G5-18a Service Manual

Service Manual
Models
G5-18A & 2505H
Agrovector
25.5
SN 0160053000 to Present including
0160051045, 0160051047, 0160051049,
0160051194 & 0160051359
31200926
Revised
January 15, 2018
An Oshkosh Corporation Company

EFFECTIVITY PAGE
DATE REVISION DESCRIPTION

May 9, 2013 A Original Issue Of Manual.
January 8, 2015 B Revise Pages 1-4, 2-2 thru 2-12, 2-16, 2-17, 7-2.
August 11, 2016 C Revise Pages 2-4 thru 2-10, 2-25 thru 2-72, 3-4, 3-15, 4-4, 4-8 thru 4-11, 7-5, 7-9,
7-12, 7-13, 8-3, 8-7 thru 8-17, 8-26, 8-27, 8-37, 9-4, 9-8 thru 9-25, 9-26 thru 9-28,
9-32, 9-33, 9-42 thru 9-51, 9-54 thru 9-57, 9-63 thru 9-67.
January 15, 2018 D Revised Pages 2-6, 2-7, 9-8, 9-17, 9-27. Added pages 3-7, 3-8, 5-9.
G5-18A, 2505H, 25.5 31200926 i

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.
MAE2820
ii 31200926 G5-18A, 2505H, 25.5

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 .......................................................................................... 2-3
2.2 Specifications ......................................................................................................................... 2-4
2.3 Fluids, Lubricants and Capacities ................................................................................................................... 2-6
2.4 Maintenance Schedule ...................................................................................................................................... 2-9
2.5 Lubrication Schedule .......................................................................................................................................... 2-12
2.6 Thread Locking Compound ............................................................................................................................. 2-13
2.7 Torque Charts ........................................................................................................................................................ 2-14
2.8 Hydraulic Connection Assembly and Torque Specification ................................................................. 2-24
Section 3
Boom ......................................................................................................................... 1-1
3.1 Boom System Component Terminology ..................................................................................................... 1-2
3.3 Two Section Boom System ............................................................................................................................... 1-3
3.4 Boom Assembly Maintenance ......................................................................................................................... 1-3
3.5 Boom Wear Pads .................................................................................................................................................. 1-11
3.6 Quick Attach Assembly ...................................................................................................................................... 1-12
3.7 Forks .......................................................................................................................................................................... 1-13
3.8 Boom Prop (if equipped) ................................................................................................................................... 1-14
3.9 Emergency Boom Lowering Procedure ....................................................................................................... 1-15
3.10 Troubleshooting ................................................................................................................................................... 1-17
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 .......................................................................................................................................................... 4-11
4.6 Cab Installation ..................................................................................................................................................... 4-12
G5-18A, 2505H, 25.5 31200926 iii

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 ............................................................................................................................................................ 5-10
5.6 Wheels and Tires .................................................................................................................................................. 5-11
5.7 Steering Angle Adjustment .............................................................................................................................. 5-12
5.8 Brakes ....................................................................................................................................................................... 5-12
5.9 Towing a Disabled Machine ............................................................................................................................. 5-13
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 .................................................................................................................................... 7-8
7.4 Fuel System ............................................................................................................................................................ 7-8
7.5 Engine Exhaust System ...................................................................................................................................... 7-10
7.6 Air Cleaner Assembly .......................................................................................................................................... 7-11
7.7 Engine Replacement ........................................................................................................................................... 7-13
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 ............................................................................................................................................. 8-15
8.9 Hydraulic System Pump .................................................................................................................................... 8-17
8.10 Front Drive Motor ................................................................................................................................................ 8-18
8.11 Control Valves ....................................................................................................................................................... 8-19
8.12 Hydraulic Cylinders ............................................................................................................................................. 8-32
iv 31200926 G5-18A, 2505H, 25.5

