SW

WHT 076-7 JS C/O 18AWG
X222
TO BASE
WHT 076-9 LSI O/R 18AWG
WHT 076-8 LSI C/O 18AWG
FRAME X226
YEL 062-23 IGN

8
YEL 062-22 IGN
7
LOW
6
YEL 062-25 IGN
5 6
YEL 062-20 IGN 18AWG WHT 071-10 LH HDLP LO
4 2
YEL 062-25 IGN 18AWG WHT 071-8 LH HDLP HI HIGH
3 3
1 x 8 Buss Bar
YEL 062-24 IGN WHT 071-12-1 LH SD LP

2 4
YEL 062-19 IGN WHT 071-5-2 LH TRN
1 5
BLK 000-9-4 GND SIDE
MS189 1
LB160
LIGHT, LEFT HEADLIGHT
2
TURN
ON PAGE 5
2
MACHINES X184
LOW
PLUGS INTO X83
FOR CE AND AUS
YEL 062-19 IGN

2 6
WHT 080-1 FCN L/O 18AWG WHT 071-9 RH HDLP LO
1 2
WHT 071-7 RH HDLP HI HIGH
X184 3
WHT 071-11-1 RH SD LP
4
YEL 062-24 IGN WHT 071-6-2 RH TRN
C 5
WHT 007-3 DR FWD 18AWG BLK 000-9-3 GND SIDE
B 1
WHT 008-1-3 DR REV 18AWG
A LB161
X183
LIGHT, RIGHT HEADLIGHT
TURN
ON
S203
X103
X183
INTO
S201
S199
PLUGS
PAGE 5
S202
S200
S194
STOP
7
X294 6
YEL 062-25 IGN WHT 071-16-1 RH STOP
1 5
WHT 084-2 RECEIVE 18AWG WHT 071-6-3 RH TRN TURN
LSI
2 4
3
WHT 084-1 TRANSMIT 18AWG WHT 008-2-3 RH BU

3 3
RS-232
BLK 000-9-15 GND WHT 071-11-2 RH TAIL

4 2
BLK 000-10-4 GND BACK
1
DIAGNOSTIC
LB162
LIGHT, TAIL LIGHT, RIGHT
3
IGN PWR (7-33V) 1
BLK 000-9-14 GND 18AWG TAIL
GROUND 2
WHT 081-2 BM STATE 2 18AWG
BOOM TELE STATE 2 3
WHT 008-1-3 DR REV 18AWG
DRIVE REVERSE 4
WHT 076-8 LSI C/O 18AWG
LSI CUTOUT 5
WHT 076-7 JS C/O 18AWG STOP
JS CUTOUT 6 7
WHT 105-1 FNR L/O
BLK CABLE 13 CAN LO

RED CABLE 13 CAN HI
F/R DRIVE CUTOUT 7 6

WHT 071-16-3 LH STOP
NC 8 5
WHT 071-5-3 LH TRN TURN
NC 9 4
B
A
C
MS114-1
WHT 008-2-4 LH BU
NC 10 3
WHT 071-12-2 LH TAIL
NC 11 2
BLK 000-10-3 GND BACK
NC 12 1
CO300-J1 LB163
LIGHT, TAIL LIGHT, LEFT
NC 1
TAIL
A
B
C
A
B
C
NC 2
NC 3
LSI REMOTE MODULE

MS114-3
MS114-2
WHT 089-1 MOD CONFIG 18AWG

4
+5V OUT 4
WHT 089-1 MOD CONFIG 18AWG
MODULE CONFIG 5
NC 6
WHT 107-1 SEAT SW 2
SEAT SWITCH 2 7
WHT 071-5-4 LH TRN
RED CAN 2 HI
RED CAN 1 HI
BLK CAN 2 LO
BLK CAN 1 LO
NC 8 1
RED CAN 1 HI
CANBUS HIGH 9 MS164-1
BLK CAN 1 LO
CANBUS LOW 10 1
ANALYZER TRANSMIT 11 MS164-2
4
BLK 000-10-2 GND
ANALYZER RECEIVE 12 1
CO300-J2 MS164-3
S190 WHT 071-6-4 RH TRN
1
MS164-4
YEL 062-20 IGN 18AWG WHT 071-11-3 RH TAIL
IGN PWR (7-33V) 1 1
GROUND 2 MS164-5
WHT 076-9 LSI O/R 18AWG WHT 071-16-2 STOP
LSI OVERRIDE 3 1
WHT 025-2 TELE CMD 18AWG
TELESCOPE COMMAND 4 MS164-6
WHT 007-3 DR FWD 18AWG WHT 071-12-3 LH TAIL
DRIVE FORWARD 5 1
WHT 081-1 BM STATE 1 18AWG
BOOM TELE STATE 1 6 MS164-7
TRAILER CONNECTOR
WHT 082-1 LFT MODE 18AWG

LIFT MODE VALVE 7
WHT 082-2 LFT DWN 18AWG
S195
LIFT DOWN VALVE 8

WHT 083-1 TELE OUT 18AWG
TELE OUT VALVE 9
5
5
WHT 083-2 TELE MODE 18AWG WHT 071-12-4 LIC LP
TELE MODE VALVE 10 1
WHT 080-1 FCN L/O 18AWG BLK 000-10-1 GND
FUNCTION LOCKOUT 11 2
WHT 085-1 LSI LP 18AWG
LSI PASSIVE LAMP 12 LB165
LIGHT, LICENSE
CO301-J1
WHT 086-1 +5V PRES SEN 18AWG
+5V OUT 1
WHT 087-1 PRS SENSE 18AWG
PRESSURE SENSOR 2
BLK 088-1 AGND 18AWG
LSI MAIN MODULE

ANALOG GROUND 3
NC 4
WHT 078-3 STR PRES SW
NC 5 1
BLK 000-9-12 GND
NC 6 2
WHT 106-1 SEAT SW 1
SEAT SWITCH 1 7 SN172-1
NC 8
RED CAN 2 HI
SW, PRES, STEER
CANBUS HIGH 9
BLK CAN 2 LO
CANBUS LOW 10
WHT 084-1 TRANSMIT 18AWG SHIELD LSI S
ANALYZER TRANSMIT 11 NC
WHT 084-2 RECEIVE 18AWG RED LSI 1 LSI
ANALYZER RECEIVE 12 A SEN1 VE-
BLU LSI PWR
CO301-J2 B SEN VE+
BLK LSI 2 LSI
C SEN2 VE-
LSI SENSOR
SN297
6
6
S196
BLK 000-9-7 GND
BLK 000-9-6 GND
7
S197
S198
X170 X160
YEL 062-23 IGN YEL 062-23
1 1
7
BLK 000-10-5 GND BLK 000-10-5
2 2
WHT 081-1 BM STATE 1 18AWG WHT 081-1
3 3
YEL 062-22 IGN YEL 062-22
4 4
BLK 000-10-6 GND BLK 000-10-6
5 5
WHT 081-2 BM STATE 2 18AWG WHT 081-2

6 6
BLK 000-9 GND 10AWG
BLK 088-1 AGND 18AWG
WHT 025-2 TELE CMD 18AWG

WHT 087-1 PRS SENSE 18AWG
WHT 083-1 TELE OUT 18AWG
WHT 086-1 +5V PRES SEN 18AWG

BLK 000-9-11 GND
WHT 083-2 TELE MODE 18AWG
BLK 000-9-9 GND
WHT 082-2 LFT DWN 18AWG
WHT 082-1 LFT MODE 18AWG
BLK 000-10 GND 10AWG

BLK 000-9-8 GND
BLK 000-9-10 GND

8
X178
X179
2
1
3
2
1
1
2
1
2
1
2
1
2
1
SN177
HV176
HV175
HV174
HV173
YEL 062-23
YEL 062-22
WHT 081-1
BLK 000-10-5
BLK 000-10-6
WHT 081-2
FOR REFERENCE ONLY

SN44
SIG
3
2
1
3
2
1
SN178
GND
PWR
8
PRESSURE SENSOR
STUD
SHEET 5
SIG
SIG
FRAME
TELE MODE VLV TELE OUT VALVE LIFT DOWNVALVE LIFT MODE VALVE
GND
GND
PWR
PWR
INTO HV102
GROUND
X178 MAY PLUG

BOOM PROX BOOM PROX
A
B
C
D
g. Option Frame Schematic
Electrical System
9-14
1 2 3 4 5 6 7 8
D D
Electrical System
h. Cables and Boom Schematic
WORKLIGHT, BOOM LEFT

051-5-2 BLU
X90 1
051-5 BLU S91 051-5-1 BLU
1 2
000-4-3 BLK 000-4-8 BLK
2 LB87
S92
000-4-7 BLK
1
2
LB88
WORKLIGHT, BOOM RIGHT
C C
X93 HV86
BOOM CABLE YEL
1 1
BOOM CABLE GRN
2 2
BOOM CABLE WHT
ENGINE 3
BOOM CABLE BRN
4
BLOCK
GROUND BATTERY, 930 CCA
VALVE, QUICK COUPLER
1
1
1
X191
BT70-
BT70+
RED 001-2 BATT
BLK 000-2 GND 2/0AWG

BLK 000-1 BATT NEG 2/0AWG
RED 001-1 BATT POS 2/0AWG
Sheet5-[3,D]
B B
ENGINE
GROUND
1 STUD
FRAME
X181
GROUND
1
STUD BLK 000-1 BATT NEG 2/0AWG
1
X44
X304
150A
IP105
BLK 000-1 GND 12AWG
EC58 PRE WIRED ON ENGINE TO RL148-2 SHEET 7

CASE GROUND
RED 001-3 FUSE LNK 2AWG

RED 001-3-1 FUSE LNK 2AWG
RED 001-1 BATT POS 2/0AWG
A A
X109
1
1
1
1
EC58
X106
EC58-B-
EC58-B+
X303
1
1
1
1
EC57-W
EC57-B+ 1
EC57-D+
W
B+
D+
M
ALTERNATOR A/C COMP
ALTERNATOR STARTER GROUND
1 2 3 4 5 6 7 8
MY8790B
G5-18A, 2505H, 25.5

Electrical System
9.5 ENGINE START CIRCUIT the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
9.5.1 Starter engine.
3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section d, “Base Frame Schematic "A".”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1 1. Park the machine on a firm, level surface, level the
place the transmission control lever in (N)
MY8810
NEUTRAL, engage the park brake and shut the
The starter (1) is located on the right side of the engine engine OFF.
attached to the bell housing. Note: Park the machine on blocks to allow proper
access under the machine.
a. Testing the Starter on the Engine
Note: The operator must be sitting on the seat to enable switch and the steering wheel, stating that the
the starting circuit. machine should not be operated.
If the starter does not engage when the ignition key 3. Open the battery and engine covers. Allow the
switch is turned, check the following: engine to cool.
1. The transmission control lever is in (N) NEUTRAL 4. Properly disconnect the battery.
and the park brake switch is set. 5. Remove the belly pan.
2. The main fuse may be blown, requiring replacement. 6. Disconnect and remove the air intake hose.
Check for the cause of the blown fuse.
7. Disconnect and remove the exhaust tube between
3. There may be a defect in the ignition key switch, the turbocharger and muffler.
ignition wiring or starter solenoid.
8. Disconnect the two connectors on the ECM.
4. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables. 9. Disconnect the diagnostic plug from the air cleaner
bracket and remove the nylon ties securing the wire
5. Check for broken wiring and damaged insulation on harness to the rear fender.
the wiring. Replace all broken or damaged wiring.
10. Loosen and remove the side skirt on the engine pod.
6. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten 11. Loosen and remove the rear fender along with the
all connections. air cleaner.
7. If the starter still does not operate after these checks 12. Disconnect the plug from the bracket and remove
have been performed, check the starting circuit. the bracket from the engine.
13. Loosen and remove the turbocharger drain tube.
b. Starter Circuit Checks 14. Plug or cap the turbocharger drain tube openings to
1. Check wires and connections for looseness, prevent dirt and/or debris from entering the engine.
corrosion, damage, etc. Note: Replace the o-ring at the base of the turbocharger
2. If a “whirring” noise is heard but the engine does not drain tube during re-assembly.
turn over, the starter is spinning but not engaging the
15. Remove the positive cables from the starter.
flywheel. The starter drive or solenoid that pushes
G5-18A, 2505H, 25.5 9-15
Electrical System
16. Remove the top bolt securing the starter to the 8. Install the previously removed rear fender along with
engine. the air cleaner to the engine pod.
Note: Use a 13mm deep well socket on a 6 in extension 9. Install the previously removed side skirt on the
to remove the top starter mounting bolt. engine pod.
17. Remove the bottom bolt securing the starter to the 10. Connect the diagnostic plug to the air cleaner
engine. bracket and securing the wire harness to the rear
fender.
18. Remove the starter (1) from the machine.
11. Connect the two connectors on the ECM.
d. Starter Cleaning and Drying 12. Install the previously removed exhaust tube between
the turbocharger and muffler. Tighten as required.
1. While the starter is being removed, wipe away any
grease or dirt that has accumulated around the 13. Install the previously removed air intake hose.
starter mounting opening. Tighten as required.
2. If reinstalling the starter, clean the exterior of the 14. Install the previously removed belly pan. Tighten as
starter with an approved solvent. DO NOT submerse required.
the starter or allow the solvent to contact the starter 15. Properly connect the battery.
bushings.
3. Dry the starter with a clean, lint-free cloth.
e. Starter Periodic Maintenance
A starter requires no routine maintenance beyond the
occasional inspection of the electrical connections, which
must be clean and tight.
Note: DO NOT disassemble the starter. The starter is
not serviceable and must be replaced in its entirety, if
defective.
f. Starter Installation
1. Position the starter in its mounting opening on the
flywheel housing. Install the bottom bolt securing the
starter to the flywheel housing.
Note: Do Not tighten the bottom bolt until the top bolt is
installed.
2. Using tape or a magnetic socket, secure the top
starter mounting bolt to the socket. Install the top
bolt securing the starter to the flywheel housing.
3. Tighten and torque the starter mounting bolts to
25Nm (18 lb-ft).
4. If necessary, install a new o-ring on the turbocharger
drain tube.
5. Remove the plugs or caps from the turbocharger
drain tube openings.
6. Install the turbocharger drain tube to the engine.
Torque the turbocharger drain tube mounting bolt to
8.5 Nm (7 lb-ft).
7. Install the previously removed bracket to the engine
and connect the electrical connector.
9-16 G5-18A, 2505H, 25.5