Section 9
Electrical System .................................................................................................................. 9-1
9.1 Electrical Component Terminology .............................................................................................................. 9-3
9.3 Fuses and Relays ................................................................................................................................................... 9-5
9.4 Electrical System Schematics ........................................................................................................................... 9-8
9.5 Dielectric Grease Application .......................................................................................................................... 9-37
9.6 Engine Start Circuit .............................................................................................................................................. 9-40
9.7 Charging Circuit .................................................................................................................................................... 9-42
9.8 Battery ...................................................................................................................................................................... 9-43
9.9 Electrical System Components ........................................................................................................................ 9-44
9.10 Window Wiper/Washer ...................................................................................................................................... 9-46
9.11 Cab Heater/AC and Fan ..................................................................................................................................... 9-48
9.12 Switches, Solenoids and Senders ................................................................................................................... 9-49
9.13 Load Stability Indicator (LSI) (2505H & 25.5) .............................................................................................. 9-53
9.14 Analyzer ................................................................................................................................................................... 9-62
9.15 Analyzer Software Accessibility ...................................................................................................................... 9-65
9.16 Telematics Gateway ............................................................................................................................................ 9-69
9.17 Diagnostic Trouble Codes (DTC) on Ground Module ............................................................................. 9-74
9.18 Engine Diagnostic Trouble Code .................................................................................................................... 9-78
G5-18A, 2505H, 25.5 31200926 v

vi 31200926 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 31200926 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 the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
directions for meeting every possible contingency during assistance and how to use a first-aid kit and fire extinguisher/
operation, maintenance, or testing. When additional fire suppression system. Keep emergency telephone
information is desired consult the local JLG Dealer. numbers (fire department, ambulance, rescue squad/
paramedics, police department, etc.) nearby. If working
Many factors contribute to unsafe conditions: carelessness, alone, check with another person routinely to help assure
fatigue, overload, inattentiveness, unfamiliarity, even drugs personal safety.
and alcohol, among others. For optimal safety, encourage
everyone to think, and to act, safely.
1.5.1 Safety Alert System and Signal Words
Appropriate service methods and proper repair procedures
are essential for the safety of the individual doing the work,
for the safety of the operator, and for the safe, reliable
operation of the machine. All references to the right side, left
DANGER
side, front and rear are given from the operator’s seat looking in
a forward direction. DANGER indicates an imminently hazardous situation
Supplementary information is available from JLG in the form which, if not avoided, will result in death or serious injury.
of Service Bulletins, Service Campaigns, Service Training
Schools, the JLG website, other literature and through
updates to the manual itself. WARNING
1.2 DISCLAIMER
WARNING indicates a potentially hazardous situation which,
All information in this manual is based on the latest product if not avoided, could result in death or serious injury.
information available at the time of publication. JLG reserves
the right to make changes and improvements to its products,
and to discontinue the manufacture of any product, at its CAUTION
discretion at any time without public notice or obligation.
1.3 OPERATION & SAFETY MANUAL CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
The mechanic must not operate the machine until the
Operation & Safety Manual has been read and 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 31200926 G5-18A, 2505H, 25.5

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider BEFORE
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator’s cab
procedures are located throughout this manual and are clean, and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions BEFORE proceeding. to use it.
CLEANLINESS: Wear eye protection and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat. Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run-off.
least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.6.2 Equipment Hazards machine is needed, ensure machine is shut down before
pressure-washing. Should pressure-washing be utilized to
LIFTING OF EQUIPMENT: Before using any lifting equipment
wash areas containing electrical/electronic components, it is
(chains, slings, brackets, hooks, etc.), verify that it is of the
recommended a maximum pressure of 750 psi (52 bar) at a
proper capacity, in good working order, and is properly
minimum distance of 12 in (30,5 cm) away from these
attached.
components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation.
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal 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 31200926 1-3

Safety Practices
1.6.4 Operational Hazards NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
ENGINE: Stop the engine before performing any service
explosion.
unless specifically instructed otherwise.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture
VENTILATION: Avoid prolonged engine operation in
can cause an explosion.
enclosed areas without adequate ventilation.
PRESSURE TESTING: When conducting any test, only use test
SOFT SURFACES AND SLOPES: NEVER work on a machine
equipment that is correctly calibrated and in good condition.
that is parked on a soft surface or slope. The machine must be
Use the correct equipment in the proper manner, and make
on a hard level surface, with the wheels blocked before
changes or repairs as indicated by the test procedure to
performing any service.
achieve the desired result.
FLUID TEMPERATURE: NEVER work on a machine when
LEAVING MACHINE: Lower the forks or attachment to the
engine, cooling or hydraulic systems are hot. Hot
ground before leaving the machine.
components and fluids can cause severe burns. Allow
systems to cool before proceeding. TIRES: Always keep tires inflated to the proper pressure to
help prevent tipover. DO NOT over-inflate tires.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear NEVER use mismatched tire types, sizes or ply ratings.
heavy, protective gloves and eye protection. NEVER check Always use matched sets according to machine
for leaks using any part of your body; use a piece of specifications.
cardboard or wood instead. If injured, seek medical attention MAJOR COMPONENTS: Never alter, remove, or substitute any
immediately. Diesel fluid leaking under pressure can items such as counterweights, tires, batteries or other items
explode. Hydraulic fluid and diesel fuel leaking under that may reduce or affect the overall weight or stability of the
pressure can penetrate the skin, cause infection, gangrene machine.
and other serious personal injury.
BATTERY: DO NOT charge a frozen battery. Charging a frozen
Engine fuel lines are pressurized. DO NOT attempt repairs battery may cause it to explode. Allow the battery to thaw
unless specific training has been completed. Refer to the before jump-starting or connecting a battery charger.
engine manufacturers’ manual for specific details
concerning the fuel system. 1.7 SAFETY DECALS
Relieve all pressure before disconnecting any component,
part, line or hose. Slowly loosen parts and allow release of Check that all safety decals are present and readable on the
residual pressure before removing any part or component. machine. Refer to the Operation & Safety Manual supplied
Before starting the engine or applying pressure, use with machine for information.
components, parts, hoses and pipes that are in good
condition, connected properly and are tightened to the
proper torque. Capture fluid in an appropriate container and
dispose of in accordance with prevailing environmental
regulations.
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.
1-4 31200926 G5-18A, 2505H, 25.5

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.4 Steering Angle Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.5 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.1 Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.1 10,1st 50 & 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.2 1st 250, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.3 1000 & 1500 Hour Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.5.1 250 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.7.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.7.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
G5-18A, 2505H, 25.5 31200926 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.8.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-28
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections. 2-29
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.8.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . 2-34
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . 2-36
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . . 2-50
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . . 2-58
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . 2-60
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . . 2-68
2.8.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
2.8.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
2.8.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
2.8.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
2-2 31200926 G5-18A, 2505H, 25.5

2.1 REPLACEMENT PARTS AND WARRANTY

INFORMATION
1
MY8351
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.
G5-18A, 2505H, 25.5 31200926 2-3

2.2 SPECIFICATIONS
2.2.1 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)
2.2.2 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
2.2.3 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
2.2.4 Steering Angle Specification
Model Angle (in Degrees)

G5-18A, 2505H, 25.5 37
2-4 31200926 G5-18A, 2505H, 25.5

2.2.5 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
2.2.6 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)
G5-18A, 2505H, 25.5 31200926 2-5

2.3 FLUIDS, LUBRICANTS AND CAPACITIES
2.3.1 Fluids
a. If Equipped for ULS
Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
SAE 0W-40 -40 104 -40 40
SAE 0W-30 -40 86 -40 30
SAE 5W-30 -22 86 -30 30
Deutz DQC III-10 LA
SAE 5W-40 -22 86 -30 30
Engine Crankcase or
SAE 10W-30 -4 86 -20 30
Deutz DQC IV-10 LA
SAE 10W-40 -4 114 -20 45
SAE 15W-40 6 114 -14 45
SAE 20W-50 24 122 -5 50
75W-90LS -40 115 -40 46
Axle Differential
85W-90LS
and API GL5 with LS Additives
or -4 115 -20 46
Wheel End
80W-90LS
MobilFluid 424 10W-30 6 115 -15 46