Electrical System
9.6 CHARGING CIRCUIT

Before using a battery charger, an attempt can be made 2
to recharge the battery by jump-starting the machine.
(Refer to the appropriate Operation & Safety Manual.)
Allow the engine to run, which will enable the alternator to
charge the battery.
If the cab gauge shows an alternator issue, perform the
following checks:
1. Check the all battery cable connections at the
battery, and verify that they are clean and tight.
2. Check the external alternator wiring and
connections, and verify that they are in good 3
condition.
MY8820
3. Check the fan belt condition and tension.
4. Verify that the alternator mounting hardware is tight. 6. Loosen the top mounting bolt (2), but don’t remove it
5. Run the engine and check the alternator for noise. A at this time. This will allow the alternator to swivel
loose drive pulley, loose mounting hardware, worn or during belt removal.
dirty internal alternator bearings, a defective stator 7. Loosen the belt tensioning adjustment bolt (3) at the
or defective diodes can cause noise. Replace a worn bottom of the alternator to loosen the fan drive belt.
or defective alternator.
8. Remove the fan drive belt from the alternator.
9.6.1 Alternator 9. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
a. Alternator Removal 10. While supporting the alternator with one hand,
1. Park the machine on a firm, level surface, level the remove the upper mounting hardware from the
machine, fully retract the boom, lower the boom, upper alternator mount. Remove the alternator from
place the transmission control lever in (N) the machine.
engine OFF. b. Alternator Installation
2. Place a Do Not Operate Tag on both the ignition key 1. Position the alternator and align with the upper
switch and the steering wheel, stating that the alternator mount on the engine bracket. Insert the
machine should not be operated. upper mounting hardware through the alternator
3. Open the battery and engine covers. Allow the mount. DO NOT tighten completely at this time.
engine to cool. 2. Align the lower alternator mount hole with the lower
4. Properly disconnect the battery. mounting bracket on the engine, and insert the lower
mounting capscrew. Be sure to leave enough room
5. Label and disconnect the wires attached to the to attach the drive belt.
alternator.
3. Attach the fan drive belt to the alternator.
Note: Record how the alternator is installed to ensure
4. Adjust the lower belt tensioning bolt to remove
correct installation later.
excessive slack from the drive belt. Check for proper
fan belt deflection.
5. Reattach the previously labeled electrical wires to
the alternator.
G5-18A, 2505H, 25.5 9-17

Electrical System
9.7 ELECTRICAL SYSTEM a. Removal

COMPONENTS
9.7.1 Back-up Alarm

NOTICE
The back-up alarm is located at the rear of the machine. Static electricity can cause damage to the operator’s
gauge. Avoid any manner of touching (hands, tools,
When the park brake is released and the transmission etc.) the printed circuit boards and terminals.
shift control switch (transmission control lever) is shifted Disconnect the battery negative (-) cable at its battery
to the (R) REVERSE position, the back-up alarm will terminal before beginning this procedure. Failure to
automatically sound. comply can result in damage and/or malfunction of the
CE Only - gauge.
Place the transmission control lever in (R) REVERSE to 1. Park the machine on a firm, level surface, level the
test the back-up alarm. The back-up alarm must not machine, fully retract the boom, lower the boom,
sound when the transmission control lever is in (N) place the transmission control lever in (N)
NEUTRAL or (F) FORWARD. Also, with the ignition key NEUTRAL, engage the park brake and shut the
switch in the RUN position, the back-up alarm will sound engine OFF.
when the transmission control lever is shifted into the (R)
REVERSE position. 2. Place a Do Not Operate Tag on both the ignition key
a. Disassembly machine should not be operated.
DO NOT disassemble the back-up alarm. Replace a
engine to cool.
defective or faulty alarm with a new part.
b. Inspection and Replacement 5. Remove the screws holding the instrument panel to
Inspect the wiring harness connector and alarm terminals the dash.
for continuity and shorting. Test the alarm by turning the 6. Slide the instrument panel out of the operator
ignition key switch to the RUN position and shifting the console.
transmission control lever into the REVERSE position. 7. Disconnect the wiring harnesses from the rear of the
The alarm should sound. gauge.
Replace a defective or faulty alarm with a new part. 8. Remove the two wing nuts and bracket securing the
gauge to the instrument panel.
9.7.2 Gauge Cluster
b. Installation
1. Position the gauge in the instrument panel and
secure with the previously removed bracket and
wing nuts.
2. Connect the wiring harnesses to the rear of the
gauge.
MY8830 3. Position the instrument panel in the operator
console.
4. Secure to the panel with four previously removed
screws.
9-18 G5-18A, 2505H, 25.5

Electrical System
9.8 WINDOW WIPER/WASHER b. Disassembly

DO NOT disassemble the motor. The motor is not
9.8.1 Windshield Wiper Motor serviceable. Replace motor if found to be defective.
c. Inspection and Replacement

Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
d. Installation and Testing

1. Install all required hardware to the motor assembly.
2. Align motor with the mounting holes and bolt the
motor to the mounting bracket.
3. Connect the wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with the flat on the
MY2220
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
a. Removal
4. Connect the cab harness connectors to windshield
Note: It may be necessary to remove several hydraulic wiper motor connectors.
hoses from under the dash in order to remove and install 5. Properly connect the battery.
the wiper motor housing.
6. Turn ignition key switch to the RUN position, and
1. Park the machine on a firm, level surface, level the operate windshield wiper in both LOW and HIGH
machine, fully retract the boom, lower the boom, speeds to ensure proper operation and that correct
place the transmission control lever in (N) wiper travel is achieved.
7. Install right side defroster hose to the dash panel
engine OFF.
hose connector.
8. If previously removed, install hydraulic hoses under
the dash.
9. Install the lower dash panel.
engine to cool. 10. Close and secure the battery and engine covers.
4. Properly disconnect the battery. 11. Remove the Do Not Operate Tags from both the
5. Remove the lower access panel below the
instrument panel.
6. Disconnect the right side defroster hose from dash
panel hose connector.
7. Disconnect the cab harness connectors from the
wiper motor.
8. Remove the linkage attached to the wiper motor.
9. Loosen and remove the four bolts holding the wiper
motor to the mounting bracket.
Note: Retain all hardware removed from the wiper
assembly for possible reuse on the replacement motor
housing.
10. Remove the motor from the inside of the cab.
G5-18A, 2505H, 25.5 9-19

Electrical System
9.8.2 Rear Window or Roof Wiper Motor d. Installation and Testing

(if equipped) 1. Install all required hardware to the motor assembly.
2. Align motor with the mounting holes and bolt the
motor to the proper location.
Note: Align the wiper to ensure wiper stroke covers
window area, and it does not swipe past the glass area.
3. Connect the cab harness connectors to wiper motor
connectors.
4. Install rear wiper cover.
5. Install wiper arm assembly.
7. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
wiper travel is achieved.
MY2520
8. Install right side defroster hose to the dash panel
a. Removal hose connector.
9. If previously removed, install hydraulic hoses under
the dash.
place the transmission control lever in (N) 10. Install the lower dash panel.
NEUTRAL, engage the park brake and shut the 11. Close and secure the battery and engine covers.
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key ignition key and the steering wheel.
machine should not be operated. 9.8.3 Windshield Washer Reservoir
3. Open the battery and engine covers. Allow the and Pump
engine to cool. The windshield washer motor and reservoir is located in
4. Properly disconnect the battery. the dash area as a unit and cannot be serviced
5. Remove the wiper arm assembly. separately.
6. Loosen and remove the rear wiper cover. a. Removal

7. Disconnect the cab harness connectors from the
wiper motor.
8. Remove the wiper motor in question. place the transmission control lever in (N)
Note: Retain all hardware removed from the wiper NEUTRAL, engage the park brake and shut the
assembly for possible reuse on the replacement motor engine OFF.
housing. 2. Place a Do Not Operate Tag on both the ignition key
b. Disassembly machine should not be operated.
DO NOT disassemble the motor. The motor is not 3. Open the battery and engine covers. Allow the
serviceable. Replace motor if found to be defective. engine to cool.
5. Remove the nuts and the lockwashers from the
Inspect the motor terminals for continuity. Replace motor washer mounting studs.
if continuity is not found. 6. Pull the washer reservoir out and away from the
mounting studs.
9-20 G5-18A, 2505H, 25.5

Electrical System
7. Rotate the washer reservoir, label and remove the 9.9 CAB HEATER/AC AND FAN
cab harness connectors from the washer reservoir
connectors.
9.9.1 Cab Heater/AC Controls
8. Remove the windshield washer hoses from the
reservoir. Note: If the suspect component is found to be within the
heater box, the heater box must be removed as a
b. Disassembly complete unit and replaced. For additional information
on the removal and installation of the heater box, refer to
DO NOT disassemble the pump. The pump is not Section 4.4.10, 4.4.10. “Heater/Defroster System (If
serviceable. Replace pump if found to be defective. Equipped).”
c. Installation and Testing The cab heater controls are located to the right of the
seat. The control panel consists of a variable speed fan
1. Connect the windshield washer hoses to the control knob and a temperature control knob.
reservoir.
2. Connect the cab wiring harness connectors to the a. Cab Heater Controls Removal
reservoir connectors. Note: After determining which control knob is not
3. Install the reservoir tank onto the mounting studs. functioning, remove only the suspect control knob. In
4. Install the lockwashers and nuts and secure. order to remove either knob, the cab heater and fan
control panel must be removed from the dash panel.
5. Fill the washer fluid reservoir with washer fluid.
7. Turn the ignition key switch to the RUN position and place the transmission control lever in (N)
press the washer switch. Verify that fluid is sprayed NEUTRAL, engage the park brake and shut the
on the windshield. engine OFF.
8. Close and secure the battery and engine covers. 2. Place a Do Not Operate Tag on both the ignition key
9. Remove the Do Not Operate Tags from both the switch and the steering wheel, stating that the
ignition key and the steering wheel. machine should not be operated.
engine to cool.
5. Remove the screws and backing locknuts from the
cab heater and fan control panel.
6. Pull the control panel out from the dash panel, and if
removing variable speed fan control, remove the cab
harness connector.
7. If removing the temperature control knob, disconnect
the cable connector and remove control knob.
8. Remove the setscrew from the variable speed fan
control knob or temperature control knob.
9. Remove the hex locknut from the suspect control
shaft.
10. Remove the control from the panel.
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
G5-18A, 2505H, 25.5 9-21

Electrical System
c. Installation and Testing 9.10 SWITCHES, SOLENOIDS AND

1. Check that the variable speed fan control is in the SENDERS
OFF position.
2. If installing the temperature control, attach the cable 9.10.1 Ignition Key Switch
connector to the back of the control.
a. Ignition Switch Removal
3. Insert the control shaft through the panel, ensuring
that the knob is in the VERTICAL position. 1. Park the machine on a firm, level surface, level the
4. Install the hex locknut on the shaft and tighten. machine, fully retract the boom, lower the boom,
5. Connect the cab harness connector to the variable NEUTRAL, engage the park brake and shut the
speed fan control. engine OFF.
6. Install the control panel screws. 2. Place a Do Not Operate Tag on both the ignition key
7. Install the setscrew, securing the knob to the control. switch and the steering wheel, stating that the
8. Properly connect the battery. machine should not be operated.
9. Turn the ignition key switch to the RUN position and 3. Open the battery and engine covers. Allow the
fan switch. Verify that the fan operates at variable engine to cool.
speeds. 4. Properly disconnect the battery.
10. Close and secure the battery and engine covers. 5. Remove lower dash panel.
11. Remove the Do Not Operate Tags from both the 6. Remove the hex nut securing the ignition key switch
ignition key and the steering wheel. to the dash.
7. Reach up under the dash to work the ignition switch
and wiring out of the mounting hole.
8. Disconnect the ignition switch connectors from the
cab harness connectors, and remove the switch
from the machine.
b. Disassembly
DO NOT disassemble the ignition switch. Replace a
defective switch with a new part.

To determine the proper operation of the ignition key
switch, test the wires on the back of the switch for
continuity with an ohmmeter.
MY2340
Test the ignition key switch for continuity, by checking

from the BAT terminal (1) to each of the remaining
terminals in their corresponding switch position.
If all terminals do not show proper continuity, replace the
ignition switch.
9-22 G5-18A, 2505H, 25.5

Electrical System
d. Ignition Switch Installation d. Switch Installation

1. Connect the ignition key switch to the cab harness 1. Connect the switch to the cab harness connector.
connectors. 2. Position the switch over the rectangular switch bezel
2. Reach up and under the dash to work the ignition and snap into position.
switch into the ignition switch-mounting hole on the 3. Replace the frame into the dash.
lower right side of the dash.
3. Align the ignition switch so that when it is in the OFF
position, the key slot is positioned vertically (straight 5. Start the machine and check the replaced switch for
up and down). Install the hex nut securing the proper function.
ignition switch to the dash. DO NOT overtighten. 6. Close and secure the battery and engine covers.
4. Install the lower dash panel. 7. Remove the Do Not Operate Tags from both the
5. Properly connect the battery. ignition key and the steering wheel.
6. Turn the ignition key switch to the START position to 9.10.3 Fuel Level Indicator and Fuel Level
verify proper operation. Sender
8. Remove the Do Not Operate Tags from both the a. Fuel Level Indicator Testing
ignition key and the steering wheel. 1. The fuel level sender wiring harness leads can be
accessed from the top of the fuel tank. Disconnect
9.10.2 Dash Switches the fuel level sender wiring harness leads. With the
help of an assistant, touch both harness leads
a. Switch Removal together.
1. Park the machine on a firm, level surface, level the 2. From the operator’s cab, have the assistant turn the
machine, fully retract the boom, lower the boom, ignition key switch to the RUN position. DO NOT
place the transmission control lever in (N) start the engine. Observe the fuel level indicator
NEUTRAL, engage the park brake and shut the needle on the operator’s instrument cluster.
engine OFF. 3. Turn the ignition key switch to the OFF position. The
2. Place a Do Not Operate Tag on both the ignition key fuel level indicator needle should return to the
switch and the steering wheel, stating that the EMPTY position.
3. Open the battery and engine covers. Allow the b. Fuel Level Circuit Tests
engine to cool. If the fuel level indicator is suspected of giving a false
4. Properly disconnect the battery. reading, perform the following checks:
5. Pull the frame out of the dash, disconnect the 1. If the fuel level indicator needle does not move,
harness connector to the switch in question and check the fuel tank for fuel.
push the switch out of the frame. 2. Check for loose or defective wiring, faulty ground
connections or corrosion on the fuel tank sender and
b. Disassembly wiring lead.
DO NOT disassemble the dash switch. Replace a 3. If the fuel level indicator needle does not move after
defective switch with a new part. the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
c. Inspection and Replacement flowing from the ignition switch to the fuel level
sender.
Inspect the switch terminals for continuity in both the
engaged and disengaged positions. Replace a defective 4. If the fuel level indicator does not move and a faulty
or faulty switch with a new switch. or defective fuel level sender in the fuel tank has
been ruled out and in addition, wiring and
connectors have been checked and ruled out, the
fuel level indicator is defective and the instrument
cluster must be replaced.
G5-18A, 2505H, 25.5 9-23

Electrical System
5. Check that the ignition terminal has current and that a. Coolant Temperature Sender Removal
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or machine, fully retract the boom, lower the boom,
damaged wiring between the fuel level indicator place the transmission control lever in (N)
wiring at the cab, fuse and relay panel, ignition key NEUTRAL, engage the park brake and shut the
switch and from the fuel level sender on the fuel tank engine OFF.
through the wiring in the cab.
7. Check the fuel level sender. The resistance of the switch and the steering wheel, stating that the
fuel level sender is 31 ohms for a full tank of fuel, machine should not be operated.
101 ohms for 1/2 tank and 255 ohms for an empty
tank. A defective fuel level sender in the fuel tank
engine to cool.
may also prevent the fuel level indicator from
moving. 4. Properly disconnect the battery.
5. Disconnect the wiring connector at the coolant
9.10.4 Hourmeter temperature sender lead.
The hourmeter is a non-repairable instrument that 6. The coolant temperature sender is threaded into the
records hours of machine engine operation in tenth of an engine block. Remove the sender.
hour increments and is located in the instrument cluster.
The hourmeter is an analog device, similar to an b. Coolant Temperature Sender Inspection and
odometer, and will display 99,999.9 hours before Replacement
resetting to zero. Inspect the sender and the wiring harness connector
If trouble is suspected, time the hourmeter for six minutes terminals for continuity. Replace a defective or faulty
to verify that a tenth of an hour has been recorded. sender with a new part.
The hourmeter is built into the instrument cluster and
c. Coolant Temperature Sender Installation and
cannot be repaired. If the hourmeter is suspect, replace
Testing
the instrument cluster.
1. Thread the coolant temperature sender into the
9.10.5 Coolant Temperature Sender engine housing snugly, then connect the sender
connector to the wiring harness connector.
3. Check for proper fluid level.
2
4. Start the engine, allow it to reach operating
temperature and observe the operator’s instrument
cluster for warning indication. If the sender is not
defective, the problem could be elsewhere; possibly
in a shorted wire, improper-running engine, improper
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument display,
etc.
MY8820 ignition key and the steering wheel.
The coolant temperature sender (2) is located on the top

of the engine behind the top radiator hose.
9-24 G5-18A, 2505H, 25.5

Electrical System
9.10.6 Oil Pressure Sender 4. Start the engine, and observe the operator’s display
for warning indication. If the sender is not defective,
the problem could be elsewhere; possibly in a
shorted wire, improper-running engine, low oil,
obstructed or faulty oil pump, defective instrument
display.
MY8820
The oil pressure sender (3) is located on the engine near

the oil filter.
a. Oil Pressure Sender Removal

engine OFF.
engine to cool.
5. Disconnect the wiring connector at the oil pressure
sender lead.
6. The oil pressure sender is threaded into the engine.
Remove the sender.
b. Oil Pressure Sender Inspection and Replacement

Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new part.
c. Oil Pressure Sender Installation and Testing

1. Thread the oil pressure sender into the engine
housing snugly, then connect the sender connector
to the wiring harness connector.
3. Check for proper fluid level.
G5-18A, 2505H, 25.5 9-25

Electrical System
9.11 LOAD STABILITY INDICATOR • Travel in accordance with the requirements set forth
SYSTEM (2505H & 25.5) in Section 1 - General Safety Practices.
• When placing a load, ensure axles are not fully
1 4 5 steered in either direction.
7
WARNING
3 TIP OVER HAZARD. If the green, orange and red
LEDs flash and warning buzzer sounds, retract and
lower boom immediately. Determine cause and
correct before continued use.
• Test the LSI (6) at the beginning of each work shift.
MAM2890
1.Fully retract and level the boom, with no load.
6 2
Do not raise the boom during this test.
The LSI (1) provides visual and audible indication of 2.Level frame using level in cab.
forward stability limitations when machine is static on 3.Press the system check button on the LSI display.
firm, level surface. This will cause all LEDs to flash on and an audible
• Green LED (2) will illuminate when LSI power is on. warning to sound. This indicates that the system
is functioning properly. If the test gives a different
• When approaching forward stability limitations LEDs
result, the system is not functioning properly and
progressively illuminate, green (3), then orange (4)
and finally red (5). the machine must be removed from service and
repaired before continued operation.
• If the red LED iluminates, the warning buzzer also
sounds. 9.11.1 LSI Axle Sensor
The LSI has two modes:
Active Mode (CE & AUS)
• As the telehandler reaches forward stability
limitations and the red LED (5) illuminates, the
automatic function cut-out is activated. All boom
functions are disabled except boom retract
(CE & AUS) and boom lift (CE). Retract boom to fully
re-enable functions.
• In some instances the LSI system may slow down or
stop boom functions if operated close to forward
stability limitations. When LEDs begin to flash,
certain functions can not be operated. Retract boom
and/or return the joystick to neutral position for a
short period to allow system to reset and LEDs to 1
stop flashing before proceeding with operation.
MAM2900
Passive Mode (CE)
The LSI axle sensor (1) is bolted on the top left of the rear
• The orange LED (7) illuminates when the following axle.
occurs:
Note: If the rear axle is removed or replaced, the LSI
• The park brake is not applied and transmission
Sensor must be installed AFTER the rear axle is
control lever is in the forward or reverse position.
installed and setting on all four wheels.
• When approaching forward stability limitations,
visual and audible indication is provided and the
automatic function cut-out and/or slow down fea-
ture is disabled.
9-26 G5-18A, 2505H, 25.5

Electrical System
a. LSI Axle Sensor Removal 10. Close and secure the battery and engine covers.
1. Remove any fork carrier or attachment from the 11. Remove the Do Not Operate Tag from the ignition
machine. key switch and the steering wheel.
2. Park the machine on a firm, level surface, level the 12. Calibrate the LSI system, refer to Section 9.11.4,
machine, fully retract the boom, fully raise the boom, “LSI System Calibration.”
NEUTRAL, engage the park brake and shut the 9.11.2 LSI Boom Sensors
engine OFF.
engine to cool.
6. Disconnect the LSI electrical connector.
7. Loosen, remove and discard the two bolts holding
the LSI assembly to the rear axle.
8. Remove and discard the sensor assembly.
2
MAM2910
b. LSI Axle Sensor Installation
1. Ensure threads of both bolt holes are clean and free The LSI sensors (2) are bolted on the left inside of the first
from rust, water and debris. boom section.
2. Clean the bare metal with a degreasing agent, a. LSI Boom Sensor Removal
Loctite® 7063™.
1. Remove any fork carrier or attachment from the
3. Remove any excess degreasing agent and allow to machine.
dry.
4. Apply a thin film of Loctite® F246™ adhesive to the machine, fully retract the boom, fully raise the boom,
flat metal surface of the sensor, ensuring the place the transmission control lever in (N)
adhesive is spread evenly over the entire surface. NEUTRAL, engage the park brake and shut the
Note: Follow all adhesive manufacturer’s engine OFF.
recommendations including storage life. 3. Place a Do Not Operate Tag on both the ignition key
5. Fit the sensor, ensuring the lead exits in the corner
direction. Secure with two new bolts - Socket HD
Capscrew M10x35x1.5, Grade 12.9. 4. Open the battery and engine covers. Allow the
engine to cool.
Note: It is important to prevent distortion of the sensor
element, therefore tighten each bolt finger tight. 5. Properly disconnect the battery.
Alternately tighten each bolt to 26 lb-ft (35 Nm) and 6. Disconnect the LSI electrical connectors.
finally to 52-59 lb-ft (70-80 Nm). 7. Loosen and remove the two bolts holding the LSI
6. Permanently mark position of bolt head and sensor assembly to the side of the boom.
body. 8. Remove and discard the sensor assembly.
7. Leave the machine undisturbed for a minimum of 6
hours before moving.
8. Plug the electrical connector into the sensor
assembly.
G5-18A, 2505H, 25.5 9-27

Electrical System
b. LSI Sensor Boom Installation 7. Loosen and remove the two bolts holding the LSI
modules to the side of the frame.
1. Mount the LSI sensor to the side of the first boom
section with the previously removed hardware. Do 8. Remove each module.
Not tighten the mounting bolts at this time. DO NOT disassemble the module(s). The module(s) are
2. Shim the LSI sensor within 2-3 mm (0.08-0.11in) of not serviceable. Replace module(s) if found to be
the second boom section. Tighten and torque the defective.
mounting bolts as required.
b. LSI Module Installation
3. Plug the electrical connector into the sensor
assembly. 1. Mount the LSI modules to the side of the frame with
4. Properly connect the battery. the previously removed hardware. Tighten and
torque the mounting bolts as required.
2. Plug the electrical connector into the module
6. Remove the Do Not Operate Tags from both the assemblies.
9.11.3 LSI Modules 4. Close and secure the battery and engine covers.
5. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
MAM2920
The LSI modules (3) are bolted to the frame at the inside
left rear corner.
a. LSI Module Removal

1. Remove any fork carrier or attachment from the
machine.
machine, fully retract the boom, fully raise the boom,
engine OFF.
engine to cool.
6. Disconnect the LSI modules electrical connectors.
9-28 G5-18A, 2505H, 25.5

Electrical System
9.11.4 LSI System Calibration 7. Press the SYSTEM CHECK button on the LSI
display and release. The first 3 green LEDs will
a. Standard Calibration illuminate. The third then second green LEDs will go
out as the calibration point is recorded.
To calibrate the LSI, certain conditions must be met:
8. The first green LED goes out and buzzer sounds
• The sensors must be installed according to Section then the red LED illuminates.
9.11.1, “LSI Axle Sensor,” and Section 9.11.2, “LSI
Boom Sensors.” 9. Lower boom until level. Pressing the LSI Override
button may be required to lower the boom.
• The machine control system must be powered on for
at least 10 minutes before calibration. 10. Attach the previously removed standard carriage,
forks and weight.
• The operator must remain in the cab.
11. Slowly extend the boom until the rear axle weight in
• The calibration shall be conducted with the standard the following table is achieved.
carriage and forks attached and weights as
necessary (a range of 60 - 80% of maximum weight Model Weight on Rear Axle
capacity).
2505H & 25.5 CE 700 ± 20 lb (318 9 kg)
• The machine must be on a level surface with the
wheels steered straight and park brake off, with 2505H & 25.5 AUS 1102 ± 29 lb (500 ± 9 kg)
straight driving over a distance of at least 2 m (6.5 ft)
being the last movement before entering a 12. Press the SYSTEM CHECK button on the LSI
calibration point. display and release. As the calibration point is
recorded, buzzer sounds and the LEDs will flash and
• While utilizing the LSI override button, 10 times lift perform a sequence until all are flashing.
and lower the boom stopping suddenly to induce the
rear axle to bounce. 13. Perform the LSI- CAN Check PT to finalize the
calibration. Refer to Section 9.11.5, “LSI-CAN Check
• Position the rear tires centrally on the scales.
PT.”
• The calibration must be completed within 30 minutes
after starting procedure.
Calibration Procedure:
1. Start and position the machine to perform the
calibration procedure.
2. Remove the standard carriage and weight assembly.
3. Fully retract the boom and if equipped, lower the
outriggers. Shut the machine OFF.
4. With ignition key in OFF position, press and hold
SYSTEM CHECK button on LSI display and turn
ignition key to engine START position. Release the
ignition key when engine start is achieved, but
continue to hold SYSTEM CHECK button on LSI
display until the orange LED on LSI display goes out
and buzzer sounds (approximately 3 seconds).
Release SYSTEM CHECK button.
5. The LEDs will perform a rolling sequence. When
only the third green LED illuminates, press the
SYSTEM CHECK button.
6. The first green LED then illuminates. With no
attachment, outriggers down (if equipped) and boom
fully retracted, lift boom to maximum boom angle.
G5-18A, 2505H, 25.5 9-29