Hydraulic System
Exxon Univis HVI -40 100 -40 40
Brake System MobilFluid 424 10W-30 6 115 -15 46
Boom Wear Pad
Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
Grease
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 122 -15 50
with Moly
Additive
Ethylene Glycol 50/50 Mix Standard

Engine Coolant
and Water 60/40 Mix Cold Weather
EN 590
ASTM D 975 Grade 1-D Ultra Low Sulfur
Fuel
ASTM D 975 Grade 2-D (S ≤ 15 mg/kg)
(Maximum B5 Biodiesel)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane
2-6 31200926 G5-18A, 2505H, 25.5

b. If Equipped for LS
Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
SAE 0W-40 -40 104 -40 40
SAE 0W-30 -40 86 -40 30
SAE 5W-30 -22 86 -30 30
Deutz DQC II-10,
SAE 5W-40 -22 86 -30 30
Engine Crankcase Deutz DQC III-10
or SAE 10W-30 -4 86 -20 30
Deutz DQC IV-10
SAE 10W-40 -4 114 -20 45
SAE 15W-40 6 114 -14 45
SAE 20W-50 24 122 -5 50
75W-90LS -40 115 -40 46
Axle Differential
85W-90LS
and API GL5 with LS Additives
or -4 115 -20 46
Wheel End
80W-90LS
Axle Differential
and 75W-90LS -40 115 -40 46
Wheel End
API GL5 with LS Additives 85W-90LS

or -4 115 -20 46
80W-90LS
Hydraulic System 10W-30 6 115 -15 46
Exxon Univis HVI -40 100 -40 40
Brake System MobilFluid 424 10W-30 6 115 -15 46
Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 122 -15 50
with Moly
Additive
Ethylene Glycol 50/50 Mix Standard

Engine Coolant
and Water 60/40 Mix Cold Weather
EN 590
ASTM D 975 Grade 1-D Low Sulfur
Fuel
ASTM D 975 Grade 2-D (S ≤ 500 mg/)kg
(Maximum B5 Biodiesel)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane
G5-18A, 2505H, 25.5 31200926 2-7

2.3.2 Capacities
Engine Crankcase Oil

Capacity with Filter Change 9.6 qt (9,1 L)
Fuel Tank
Capacity
Prior to SN 0160076806 excluding 0160076010,
24 gal (91 L)
0160076011, 0160076012
SN 0160076806 excluding 0160076010, 0160076011,
20 gal (76 L)
0160076012
Cooling System
System Capacity 14 qt (13,2 L)
Hydraulic System
System Capacity
24 gal (91 L)
0160076011, 0160076012
SN 0160076806 excluding 0160076010, 0160076011,
27 gal (103 L)
0160076012
Reservoir Capacity to Full Mark
16 gal (61 L)
0160076011, 0160076012
SN 0160076806 excluding 0160076010, 0160076011,
19 gal 973 L)
0160076012
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 (160 ml)
Wheel End Capacity 24 oz (0,7 L)
Front Axle Drop Box 21 oz (0,6 L)
Air Conditioning System (if equipped)
System Capacity 2.5 lb (1134 g)
2-8 31200926 G5-18A, 2505H, 25.5

2.4 MAINTENANCE SCHEDULE
2.4.1 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
G5-18A, 2505H, 25.5 31200926 2-9

2.4.2 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
2-10 31200926 G5-18A, 2505H, 25.5

2.4.3 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
G5-18A, 2505H, 25.5 31200926 2-11

2.5 LUBRICATION SCHEDULE
2.5.1 