Electrical System
b. Field Calibration 4. The machine must be on a level surface with the

wheels steered straight and park brake OFF. Drive
To calibrate the LSI, certain conditions must be met:
the machine forward over a distance of at least 2 m
• The sensor must be installed according to Section (6.5 ft) before entering a calibration point.
9.11.1, “LSI Axle Sensor,” and Section 9.11.2, “LSI
5. Place test weight on ground, apply park brake and
Boom Sensors.”
shut engine OFF. Do Not move machine.
• The test weight matches the model being calibrated Field Calibration Procedure:
in the table shown on page 9-30.
Note: The following procedure must be completed
• The calibration shall be conducted with standard
carriage and forks attached to the machine. within 30 minutes of starting the procedure.
• While utilizing the LSI override button, 10 times lift 1. With ignition key in OFF position, press and hold
and lower the boom stopping suddenly to induce the SYSTEM CHECK button on LSI display and turn
rear axle to bounce. ignition key to engine START position. Release the
ignition key when engine start is achieved, but
Note: If the test weight is not known, follow steps 1 & 2.
continue to hold SYSTEM CHECK button on LSI
Test display until the orange LED on LSI display goes out
Model Market Weight Xtip (1) Xcal (2) and buzzer sounds (approximately 3 seconds).
(W) Release SYSTEM CHECK button.
With Manual Quick Attach 2. The LEDs will perform a sequence. When only the
third green LED illuminates, press the SYSTEM
2505H CE & 2000 kg 1225 mm 978 mm
CHECK button.
& 25.5 AUS (4408 lb) (48.25 in) (38.5 in)
3. The first green LED then illuminates. With no
With Hydraulic Quick Attach
attachment and boom retracted, lift boom fully.
2505H CE & 2000 kg 1200 mm 952 mm
4. Press the SYSTEM CHECK button on the LSI
& 25.5 AUS (4408 lb) (47.25 in) (37.5 in)
display and release. The first 3 green LEDs will
illuminate. The third then second green LEDs will go
1 out as the calibration point is recorded.
5. The first green LED goes out and buzzer sounds
then the red LED illuminates.
6. Lower boom and without moving the machine, pick
up the proper test weight (W) listed in the table.
Pressing the LSI Override button may be required to
lower the boom.
2
MU7740
1. With the estimated test weight on the forks, start the

machine and extend the boom horizontally until the
machine starts to tip. This point should be at an
extension of Xtip (1) of the second boom section. If
the machine is not tipping at this extension, weight
needs to be added or removed from the forks.
MU7740
2. By confirming that the machine tips at this point, the
correct amount of weight is now on the forks. 7. With the boom horizontal, slowly extend the boom to
3. The machine control system must be powered on for the distance of Xcal (2). The proper calibration
at least 10 minutes before calibration. weight is now on the rear axle and the LSI can now
be calibrated.
9-30 G5-18A, 2505H, 25.5

Electrical System
8. Press the SYSTEM CHECK button on the LSI 9.11.5 LSI-CAN Check PT
display and release. As the calibration point is
With the LSI calibrated, the UGM also needs calibrated
recorded, buzzer sounds and the LEDs will flash and
and verified.
perform a sequence until all are flashing.
1. The machine must be on a level surface, wheels
9. Perform the LSI- CAN Check PT to finalize the
steered straight and park brake ON.
calibration. Refer to Section 9.11.5, “LSI-CAN Check
PT.” 2. Connect the analyzer cable connector to the
connector at the right rear corner of the cab by the
Note: The following procedure MUST BE performed to operator seat.
finalize the LSI System Calibration.
3. Start the machine.
4. Press the “C” and “OK” buttons simultaneously on
the analyzer.
5. Go to “ACCESS LEVEL 3” and press “OK”.
6. Enter the proper access code and press “OK”.
7. “ACCESS LEVEL 2” is now visible.
8. Go to “CALIBRATIONS” menu, press “OK”.
9. Scroll to “LSI_CAN CHECK PT”.
10. “SET LSI_CAN CHECK POINT”, use the arrow keys
to change “NO” to “YES”.
11. Follow and execute the screen instructions:
a. “Remove Weights and Attachments”, press “OK”.
b. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”.
c. “STOP, WAIT ONE MINUTE”, wait at least one
minute and press “OK”.
d. “PRESS ENTER TO SET CHECK POINT”, press
“OK”
e. Screen defaults back to “CALIBRATIONS:
LSI_CAN CHECK POINT”.
f. Press “C” for approximate two seconds to return
to normal display screen.
g. LSI Can Check is now complete.
12. Remove the analyzer.
13. Return machine to service.
G5-18A, 2505H, 25.5 9-31

Electrical System
9.11.6 500 Hour - LSI UGM Calibration Check 9.12 HAND HELD ANALYZER (2505H &
1. The machine must be on a level surface, wheels 25.5)
steered straight and park brake ON.
2. Start machine.
3 4
ESC ENTER
MY2480 8 5 6
3. Connect the analyzer cable connector to the

connector behind the access panel on the right side
of the dash (8).
MY8200
4. Press the “C” and “OK” buttons simultaneously on
the analyzer.
1. Cable Connector.
5. Go to “ACCESS LEVEL 3” and press “OK”.
2. Analyzer Display Screen.
6. Enter the proper access code and press “OK”.
3. Escape Key: To return home or access previous
7. “ACCESS LEVEL 2” is now visible. menu.
8. Go to “OPERATOR TOOLS” menu, press “OK”. 4. Enter Key: Stores and selects Top Level, Sub Level
9. Scroll to “LSI_CAN SYSTEM CHECK”. and Items Menus.
10. “PERFORM LSI_CAN SYSTEM CHECK?”, use the 5. Up/Down Arrow Keys: Change adjustable values.
arrow keys to change “NO” to “YES”. 6. Left and Right Arrow Keys: Used to move between
11. Follow and execute the screen instructions: Top Level, Sub Levels and Item Menus.
a. “Remove Weights and Attachments”, press “OK”.
9.12.1 Analyzer Usage
b. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”. Help messages can be viewed using the Analyzer
c. “STOP, WAIT ONE MINUTE”, wait at least one (P/N 2901443). The Help messages can be accessed by
minute and press “OK”. pressing the ENTER key while viewing the current Help
message. The Help message shall be EVERYTHING OK
d. “PRESS ENTER TO START TEST”, press “OK”.
when no fault is present. The Analyzer cable plugs into
e. Screen will show: “PRESS ENTER TO START the connector located behind the access panel on the
TEST: PASS”. right side of the dash.
f. Must receive a “PASS”. For more information, contact the local JLG Dealer.
g. Press “C” for approximate two seconds to return
to normal display screen.
h. LSI UGM Calibration Check is now complete.
12. Remove the analyzer.
13. Return machine to service.
9-32 G5-18A, 2505H, 25.5

Electrical System
9.12.2 Analyzer Software - Version 1.0
NOTE: THE LAYOUT SHOWS ALL POSSIBLE ANALYZER SCREENS. PLEASE NOTE, SOME SCREENS MAY NOT BE AVAILABLE DEPENDING UPON MACHINE CONFIGURATION.
MENU : HELP : ( 001 )

HELP : PRESS ENTER EVERYTHING OK
LOG : (xxx )
x : xxxxxxxxxxx
MENU : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : 2 DIAGNOSTICS : DIAGNOSTICS :
DIAGNOSTICS DRIVE CAB INPUTS BOOM FUNCTIONS FAN SYSTEM LOAD MOMENT CAN STATISTICS CALIBRATION DATA VERSIONS
TRANS MTR OUTPUT LSI CANCEL SW : 2

LIFT DN OUTPUT : HYD FLUID TEMP POWER MODULE : LOAD MOMENT CAN 1 STATISTICS CALIBRATION DATA POWER MODULE
CURRENT : XXXmA ENGAGED XXX % XX C VOLTAGE : XX . XV STATUS : STABLE RX/ SEC : XXX LSI CELL A : XXXX SOFTWARE : PX . X
TRANS MTR FDBK TELE MODE SW : LIFT DN OUTPUT ENGINE COOLANT GROUND MODULE : LOAD MOMENT CAN 1 STATISTICS 2
CALIBRATION DATA GROUND MODULE
mA : XXXmA ENGAGED CURRENT : XXXMA TEMP : XX C VOLTAGE : XX . XV OVERRIDE : YES TX / SEC : XXX LSI CELL B : XXXX SOFTWARE : PX . X
LIFT DN FDBK mA FAN SPEED OUTPUT CAN 1 STATISTICS 2

F / R DRIVE CUTOUT LIFT DN PILOT REMOTE IO MODULE LOAD MOMENT %:
ENGAGED SENSOR : X. XV XXXmA CURRENT : XXXmA VOLTAGE : XX . XV XXX % BUS OFF : XXX REMOTE INPUT MOD
SOFTWARE : PX . X
LIFT DN PILOT LIFT ENABLE FAN SPEED FDBK MOMENT CELLA RAW CAN 1 STATISTICS 2
LSI MODULE
PRESSURE : XXXPSI ENGAGED mA : XXXmA VALUE : XXXXXX PASSIVE : XXX SOFTWARE : X. X
JOYSTICK LOCK : TELE OUT %: MOMENT CELLB RAW CAN 1 STATISTICS 2

FAN REVERSE
ANALYZER :
ENGAGED XXX % VALVE : ENGAGED VALUE : XXXXXX MSG OVERRUN : XXXX
ANALYZER VER 6 . 2
FORWARD AND PARK TELE OUT CELL DISAGREE %:

BRK OFF : TRUE CURRENT : XXXMA XXX %
REVERSE AND PARK TELE OUT FDBK mA MIDBOOM # 1 SW :

BRK OFF : TRUE XXXmA OPEN
FAN REV CYCLING TELE ENABLE MIDBOOM # 2 SW :

SW : ENGAGED ENGAGED OPEN
FAN REV DEMAND FUNCTION ENABLE OPERATING MODE :

SW : ENGAGED ENGAGED ACTIVE
2
MENU : ACCESS LEVEL : SEAT SW 1
ACCESS LEVEL CODE XXXXXX ENGAGED
2
MENU : PERSONALITIES : SEAT SW 2
PERSONALITIES LIFT DOWN ENGAGED
2
LIFT DN ZN 1
OMD< 50 : XX %
2
LIFT DN ZN 1
50 < OMD< 75 : XX %
2
LIFT DN ZN 1
OMD>75 : XX %
2
LIFT DN ZN 2
OMD< 50 : XX %
2
LIFT DN ZN 2
50 < OMD< 75 : XX %
2
LIFT DN ZN 2
OMD> 75 : XX %
2
CREEP : XX %
2
MENU :
MARKET : CE
MACHINE SETUP
2
FAN CONFIG :
FAN SPD & REV
2
TIRE :
LARGE - 273 . 05 CM
2
SPEED UNIT :
KPH
2
TEMP UNIT :
CELCIUS
2
MENU : FAN REVERSE
LSI SYSTEM CHECK
OPERATOR TOOLS INTERVAL : XX MIN
PERFORM LSI 2
FAN REVERSE
TIMER : XX MIN SYSTEM CHECK?
2
REMOVE WEIGHTS
AND ATTACHMENTS
2
TELESCOPE IN AND
FULLY LIFT UP
2
**** STOP ****
WAIT 1 MINUTE
2
PRESS ENTER TO
START TEST : ----
2 2 2
MENU :
LSI CHECK POINT EMULATE AXL LOAD
CALIBRATION TOOLS
2 2 2
SET LSI CHECK EMULATE 60 % : EMULATE 80 % :
POINT : YES YES / NO YES / NO
2
REMOVE WEIGHTS
AND ATTACHMENTS
2
TELESCOPE IN AND
FULLY LIFT UP
2
**** STOP ****
WAIT 1 MINUTE
2
PRESS ENTER TO
SET CHECKPOINT MY8840
G5-18A, 2505H, 25.5 9-33

Electrical System
9.13 DIAGNOSTIC TROUBLE CODES

(DTC) ON GROUND MODULE
9.13.1 Gauge Fault Code Display
8
7
MY9030
Fault codes will appear in the display area (7) of the gauge (8).
9.13.2 Fault Codes
Trigger / Possible Latch / Reset

Help Message DTC Actions
Symptom Condition
The Ground Module detects
System OK 1 - -
no problems exist
Power Cycle 211 Power was cycled on - -
Default machine to LSI
Cutout (if not in passive Latched. Check wiring to
Load Moment LSI Cancel Switch
mode and not in LSI Pin J1-3 on the Ground
Shutoff Input - 2336 depressed at Startup or for
calibration mode) and Module and integrity of
Invalid Signal longer than 40seconds
disregard LSI Cancel mechanical switch
Switch Input override
Deactivate Lift Down Valve
Latched. Check wiring to
Lift Down Valve - The module is detecting Output. Also deactivate Lift
335 Pin J1-8 on the Ground
Short to Battery short to B+ Enable if machine is in
Module
LSI Cutout
Lift Down Valve - The module is detecting an Deactivate Lift Down
Open Circuit open circuit Output
Module
The desired current is 0mA Deactivate Telescope Out
Telescope Out Latched. Check wiring to
and the digital output driver’s Output. Also deactivate
Valve - Short to 33123 Pin J1-9 on the Ground
diagnostic feedback is low Telescope Enable if
Battery Module
for a period of 250ms machine is in LSI Cutout
Lift Enable Valve – The module is detecting a Deactivate Lift Enable
Short to Ground short to ground Output
Module
Lift Enable Valve – The module is detecting an Deactivate Lift Enable
Open Circuit open circuit Output
Module
9-34 G5-18A, 2505H, 25.5

Electrical System

Symptom Condition
Lift Enable Valve - The module is detecting Deactivate Lift Enable
Short to Battery short to B+ Output
Module
The module is detecting an Deactivate Telescope
Valve - Open 33186 Pin J1-9 on the Ground
open circuit Out Output
Circuit Module
The module is detecting a Deactivate Telescope
short to ground Out Output
Ground Module
Lift Down Valve - The module is detecting a Deactivate Lift Down
Short to Ground short to ground Output
Module
Function Enable Latched. Check wiring to
The module is detecting
Output – Short to 33438 Deactivate Function Enable Pin J1-11 on the Ground
short to B+
Battery Module
Function Enable Latched. Check wiring to
The module is detecting a
Output – Short to 33443 Deactivate Function Enable Pin J1-11 on the Ground
short to ground
Ground Module
Telescope Enable Latched. Check wiring to
The module is detecting a Deactivate Telescope
Valve – Short to 33444 Pin J1-10 on the Ground
short to ground Enable Output
Ground Module
The module is detecting an Deactivate Telescope
Valve – Open 33439 Pin J1-10 on the Ground
open circuit Enable Output
Circuit Module
The module is detecting Deactivate Telescope
short to B+ Enable Output
Battery Module
Passive Mode Latched. Check wiring to
The module is detecting a
Indicator – Short to 33441 Deactivate Indicator Output Pin J1-12 on the Ground
short to ground
Ground Module
This fault can only be
Passive Mode detected if the machine is Latched. Check wiring to
Indicator – Short to 33442 configured for the CE Deactivate Indicator Output Pin J1-12 on the Ground
Battery market. The module is Module
detecting short to B+
Not Latched
Battery voltage is less than Revert to normal
Battery Voltage
9V for at least 250ms and Deactivate all Module operation when battery
Low – System 441
engine is not in a cranking Outputs voltage greater than or
Shutdown
state equal to 11V for at least
1000mS
Battery Voltage
Battery voltage greater than Deactivate all Module Latched
Too High - System 442
16V for at least 250mS Outputs Fix supply voltage
Shutdown
Lift Valve – The Ground module has
Limit all lift down speed to Latched. Check wiring to
Pressure Sensor detected that the pressure
4578 Creep mode without Pins J2-1, J2-2 on the
Voltage Out of sensor voltage is less than
activating LSI Cutout Ground Module
Range 0.25V or greater than 4.75V
G5-18A, 2505H, 25.5 9-35

Electrical System

Symptom Condition
This fault can only be
present if the machine is
configured for the CE
Conflicting Drive Default machine to Pins J1-5 on Ground
462 market. Both passive mode
Direction Signals Active Mode Module and Pin J1-4 on
inputs (fwd/park brake off
Remote IO Module
AND rev/park brake off) are
present concurrently
Ground Module lost CAN Default machine to LSI
Not Latched
bus communication with LSI Cutout if not in passive
Revert to normal
CAN Bus Failure – module and no messages mode with operation only
6638 operation when CAN
LSI have been received for a available via LSI Cancel
bus communication is
period of switch (Creep Mode
re-established
1 second operation)
This fault can only occur if
the machine detects itself
to be a Tier 3 configuration:
Cutout (if not in passive
Ground Module lost CAN
mode or not in LSI Not Latched
bus communication with
CAN Bus Failure - calibration mode) with Revert to normal
Remote Input Module and
Remote Input 6642 operation only available via operation when CAN
no messages have been
Module LSI Cancel switch (Creep bus communication is
received for a period of 250
Mode operation) re-established
ms
the machine detects itself
to be a Tier 4 configuration:
Deactivate all
Module Outputs
Not Latched. Once
LSI CAN display indicates Permit LSI-CAN display to calibrated sequence
LSI Not Calibrated 8514
calibration is required control its internal alarm performed, LSI display
indicates completion
Machine automatically in
LSI Cutout with operation
only available via LSI
LSI Load Cell A - LSI module detects condition Latched. Check LSI
8516 Cancel Switch (Creep
Out of Range and OMD reading is 100% gauge and sensor wiring
Mode operation)
Permit LSI-CAN display to
control its internal alarm
LSI Cutout with operation
only available via LSI
LSI Load Cell B - LSI module detects condition Latched. Check LSI
8517 Cancel Switch (Creep
Out of Range and OMD reading is 100% gauge and sensor wiring
Mode operation)
Permit LSI-CAN display to
9-36 G5-18A, 2505H, 25.5

Electrical System

Symptom Condition
LSI Cutout Output - LSI Cutout with operation
LSI module detects condition Latched. Check LSI
Short to Battery or 8518 only available via LSI
and OMD reading is 100% gauge and sensor wiring
Open Circuit Cancel Switch (Creep
Mode operation)
Activate LSI Cutout if not in
passive mode or not in LSI
calibration mode
LSI has not been calibrated
Note: If fault is set due to Not Latched – fault
via CALIBRATION à LSI
LSI CAN CHECK PT not clears if:
LSI Out of CAN CHECK PT or is not
8519 being completed, suppress LSI is calibrated or LSI
Calibration within tolerance during a
LSI Cutout during the CAN System Check is
OPERATOR TOOLS à LSI-
subsequent calibration performed and passes
CAN SYSTEM CHECK
procedure
Permit LSI-CAN Display to
The LSI System has
detected a checksum error
LSI Faulty - mode or not in LSI
with its system flash and is Latched. Possibly
System Flash CRC 99152 calibration mode) with
reporting the issue on a CAN replace LSI gauge
Error operation only available via
bus message to the Ground
LSI Cancel switch (Creep
Module
Mode operation)
The LSI System has
detected a checksum error
mode or not in LSI
LSI Faulty - Data with its system flash and is Latched. Possibly
99153 calibration mode) with
Flash CRC Error reporting the issue on a CAN replace LSI gauge
operation only available via
bus message to the Ground
LSI Override switch (Creep
Module
Mode operation)
The LSI System has
detected a unacceptable
variance in the readings
LSI Faulty - Load mode or not in LSI
between Load Cell A and Latched. Possibly
Cells A and B 99154 calibration mode) with
Load Cell B and is reporting replace LSI gauge
Disagreement operation only available via
the issue on a CAN bus
LSI Cancel switch (Creep
message to the Ground
Mode operation)
Module
The Ground module has
Functions Locked
detected that Remote input Latched. Check ground
Out – Remote Input Deactivate all
99161 module software is not and remote module
Module Software Module Outputs
compatible (Major version software versions
Version Improper
does not match)
G5-18A, 2505H, 25.5 9-37

Electrical System

Symptom Condition
the machine detects itself to Latched. Check wiring to
Seat Switch be a Tier 4 configuration. Pins J2-7 on Ground
23119 N/A
Disagreement Disagreement between seat and Remote
switch inputs is present IO modules
for 5 seconds
This fault can only occur if Cutout (if not in passive
the machine detects itself to mode or not in LSI
Ground Module
be a Tier 4 configuration. calibration mode) with
Parameters not
6643 startup delay of 1500ms has operation only available via Not Latched
Received from
expired and has not received LSI Override switch (Creep
Power Module
parameters from the Power Mode operation)
Module This fault shall suppress
DTC 9924 from being set
9-38 G5-18A, 2505H, 25.5

Electrical System
9.14 ENGINE DIAGNOSTIC TROUBLE

CODE EMR4
9.14.1 Gauge Fault Code Display

Fault SPN FMI
Deutz Description
Codes Codes Codes
Air flow sensor load correction factor exceeding the maximum drift limit; plausibility
1 132 11
error
2 132 11 Air flow sensor load correction factor exceeding drift limit; plausibility error
3 132 11 Air flow sensor low idle correction factor exceeding the maximum drift limit
4 132 11 Air flow sensor load correction factor exceeding the maximum drift limit
9 172 2 Sensor ambient air temperature; plausibility error
34 523006 3 Controller mode switch; short circuit to battery
35 523006 4 Controller mode switch; short circuit to ground
36 523923 3 UB1; Short circuit to battery error of actuator relay 1
45 168 3 Sensor error battery voltage; signal range check high
46 168 4 Sensor error battery voltage; signal range check low
47 168 2 High battery voltage; warning threshold exceeded
48 168 2 Low battery voltage; warning threshold exceeded
Break lever main switch and break lever redundancy switch status
49 597 2
not plausible
55 523910 14 Air pump doesn't achieve air mass flow set point
56 524013 7 Burner flame unintentional deleted
57 524020 14 Engine power; Not enough oxygen for regeneration
58 523911 0 Burner dosing valve (DV2); over current at the end of the injection phase
59 523911 12 Burner dosing valve (DV2); powerstage over temperature
60 523911 3 Burner dosing valve (DV2); short circuit to battery
61 523911 3 Burner dosing valve (DV2); short circuit to battery on high side
62 523911 4 Burner dosing valve (DV2); short circuit to ground
63 523911 11 Burner dosing valve (DV2); short circuit high side powerstage
64 523912 2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error
Physical range check high for burner dosing valve (DV2) downstream pressure; shut
66 523912 0
off regeneration
Physical range check low for burner dosing valve (DV2) downstream pressure; shut
off regeneration. When burner injector is actuated, the measured pressure does not
69 523912 1
rise above ca. 1250mbarabs
(expected; ca. 2400mbar).
Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range
72 523912 3
check high
Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range
73 523912 4
check low
Sensor error glow plug control diagnostic line voltage; signal range
74 523913 3
check high
G5-18A, 2505H, 25.5 9-39

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
Sensor error glow plug control diagnostic line voltage; signal range
75 523913 4
check low
76 523914 5 Glow plug control; open load
77 523914 12 Glow plug control; powerstage over temperature
78 523914 3 Glow plug control; short circuit to battery
79 523914 4 Glow plug control; short circuit to ground
82 1235 14 CAN Bus error passive; warning CAN C
84 639 14 CAN-Bus 0 "BusOff-Status"
88 102 2 Charged air pressure above warning threshold
89 102 2 Charged air pressure above shut off threshold
96 110 3 Sensor error coolant temperature; signal range check high
97 110 4 Sensor error coolant temperature; signal range check low
98 110 0 High coolant temperature; warning threshold exceeded
99 110 0 High coolant temperature; shut off threshold exceeded
101 111 1 Coolant level too low
Fuel Balance Control integrator injector 1 (in firing order); maximum
109 523929 0
value exceeded
110 523930 0
value exceeded
111 523931 0
value exceeded
112 523932 0
value exceeded
113 523933 0
value exceeded
114 523934 0
value exceeded
Fuel Balance Control integrator injector 1 (in firing order); minimum
115 523929 1
value exceeded
116 523930 1
value exceeded
117 523931 1
value exceeded
118 523932 1
value exceeded
119 523933 1
value exceeded
120 523934 1
value exceeded
121 1109 2 Engine shut off demand ignored
122 523698 11 Shut off request from supervisory monitoring function
125 523717 12 Time out Error of CAN-Transmit-Frame AmbCon; Weather environments
126 523603 9 Time out Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor
9-40 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream
127 3224 2
cat; DPF-system downstream cat); length of frame incorrect
128 3224 9 Time out Error of CAN-Receive-Frame AT1IG1; NOX sensor upstream
DLC Error of CAN-Receive-Frame ATllGlVol NOX Sensor (SCR-system upstream
129 3224 2
cat; DPF-system downstream cat); length of frame incorrect
Time out Error of CAN-Receive-Frame ATllGlVol; NOX sensor (SCR-system
130 3224 9
upstream cat; DPF-system downstream cat)
Time out Error (BAM to packet) for CAN-Receive-Frame ATllGCVoll information;
133 523938 9 factors & Sensor calibration for NOX Sensor (SCR-system upstream cat; DPF-
system downstream cat)
Time out Error (BAM to BAM) for CAN-Receive-Frame ATllGCVoll information;
134 523939 9 factors & Sensor calibration for NOX Sensor (SCR-system upstream cat; DPF-
Time out Error (PCK2PCK) for CAN-Receive-Frame ATllGCVoll information; factors
135 523940 9 & Sensor calibration for NOX Sensor (SCR-system upstream cat; DPF-system
downstream cat)
Time out Error of CAN-Receive-Frame AT1OG1; NOX sensor (SCR-system
137 3234 9
downstream cat; DPF system downstream cat)
DLC Error of CAN-Receive-Frame ATlOlVol NOX Sensor (SCR-system
138 3234 2
downstream cat; DPF-system downstream cat); length of frame incorrect
Time out Error of CAN-Receive-Frame ATlOGlVol; NOX sensor (SCR-system
139 3234 9
downstream cat; DPF-system downstream cat)
Time out Error (BAM to packet) for CAN-Receive-Frame ATlOGCVol2 information;
140 523941 9 factors & Sensor calibration for NOX Sensor (SCR-system downstream cat; DPF-
Time out Error (BAM to BAM) for CAN-Receive-Frame ATlOGCVol2 information;
Time out Error (PCK2PCK) for CAN-Receive-Frame ATlOGCVol2 information;
168 523935 12 Time out Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages
169 523936 12 Time out Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages
171 523212 9 Time out Error of CAN-Receive-Frame ComEngPrt; Engine Protection
179 523240 9 Time out CAN-message FunModCtl; Function Mode Control
Time out Error of CAN-Receive-Frame PrHtEnCmd; pre-heat
198 523216 9
command, engine command
Time out Error of CAN-Receive-Frame UAA10; AGS sensor
202 523793 9
service message
203 523794 9 Time out Error of CAN-Receive-Frame UAA11; AGS sensor data
212 523803 9 Time out Error of CAN-Receive-Frame RxEngPres; Status burner air pump
281 523766 9 Time out Error of CAN-Receive-Frame Active TSC1AE
282 523767 9 Time out Error of CAN-Receive-Frame Passive TSC1AE
283 523768 9 Time out Error of CAN-Receive-Frame Active TSC1AR
284 523769 9 Time out Error of CAN-Receive-Frame Passive TSC1AR
285 523770 9 Time out Error of CAN-Receive-Frame Passive TSC1DE
291 523776 9 Time out Error of CAN-Receive-Frame TSC1TE - active
G5-18A, 2505H, 25.5 9-41

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
292 523777 9 Passive Time out Error of CAN-Receive-Frame TSC1TE; Set point
293 523778 9 Active Time out Error of CAN-Receive-Frame TSC1TR
294 523779 9 Passive Time out Error of CAN-Receive-Frame TSC1TR
299 523788 12 Time out Error of CAN-Transmit-Frame TrbCH; Status Wastegate
300 523605 9 Time out Error of CAN-Receive-Frame TSC1AE; Traction Control
301 523606 9 Time out Error of CAN-Receive-Frame TSC1AR; Retarder
305 898 9 Time out Error of CAN-Receive-Frame TSC1TE; Set point
306 520 9 Time out Error of CAN-Receive-Frame TSC1TR; Set point
Time out Error of CAN-Transmit-Frame UAA1 on CAN 2; Burner Air
322 523867 12
Pump Control
360 523982 0 Powerstage diagnosis disabled; high battery voltage
361 523982 1 Powerstage diagnosis disabled; low battery voltage
376 630 12 Access error EEPROM memory (delete)
377 630 12 Access error EEPROM memory (read)
378 630 12 Access error EEPROM memory (write)
381 411 4 Physical range check low for EGR differential pressure
383 2791 5 Actuator EGR Valve; open load
384 2791 12 Actuator EGR Valve; powerstage over temperature
385 2791 3 Actuator EGR Valve; short circuit to battery
386 2791 4 Actuator EGR Valve; short circuit to ground
387 523612 12 Internal software error ECU; injection cut off
388 190 0 Overspeed detection in component engine protection
389 190 0 Engine speed above warning threshold (FOC-Level 1)
390 190 11 Engine speed above warning threshold (FOC-Level 2)
391 190 14 Engine speed above warning threshold (Overrun Mode)
412 108 3 Sensor error ambient air pressure; signal range check high
413 108 4 Sensor error ambient air pressure; signal range check low
417 171 3 Sensor error environment temperature; signal range check high
418 171 4 Sensor error environment temperature; signal range check low
419 190 8 Sensor camshaft speed; disturbed signal
420 190 12 Sensor camshaft speed; no signal
421 190 2 Offset angle between crank- and camshaft sensor is too large
422 190 8 Sensor crankshaft speed; disturbed signal
423 190 12 Sensor crankshaft speed; no signal
424 703 5 Engine running lamp; open load
425 703 12 Engine running lamp; powerstage over temperature
426 703 3 Engine running lamp; short circuit to battery
427 703 4 Engine running lamp; short circuit to ground
450 975 5 Digital fan control; open load
451 975 12 Digital fan control; powerstage over temperature
452 975 3 Digital fan control; short circuit to battery
453 975 4 Digital fan control; short circuit to ground
455 975 5 Fan actuator (PWM output); open load
456 975 12 Fan actuator (PWM output); powerstage over temperature
9-42 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
457 975 3 Fan actuator (PWM output); short circuit to battery
458 975 4 Fan actuator (PWM output); short circuit to ground
460 1639 0 Sensor error fan speed; signal range check high
461 1639 1 Sensor error fan speed; signal range check low
462 523602 0 High fan speed; warning threshold exceeded
463 523602 0 High fan speed; shut off threshold exceeded
464 97 3 Sensor error water in fuel; signal range check high
465 97 4 Sensor error water in fuel; signal range check low
472 94 3 Sensor error low fuel pressure; signal range check high
473 94 4 Sensor error low fuel pressure; signal range check low
474 94 1 Low fuel pressure; warning threshold exceeded
475 94 1 Low fuel pressure; shut off threshold exceeded
481 174 0 High low fuel temperature; warning threshold exceeded
482 174 0 High Low fuel temperature; shut off threshold exceeded
488 523619 2 Physical range check high for exhaust gas temperature up stream (SCR-CAT)
500 523915 0 HCI dosing valve (DV1); over current at the end of the injection phase
501 523915 12 HCI dosing valve (DV1); powerstage over temperature
502 523915 3 HCI dosing valve (DV1); short circuit to battery
503 523915 3 HCI dosing valve (DV1); short circuit to battery high side
504 523915 4 HCI dosing valve (DV1); short circuit to ground
505 523915 11 HCI dosing valve (DV1); short circuit high side powerstage
506 523916 2 Sensor HCI dosing valve (DV1) downstream pressure; plausibility error
Physical range check high for HCI dosing valve (DV1) downstream pressure; shut
508 523916 0
off regeneration
Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off
511 523916 1
regeneration
514 523916 3 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high
515 523916 4 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low
516 523917 2 Sensor DV1 & DV2 upstream pressure; plausibility error
Physical range check high for DV1 & DV2 upstream pressure;
518 523917 0
shut off regeneration
Physical range check low for DV1 & DV2 upstream pressure;
521 523917 1
524 523917 3 Sensor error DV1 & DV2 upstream pressure; signal range check high
525 523917 4 Sensor error DV1 & DV2 upstream pressure; signal range check low
526 523918 2 Sensor DV1 & DV2 upstream temperature; plausibility error
Physical range check high for DV1 & DV2 upstream temperature;
528 523918 0
Physical range check low for DV1 & DV2 upstream temperature; shut off
531 523918 1
regeneration
534 523918 3 Sensor error DV1 & DV2 upstream temperature; signal range check high
535 523918 4 Sensor error DV1 & DV2 upstream temperature; signal range check low
543 676 11 Cold start aid relay error.
544 676 11 Cold start aid relay open load
545 729 5 Cold start aid relay open load
G5-18A, 2505H, 25.5 9-43

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
547 729 12 Cold start aid relay; over temperature error
Check of missing injector adjustment value programming (IMA) injector 1
559 523895 13
(in firing order)
check of missing injector adjustment value programming (IMA) injector 2
560 523896 13
(in firing order)
561 523897 13
(in firing order)
562 523898 13
(in firing order)
563 523899 13
(in firing order)
564 523900 13
(in firing order)
565 523350 4 Injector cylinder-bank 1; short circuit
566 523352 4 Injector cylinder-bank 2; short circuit
567 523354 12 Injector powerstage output defect
568 651 5 Injector 1 (in firing order); interruption of electric connection
580 651 3 Injector 1 (in firing order); short circuit
586 651 4 High side to low side short circuit in the injector 1 (in firing order)
592 523615 5 Metering unit (Fuel-System); open load
593 523615 12 Metering unit (Fuel-System); powerstage over temperature
594 523615 3 Metering unit (Fuel-System); short circuit to battery high side
595 523615 4 Metering unit (Fuel-System); short circuit to ground high side
596 523615 3 Metering unit (Fuel-System); short circuit to battery low side
597 523615 4 Metering Unit (Fuel-System); short circuit to ground low side
604 1323 12 Too many recognized misfires in cylinder 1 (in firing order)
9-44 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
610 1322 12 Too many recognized misfires in more than one cylinder
612 523612 12 Internal ECU monitoring detection reported error
648 523008 1 Manipulation control was triggered
649 523008 2 Time out error in Manipulation control
732 100 3 Sensor error oil pressure; signal range check high
733 100 4 Sensor error oil pressure sensor; signal range check low
734 100 0 High oil pressure; system reaction initiated
735 100 0 High oil pressure; shut off threshold exceeded
736 100 1 Low oil pressure; warning threshold exceeded
737 100 1 Low oil pressure; shut off threshold exceeded
738 175 2 Sensor oil temperature; plausibility error
739 175 2 Sensor oil temperature; plausibility error oil temperature too high
740 175 0 Physical range check high for oil temperature
741 175 1 Physical range check low for oil temperature
743 175 3 Sensor error oil temperature; signal range check high
744 175 4 Sensor error oil temperature; signal range check low
745 175 0 High oil temperature; warning threshold exceeded
746 175 0 High oil temperature; shut off threshold exceeded
747 1237 2 Override switch; plausibility error
750 107 3 Sensor error air filter differential pressure; short circuit to battery
751 107 4 Sensor error air filter differential pressure; short circuit to ground
752 107 0 High air filter differential pressure; warning threshold exceeded
753 523919 2 Sensor air pump pressure; plausibility error
755 523919 0 Physical range check high for air pump pressure; shut off regeneration
758 523919 1 Physical range check low for air pump pressure; shut off regeneration
761 523919 3 Sensor error air pump pressure; signal range check high
762 523919 4 Sensor error air pump pressure; signal range check low
763 523920 2 Sensor exhaust gas back pressure; plausibility error
G5-18A, 2505H, 25.5 9-45

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
Physical range check high for exhaust gas back pressure burner; shut
765 523920 0
off regeneration
Physical range check low for exhaust gas back pressure burner; shut
768 523920 1
off regeneration
770 523920 3 Sensor error exhaust gas back pressure burner; signal range check high
771 523920 4 Sensor error exhaust gas back pressure burner; signal range check low
776 102 3 Sensor error charged air pressure; signal range check high
777 102 4 Sensor error charged air pressure; signal range check low
791 411 0 Physical range check high for differential pressure Venturi unit (EGR)
792 411 1 Physical range check low for differential pressure Venturi unit (EGR)
793 411 11 Sensor differential pressure Venturi unit (EGR); plausibility error
794 411 2 Sensor differential pressure Venturi unit (EGR); CAN signal invalid
795 411 3 Sensor error differential pressure Venturi unit (EGR); signal range check high
796 411 4 Sensor error differential pressure Venturi unit (EGR); signal range check low
805 524025 14 Particulate filter; regeneration not successful
807 3253 2 Sensor differential pressure (DPF); plausibility error regarding signal offset
Physical range check high for differential pressure (DPF); shut
809 3251 0
off regeneration
Physical range check low for differential pressure (DPF); shut
812 3251 1
off regeneration
814 3253 3 Sensor error differential pressure (DPF); signal range check high
815 3253 4 Sensor error differential pressure (DPF); signal range check low
825 523009 9 Pressure Relief Valve (PRV) reached maximum allowed opening count
826 523470 2 Pressure Relief Valve (PRV) forced to open; performed by pressure increase
827 523470 2 Pressure Relief Valve (PRV) forced to open; performed by pressure shock
828 523470 12 Open Pressure Relief Valve (PRV); shut off condition
829 523470 12 Open Pressure Relief Valve (PRV); warning condition
830 523470 14 Pressure Relief Valve (PRV) is open
831 523470 11 The PRV can not be opened at this operating point with a pressure shock
832 523470 11 Rail pressure out of tolerance range
833 523009 10 Pressure relief valve (PRV) reached maximum allowed open time
834 523906 5 Electrical fuel pre - supply pump; open load
835 523906 12 Electrical fuel pre - supply pump; power stage over temperature
836 523906 3 Electrical fuel pre - supply pump; short circuit to battery
837 523906 4 Electrical fuel pre - supply pump; short circuit to ground
838 523450 3 Multiple Stage Switch constant speed; short circuit to battery
839 523450 4 Multiple Stage Switch constant speed; short circuit to ground
840 523450 2 Multiple Stage Switch constant speed; plausibility error
Multiple Stage Switch engine speed control parameter; short circuit
841 523451 3
to battery
Multiple Stage Switch engine speed control parameter; short circuit
842 523451 4
to ground
843 523451 2 Multiple Stage Switch engine speed control parameter; plausibility error
844 523452 3 Multiple Stage Switch engine torque limitation curve; short circuit to battery
845 523452 4 Multiple Stage Switch engine torque limitation curve; short circuit to ground
9-46 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
846 523452 2 Multiple Stage Switch engine torque limitation curve; plausibility error
849 1176 3 Sensor error pressure sensor upstream turbine; signal range check high
850 1176 4 Sensor error pressure sensor downstream turbine; signal range check high
856 523613 0 Maximum positive deviation of rail pressure exceeded (RailMeUnO)
Maximum positive deviation of rail pressure in metering unit
857 523613 0
exceeded (RailMeUnl)
858 523613 0 Rail system leakage detected (RailMeUnlO)
Maximum negative deviation of rail pressure in metering unit
859 523613 0
exceeded (RailMeUn2)
860 523613 0 Negative deviation of rail pressure second stage (RailMeUn22)
861 523613 1 Minimum rail pressure exceeded (RailMeUn3)
862 523613 0 Maximum rail pressure exceeded (RailMeUn4)
864 523613 2 Set point of metering unit in overrun mode not plausible
876 523470 7 Maximum rail pressure in limp home mode exceeded (PRV)
877 157 3 Sensor error rail pressure; signal range check high
878 157 4 Sensor error rail pressure; signal range check low
881 523633 11 Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue quality)
Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue quality); temperature
882 523633 11
range 1
Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue quality); temperature
883 523633 11
range 2
887 3234 11 Nox Sensor downstream of SCR Catalysator; plausibility error "stuck in range"
889 3224 1 Nox sensor upstream of SCR Catalysator; low signal not plausible
892 4345 11 Sensor back flow line pressure (SCR); plausibility error
893 4343 11 General pressure check error (SCR)
894 4374 13 Pressure stabilization error dosing valve (SCR)
896 523723 11 Detection of AdBlue filled SCR system in Init-State
897 523632 16 Pump pressure SCR metering unit too high
898 523632 18 Pump pressure SCR metering unit too low
899 523632 0 Pressure overload of SCR-System
900 523632 1 Pressure build-up error SCR-System
903 4365 0 Urea tank temperature too high
905 3241 0 Sensor SCR catalyst upstream temperature too high; plausibility error
906 3241 1 Sensor SCR catalyst upstream temperature too low; plausibility error
908 3361 7 AdBlue dosing valve blocked (SCR)
Sensor urea supply module heater temperature; plausibility error
914 523720 2
(normal condition)
Sensor urea supply module heater temperature; plausibility error
915 523720 2
(cold start condition)
916 523721 2 Sensor urea supply module temperature; plausibility error (normal condition)
Sensor urea supply module temperature; plausibility error
917 523721 2
(cold start condition)
918 523981 11 Urea-tank without heating function (heating phase)
919 523330 14 Immobilizer status; fuel blocked
925 523720 8 Urea supply module heater temperature; duty cycle in failure range
G5-18A, 2505H, 25.5 9-47

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
926 523720 8 Urea supply module heater temperature; duty cycle in invalid range
927 523721 11 Urea supply module temperature measurement not available
928 523722 8 Urea supply module PWM signal; period outside valid range
929 523722 8 Detect faulty PWM signal from Supply Module
930 523721 8 Urea supply module temperature; duty cycle in failure range
931 523721 8 Urea supply module temperature; duty cycle in invalid range
932 29 3 Hand throttle idle validation switch; short circuit to battery
935 91 3 Sensor error accelerator pedal; signal range check high
936 29 3 Sensor error hand throttle; signal range check high
937 29 4 Hand throttle idle validation switch; short circuit to ground
940 91 4 Sensor error accelerator pedal; signal range check low
941 29 4 Sensor error hand throttle sensor; signal range check low
942 523921 3 Sensor error burner temperature; signal range check high
943 3532 3 Sensor error urea tank level; signal range check high
944 523921 4 Sensor error burner temperature; signal range check low
945 3532 4 Sensor error urea tank level; signal range check low
946 1079 13 Sensor supply voltage monitor 1 error (ECU)
956 677 3 Starter relay high side; short circuit to battery
957 677 4 Starter relay high side; short circuit to ground
958 677 5 Starter relay; no load error
959 677 12 Starter relay; power stage over temperature
960 677 3 Starter relay low side; short circuit to battery
961 677 4 Starter relay low side; short circuit to ground
963 523922 5 Burner shut off valve; open load
965 523922 3 Burner shut of valve; short circuit to battery
967 523922 4 Burner shut of valve; short circuit to ground
969 624 5 SVS lamp; open load
970 624 12 SVS lamp; power stage over temperature
971 624 3 SVS lamp; short circuit to battery
972 624 4 SVS lamp; short circuit to ground
973 523612 14 Software reset CPU SWReset 0
976 91 11 Plausibility error between APPl and APP2 or APPl and idle switch
980 523550 12 T50 start switch active for too long
981 172 3 Sensor error intake air; signal range check high
982 172 4 Sensor error intake air sensor; signal range check low
983 172 2 Intake air sensor; plausibility error
984 523921 11 Sensor burner temperature; plausibility error
986 523921 0 Physical range check high for burner temperature
989 523921 1 Physical range check low for burner temperature
994 105 3 Sensor error charged air temperature; signal range check high
9-48 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
995 105 4 Sensor error charged air temperature; signal range check low
996 105 0 High charged air cooler temperature; warning threshold exceeded
997 105 0 High charged air cooler temperature; shut off threshold exceeded
1007 412 3 Sensor error EGR cooler downstream temperature; signal range check high
1008 412 4 Sensor error EGR cooler downstream temperature; signal range check low
1009 412 2 Sensor exhaust gas temperature Venturi unit (EGR); plausibility error
1011 523960 0 Physical range check high for EGR cooler downstream temperature
1012 523960 1 Physical range check low for EGR cooler downstream temperature
1013 523960 11 Sensor exhaust gas temperature Venturi unit (EGR); plausibility error
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check
1014 51 6
high
1015 51 5
low
Actuator position for EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8)
1016 51 7
not plausible
1017 51 5 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); open load
Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); power stage
1018 51 12
over temperature
1019 51 3 EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery
1020 51 4 EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground
1021 51 12 Mechanical actuator defect EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8)
1022 51 6
high
1023 51 5
low
Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8);
1024 51 3
signal range check high
Position sensor error actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal
1025 51 4
range check low
1026 4769 2 Sensor exhaust gas temperature downstream (DOC); plausibility error
1029 4766 0 Physical range check high for exhaust gas temperature downstream (DOC)
1032 4766 1 Physical range check low for exhaust gas temperature downstream (DOC)
1034 4769 3 Sensor error exhaust gas temperature downstream (DOC); signal range check high
1035 4769 4 Sensor error exhaust gas temperature downstream (DOC); signal range check low
1036 4768 2 Sensor exhaust gas temperature upstream (DOC); plausibility error
1039 4765 0 Physical range check high for exhaust gas temperature upstream (DOC)
1042 4765 1 Physical range check low for exhaust gas temperature upstream (DOC]
Sensor error exhaust gas temperature upstream (DOC); signal range
1044 4768 3
check high
Sensor error exhaust gas temperature upstream (DOC); signal range
1045 4768 4
check low
1047 3248 4 Sensor error particle filter downstream temperature; signal range check low
1066 1180 11 Sensor exhaust gas temperature upstream turbine; plausibility error
Sensor error exhaust gas temperature upstream turbine; signal range
1067 1180 3
check high
G5-18A, 2505H, 25.5 9-49

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
Sensor error exhaust gas temperature upstream turbine; signal range
1068 1180 4
check low
1069 4360 0 Physical range check high for urea catalyst upstream temperature
1070 4360 1 Physical range low for urea catalyst upstream temperature
Sensor error urea catalyst exhaust gas temperature upstream; signal range check
1072 4360 3
high
Sensor error urea catalyst exhaust gas temperature upstream; signal range check
1073 4360 4
low
1074 1761 14 Urea tank level; warning threshold exceeded
1077 3361 3 Urea dosing valve; short circuit to battery on high side
1078 3361 3 Urea dosing valve; short circuit to battery or open load on high side
1079 3361 4 Urea dosing valve; short circuit to ground or open load on low side
1080 3361 4 Urea dosing valve; short circuit on high side
1081 4345 5 SCR heater relay urea return line secondary side; open load
1082 4366 5 SCR main relay (secondary side); open load
1083 4343 5 SCR heater relay urea pressure line secondary side; open load
1084 4366 5 SCR main relay (secondary side); Shortcut to battery
1085 4366 5 SCR main relay (secondary side); shortcut to ground
1086 4341 5 SCR heater relay urea supply line secondary side; open load
1087 523719 5 SCR heater relay urea supply module secondary side; open load
1088 4366 5 SCR Tank heating valve secondary side; open load
1089 4243 11 SCR system heater diagnostic reports error; shut off SCR-system
1090 4345 5 SCR heater relay urea return line primary side; open load
1092 4345 3 SCR heater urea return line; short circuit to battery
1093 4345 4 SCR heater urea return line; short circuit to ground
1094 4343 5 SCR heater relay urea pressure line primary side; open load
1096 4343 3 SCR heater urea pressure line; short circuit to battery
1097 4343 4 SCR heater urea pressure line; short circuit to ground
1098 523718 5 SCR main relay (primary side); open load
1099 523718 12 SCR main relay (primary side); powerstage over temperature
1100 523718 3 SCR main relay (primary side); short circuit to battery
1101 523718 4 SCR main relay (primary side); short circuit to ground
1102 4341 5 SCR heater relay urea supply line primary side; open load
1104 4341 3 SCR-heater urea supply line; short circuit to battery
1105 4341 4 SCR-heater urea supply line; short circuit to ground
1106 523719 5 SCR heater relay urea supply module primary side; open load
1108 523719 3 SCR heater urea supply module; short circuit to battery
1109 523719 4 SCR heater urea supply module; short circuit to ground
1110 4366 5 SCR tank heating valve primary side; open load
1111 4366 12 SCR-heater relay urea tank powerstage output; over temperature
1112 4366 3 SCR Tank heating valve; short circuit to battery
1113 4366 4 SCR Tank heating valve; short circuit to ground
1118 4375 5 Urea pump motor; open load
1120 4375 3 Urea pump motor; short circuit to battery
9-50 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
1121 4375 4 Urea pump motor; short circuit to ground
1122 4334 0 Physical range check high for Urea Pump Pressure
1123 4334 1 Physical range check low for Urea Pump Pressure
1124 4334 0 Urea pump pressure sensor; high signal not plausible
1125 4334 1 Urea pump pressure sensor; low signal not plausible
1127 4334 3 Sensor error urea pump pressure; signal range check high
1128 4334 4 Sensor error urea pump pressure; signal range check low
1129 4376 5 SCR reversing valve; open load
1130 4376 12 SCR reversing valve; over temperature
1131 4376 3 SCR reversing valve; short circuit to battery
1132 4376 4 SCR reversing valve; short circuit to ground
1135 3031 0 AdBlue-Tank temperature; maximum exceeded
1136 3031 1 DEF-Tank temperature; below minimum
1138 3031 3 Sensor error urea tank temperature; short circuit to battery
1139 3031 4 Sensor error urea tank temperature; short circuit to ground
1157 97 12 Water in fuel level prefilter; maximum value exceeded
1158 523946 0 Zero fuel calibration injector 1 (in firing order); maximum value exceeded
1164 523946 1 Zero fuel calibration injector 1 (in firing order); minimum value exceeded
1170 523612 12 Internal software error ECU
1171 175 2 Customer oil temperature; signal un-plausible
1173 523973 14 SCR Tamper detection; derating timer below limit 1
1174 523974 14 SCR Tamper detection; derating timer below limit 2
1175 523975 14 Urea quality; derating timer below limit 1
1176 523976 14 Urea quality; derating timer below limit 2
1177 523977 14 Urea tank level; derating timer below limit 1
1178 523978 14 Urea tank level; derating timer below limit 2
1180 168 0 Physical range check high for battery voltage
1181 168 1 Physical range check low for battery voltage
1182 172 0 Physical range check high for intake air temperature
1183 172 1 Physical range check low for intake air temperature
1187 523980 14 Bad quality of reduction agent detected
1192 523922 12 Over temperature error on burner shut of valve
1193 1180 0 Physical range check high for exhaust gas temperature upstream turbine
1194 1180 1 Physical range check low for exhaust gas temperature upstream turbine
G5-18A, 2505H, 25.5 9-51

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
1216 523914 5 Glow plug control release line; short circuit error
1217 523914 11 Glow plug control; internal error
DPF wasn't regenerated, power reduction phase 1 (manual
1219 524018 14
regeneration request)
DPF wasn't regenerated, power reduction phase 2 (manual
1220 524022 14
regeneration request)
1221 524023 14 DPF wasn't regenerated, warning condition (manual regeneration mode)
1222 190 14 Camshaft- and Crankshaft speed sensor signal not available on CAN
1223 51 5 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); open load
1224 51 6 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over current
1225 51 12 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over temperature
1226 51 3 EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A02)
1227 51 3 EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A67)
1228 51 4 EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground (A02)
1229 51 4 EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground (A67)
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Overload by short-
1230 51 6
circuit
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Power stage over
1231 51 11
temperature due to high current
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Voltage
1232 51 4
below threshold
1240 523985 3 UB7; Short circuit to battery error of actuator relay £
1243 523988 5 Charging lamp; open load
1244 523988 12 Charging lamp; over temperature
1245 523988 3 Charging lamp; short circuit to battery
1246 523988 4 Charging lamp; short circuit to ground
1247 524019 11 Air Pump; air lines blocked
1248 523910 9 Air Pump; CAN communication lost
1249 523910 7 Air pump; CAN communication interrupted no purge function available
1250 523910 12 Air Pump; internal error
1251 523910 0 Air Pump; power stage over temperature
1252 523910 0 Air Pump; operating voltage error
1253 523911 7 Burner dosing valve (DV2); blocked closed
1254 524014 1 Air pressure glow plug flush line; below limit
1255 524013 7 Burner operation is interrupted too often
1256 523915 7 HCI dosing valve (DV1); blocked closed
1257 523915 7 HCI dosing valve (DV1); blocked open
1258 524016 11 HFM sensor; electrical fault
1259 524016 2 Amount of air is not plausible to pump speed
1260 524016 2 Calculated amount of air is not plausible to HFM reading
1261 523910 6 Air Pump; over current
1262 523922 7 Burner Shut Off Valve; blocked closed
1263 524021 11 Burner fuel line pipe leak behind Shut Off Valve
1264 523922 7 Burner Shut Off Valve; blocked open
9-52 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
1265 524017 12 Spark plug control unit (SPCU); electrical fault
1266 524017 12 Spark plug control unit (SPCU); internal error
1267 523989 0
value exceeded
1268 523990 0
value exceeded
1269 523989 1
value exceeded
1270 523990 1
value exceeded
1279 523992 9 Time out Error of CAN-Receive-Frame DM19Voll; NOX sensor upstream
1283 523993 9 Time out Error of CAN-Receive-Frame DM19Vol2; NOX sensor downstream
Time out error of CAN-Receive-Frame ComMS_SyslTO (error memory Slave);
1285 524038 9
Master-Slave internal CAN message
Time out error of CAN-Receive-Frame ComMS_Sys2TO (error memory Slave);
1286 524039 9
1287 524040 9
1288 524041 9
1289 524042 9
1290 524043 9
Master-Slave CAN; Message-Counter-Error of CAN-Receive-Frame
1291 524045 9
ComMSMoFOvR
1292 524046 9 Master-Slave CAN; Checksum-Error of CAN-Receive-Frame ComMSMoFOvR
Master-Slave CAN; Messsage-Length-Error of CAN-Receive-Frame
1293 524047 9
ComMSMoFOvR
1294 524048 9 Time out error CAN message ComMSMoFOvRlTO error memory Slave
1295 524049 9 Message copy error in the Master/ Slave data transfer
1297 523788 0 CAN-Transmit-Frame ComTrbChActr "BusOff-Satus"; Wastegate
1298 523788 0 CAN-Transmit-Frame ComTrbChActr disable error; wastegate
1299 523788 0 CAN-Transmit-Frame ComTrbChActr plausibility error; wastegate
1300 523788 0 Time out Error of CAN-Transmit-Frame ComTrbChActr; Wastegate
Deviation of the exhaust gas temperature set point to actual value downstream
1302 524024 11
(DOC) too high
check of missing injector adjustment value programming (IMA) injector 7 (in firing
1324 523995 13
order)
check of missing injector adjustment value programming (IMA) injector 8 (in firing
1325 523996 13
order)
1327 523998 4 Injector cylinder bank 2 slave; short circuit
1328 523999 12 Injector powerstage output Slave defect
G5-18A, 2505H, 25.5 9-53

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
Injector diagnostics; time out error of short circuit to ground measurement cyl.
1337 2797 4
Bank 0
Injector diagnostics; time out error of short circuit to ground measurement cyl.
1338 2798 4
Bank 1
1339 2798 4 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 0
1340 2798 4 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 1
1341 524035 12 Injector diagnostics; time out error in the SPI communication
1342 524036 12 Injector diagnostics Slave; time out error in the SPI communication
Time out Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN
1345 524069 9
communication faulty
Error memory Slave reports FID MSMonFC2; Shut-Off Path test error of fuel
1357 524052 11
injection system
Error memory Slave reports FID MSMonFC3; time out of engine state messages
1368 524052 11
(ComMS_Sysl-7) from master ECU
1378 523919 2 Sensor air pump airpressure; plausibility error
1379 523920 2 Sensor exhaust gas back pressure burner; plausibility error
1380 3253 2 Sensor differential pressure (DPF); plausibility error
1381 164 2 Rail pressure safety function is not executed correctly
1389 523922 5 Burner Shut Off Valve; open load
1390 523922 12 Burner Shut Off Valve; powerstage over temperature
1392 523922 4 Burner Shut Off Valve; short circuit to ground
1395 523921 2 Sensor burner temperature; plausibility error
1398 1136 0 Physical range check high for ECU temperature
1399 1136 1 Physical range check low for ECU temperature
1400 1136 3 Sensor error ECU temperature; signal range check high
1401 1136 4 Sensor error ECU temperature; signal range check low
Sensor exhaust gas temperature OxiCat downstream (normal operation); plausibility
1402 4769 2
error
Sensor exhaust gas temperature OxiCat downstream (regeneration); plausibility
1403 4769 2
error
1404 3248 2 Sensor exhaust gas temperature downstream DPF; plausibility error
Physical range check high for exhaust gas temperature particulate
1405 3248 0
filter downstream
1406 3248 0
filter downstream; shut off regeneration
1407 3248 0
filter downstream; warning
Physical range check low for exhaust gas temperature particulate
1408 3248 1
filter downstream
Physical range check low for exhaust gas temperature particulate filter downstream;
1409 3248 1
9-54 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
Physical range check low for exhaust gas temperature particulate filter downstream;
1410 3248 1
warning
1411 1188 11 Wastegate actuator; internal error
1412 1188 11 Wastegate actuator; EOL calibration not performed correctly
1413 1188 13 Wastegate actuator calibration deviation too large, re-calibration required
1414 1188 2 Wastegate; status message from ECU missing
1415 1188 7 Wastegate actuator; blocked
1416 1188 11 Wastegate actuator; over temperature (> 145°C]
1417 1188 11 Wastegate actuator; over temperature (> 135°C]
1418 1188 11 Wastegate actuator; operating voltage error
1431 524028 2 CAN message PROEGRActr; plausibility error
Time out Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation
1432 524029 2
positioner
1436 524034 5 Disc Separator; open load
1437 524034 12 Disc Separator; power stage over temperature
1438 524034 3 Disc separator; short circuit to battery
1439 524034 4 Disc separator; short circuit to ground
1440 524030 7 EGR actuator; internal error
1441 524031 13 EGR actuator; calibration error
1442 524032 2 EGR actuator; status message "EGRCust" is missing
1443 524033 7 EGR actuator; due to overload in Save Mode
1444 2621 5 Flush valve burner (EPV DPF-System); open load
1445 2621 12 Flush valve burner (EPV DPF-System); powerstage over temperature
1446 2621 3 Flush valve burner (EPV DPF-System); short circuit to battery
1447 2621 4 Flush valve burner (EPV DPF-System); short circuit to ground
1448 175 0 High customer oil temperature; warning threshold exceeded
1449 175 0 High customer oil temperature; shut off threshold exceeded
1453 411 0 Differential pressure Venturi unit (EGR); warning threshold exceeded
1454 411 1 Differential pressure Venturi unit (EGR); shut off threshold exceeded
Regeneration temperature (PFItRgn LigtOff) not reached;
1455 3711 12
regeneration aborted
1457 524055 4 Spark Plug Control Unit (SPCU); short circuit to ground
High exhaust gas temperature EGR cooler downstream; warning
1458 523960 0
threshold exceeded
High exhaust gas temperature EGR cooler downstream; shut off
1459 523960 1
threshold exceeded
1460 1180 0 Turbocharger Wastegate CAN feedback; warning threshold exceeded
1460 1180 0 Turbocharger Wastegate CAN feedback; warning threshold exceeded
1461 1180 1 Turbocharger Wastegate CAN feedback; shut off threshold exceeded
1461 1180 1 Turbocharger Wastegate CAN feedback; shut off threshold exceeded
1462 1180 0 Exhaust gas temperature upstream turbine; warning threshold exceeded
G5-18A, 2505H, 25.5 9-55

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
1462 1180 0 Exhaust gas temperature upstream turbine; warning threshold exceeded
1463 1180 1 Exhaust gas temperature upstream turbine; shut off threshold exceeded
1463 1180 1 Exhaust gas temperature upstream turbine; shut off threshold exceeded
1474 524037 5 Ash lamp; open load
1474 524037 5 Ash lamp; open load
1475 34 2 Sensor vehicle speed; plausibility error
1475 84 2 Sensor vehicle speed; plausibility error
1477 524037 3 Ash lamp; short circuit to battery
1477 524037 3 Ash lamp; short circuit to battery
1478 524037 4 Ash lamp; short circuit to ground
1478 524037 4 Ash lamp; short circuit to ground
1479 524062 12 Regeneration inhibit switch not available; ComlnhSwtNA
1479 524062 12 Regeneration inhibit switch not available; ComlnhSwtNA
1480 524062 12 Regeneration release switch not available; ComRegSwtNA
1480 524062 12 Regeneration release switch not available; ComRegSwtNA
1481 524025 5 DPF system; operating voltage error
1482 524044 9 CAN message ComMS_Sys7 not received from slave
1483 523632 2 Metering control is not performed in time error
1484 524068 2 Master ECU and Slave ECU have been identified as the same types
1484 524068 2 Master ECU and Slave ECU have been identified as the same types
1485 524052 11 Master ECU and Slave ECU data sets or software are not identical
1485 524052 11 Master ECU and Slave ECU data sets or software are not identical
1486 523718 5 SCR main relay; open load (only CV56B)
1487 523718 12 SCR main relay; powerstage over temperature (only CV56B)
1487 523718 12 SCR main relay; powerstage over temperature (only CV56B)
1488 523718 3 SCR main relay; short circuit to battery (only CV56B)
1488 523718 3 SCR main relay; short circuit to battery (only CV56B)
1489 523718 4 SCR main relay; short circuit to ground (onlyCV56B)
1489 523718 4 SCR main relay; short circuit to ground (only CV56B)
1494 2659 0 Physical range check high for EGR mass flow
1494 2659 0 Physical range check high for EGR mass flow
1495 2659 1 Physical range check low for EGR mass flow
1495 2659 1 Physical range check ow for EGR mass flow
1496 2659 11 Exhaust gas recirculation; EGR mass flow; shut off demand
1496 2659 11 Exhaust gas recirculation; EGR mass flow; shut off demand
1505 524057 2 Electric fuel pump; fuel pressure build up error
1505 524057 2 Electric fuel pump; fuel pressure build up error
1523 2659 2 Exhaust gas recirculation AGS sensor; plausibility error
9-56 G5-18A, 2505H, 25.5

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
1523 2659 2 Exhaust gas recirculation AGS sensor; plausibility error
1524 2659 0 Physical range check high for EGR exhaust gas mass flow
1524 2659 0 Physical range check high for EGR exhaust gas mass flow
1525 2659 1 Physical range check low for EGR exhaust gas mass flow
1525 2659 1 Physical range check low for EGR exhaust gas mass flow
1526 2659 12 Exhaust gas recirculation; AGS sensor has "burn off" not performed
1526 2659 12 Exhaust gas recirculation; AGS sensor has "burn off1' not performed
1527 2659 2 AGS sensor temperature exhaust gas mass flow; plausibility error
1527 2659 2 AGS sensor temperature exhaust gas mass flow; plausibility error
1615 3699 14 Maximum stand-still-duration reached; oil exchange required
1615 3699 14 Maximum stand-still-duration reached; oil exchange required
DPF differential pressure sensor and a further sensor or actuator CRT system
1616 3699 2
defective
DPF differential pressure sensor and a further sensor or actuator CRT system
1616 3699 2
defective
1617 3699 2 Temperature sensor us. and ds. DOC simultaneously defect
1617 3699 2 Temperature sensor us, and ds, DOC simultaneously defect
1659 524114 9 Time out error of CAN-Transmit-Frame A1DOC
1659 524114 9 Time out error of CAN-Transmit-Frame A1DOC
1660 524115 9 Time out error of CAN-Transmit-Frame AT1S
1660 524115 9 Time out error of CAN-Transmit-Frame AT IS
1661 524116 9 Time out error of CAN-Transmit-Frame SCR2
1663 524097 9 Time out error of CAN-Transmit-Frame DPFBrnAirPmpCtl
1663 524097 9 Time out error of CAN-Transmit-Frame DPFBrnAirPmpCtl
1664 524098 9 Time out error of CAN-Transmit-Frame ComDPFBrnPT
1664 524098 9 Time out error of CAN-Transmit-Frame ComDPFBrnPT
1665 524099 9 Time out error of CAN-Transmit-Frame ComDPFCl
1665 524099 9 Time out error of CAN-Transmit-Frame ComDPFCl
1666 524100 9 Time out error of CAN-Transmit-Frame ComDPFHisDat
1666 524100 9 Time out error of CAN-Transmit-Frame ComDPFHisDat
1667 524101 9 Time out error of CAN-Transmit-Frame ComDPFTstMon
1667 524101 9 Time out error of CAN-Transmit-Frame ComDPFTstMon
1668 524105 9 Time out error of CAN-Transmit-Frame ComEGRMsFlw
1668 524105 9 Time out error of CAN-Transmit-Frame ComEGRMsF Iw
1669 524108 9 Time out error of CAN-Transmit-Frame ComEGRTVActr
1669 524108 9 Time out error of CAN-Transmit-Frame ComEGRTVActr
1670 524110 9 Time out error of CAN-Transmit-Frame ComETVActr
1670 524110 9 Time out error of CAN-Transmit-Frame ComETVActr
1671 524112 9 Time out ComlTVActr
1671 524112 9 Time out ComlTVActr
1672 524118 9 Time out error of CAN-Receive-Frame ComRxCMl
G5-18A, 2505H, 25.5 9-57

Electrical System
Fault SPN FMI

Deutz Description
Codes Codes Codes
1672 524118 9 Time out error of CAN-Receive-Frame ComRxCMl
1673 524119 9 Time out error of CAN-Receive-Frame ComRxCustSCR3
1673 524119 9 Time out error of CAN-Receive-Frame ComRxCustSCR3
1674 524102 9 Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
1674 524102 9 Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
1675 524103 9 Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmp
1675 524103 9 Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmp
1676 524104 9 Time out error of CAN-Receive-Frame ComRxDPFCtl
1676 524104 9 Time out error of CAN-Receive-Frame ComRxDPFCtl
1677 524106 9 Time out error of CAN-Receive-Frame ComRxEGRMsFlwl
1677 524106 9 Time out error of CAN-Receive-Frame ComRxEGRMsFlwl
1678 524107 9 Time out error of CAN-Receive-Frame ComRxEGRMsFlw2
1678 524107 9 Time out error of CAN-Receive-Frame ComRxEGRMsFlw2
1679 524109 9 Time out error of CAN-Receive-Frame ComRxEGRTVActr
1679 524109 9 Time out error of CAN-Receive-Frame ComRxEGRTVActr
1680 524111 9 Time out error of CAN-Receive-Frame ComRxETVActr
1680 524111 9 Time out error of CAN-Receive-Frame ComRxETVActr
1681 524113 9 Time out error of CAN-Receive-Frame ComRxlTVActr
1681 524113 9 Time out error of CAN-Receive-Frame ComRxlTVActr
1682 524120 9 Time out error of CAN-Receive-Frame ComRxSCRHtDiag
1682 524120 9 Time out error of CAN-Receive-Frame ComRxSCRHtDiag
1683 524121 9 Time out error of CAN-Receive-Frame ComRxTrbChActr
1683 524121 9 Time out error of CAN-Receive-Frame ComRxTrbChActr
1684 524122 9 Time out error of CAN-Receive-Frame ComRxUQSens
1684 524122 9 Time out error of CAN-Receive-Frame ComRxUQSens
1685 524123 9 Time out error of CAN-Receive-Frame ComSCRHtCtl
1685 524123 9 Time out error of CAN-Receive-Frame ComSCRHtCt
1686 524124 9 Time out error of CAN-Receive-Frame ComTxATllMG
1686 524124 9 Time out error of CAN-Receive-Frame ComTxATllMG
1687 524125 9 Time out error of CAN-Receive-Frame ComTxTrbChActr
1687 524125 9 Time out error of CAN-Receive-Frame ComTxTrbChActr
14S1 524025 5 DPF system; operating voltage error
14S2 524044 9 CAN message ComMS_Sys7 not received from slave
14S3 523632 2 Metering control is not performed in time error
I486 523718 5 SCR main relay; open load (only CV56B)
9-58 G5-18A, 2505H, 25.5

31200926
An Oshkosh Corporation Company
JLG Industries, Inc.

1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: +1-717-485-5161
Customer Support Toll Free: 1-877-554-5438
Fax: +1-717-485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Antonia Martins Luiz, 580 Bentley House Z.I. de Baulieu
11 Bolwarra Road Distrito Industrial João Narezzi Bentley Avenue 47400 Fauillet
Port Macquarie 13347-404 Indaiatuba - SP Middleton France
N.S.W. 2444 Brazil Greater Manchester Phone: +33 (0)5 53 88 31 70
Australia Phone: +55 19 3936 8870 M24 2GP Fax: +33 (0)5 53 88 31 79
Phone: +61 2 65811111 Fax: +55 19 3935 2312 England
Fax: +61 2 65813058 Phone: +44 (0)161 654 1000
Fax: +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude-lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N.T. Italy The Netherlands
Phone: +49 (0)421 69 350 20 Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
Fax: +852 2639 5797
JLG Polska Plataformas Elevadoras JLG Sverige AB

UI. Krolewska JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa Trapadella, 2 Box 704
Poland P.I. Castellbisbal Sur SE - 176 27 Jarfalla
Phone: +48 (0)914 320 245 08755Castellbisbal, Barcelona Sweden
Fax: +48 (0)914 358 200 Spain Phone: +46 (0)850 659 500
Phone: +34 93 772 4 700 Fax: +46 (0)850 659 534
Fax: +34 93 771 1762
www.jlg.com

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Service Manual

An Oshkosh Corporation Company

May 9, 2013 - A - Original Issue Of Manual

31200926 G5-18A, 2505H, 25.5 a

b G5-18A, 2505H, 25.5 31200926

G5-18A, 2505H, 25.5 i

ii G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 iii

iv G5-18A, 2505H, 25.5

PARAGRAPH TITLE PAGE

G5-18A, 2505H, 25.5 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1-2 G5-18A, 2505H, 25.5

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

G5-18A, 2505H, 25.5 1-3

1-4 G5-18A, 2505H, 25.5

PARAGRAPH TITLE PAGE

G5-18A, 2505H, 25.5 2-1

2.1 REPLACEMENT PARTS AND

Before ordering parts or initiating service inquiries, make

2-2 G5-18A, 2505H, 25.5

2.2 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

G5-18A, 2505H, 25.5 2-3

2.2.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2-4 G5-18A, 2505H, 25.5

2.2.1 SAE Fastener Torque Chart (Continued)

SOCKET HEAD CAP SCREWS

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

G5-18A, 2505H, 25.5 2-5

2.2.1 SAE Fastener Torque Chart (Continued)

SOCKET HEAD CAP SCREWS

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2-6 G5-18A, 2505H, 25.5

2.2.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

G5-18A, 2505H, 25.5 2-7

2.2.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2-8 G5-18A, 2505H, 25.5

2.2.2 Metric Fastener Torque Chart (Continued)

CLASS 12.9 SOCKET HEAD CAP SCREWS

Sq mm kN [N.m] [N.m] [N.m]

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

G5-18A, 2505H, 25.5 2-9

2.2.3 Hydraulic Hose Torque Chart Torque Wrench: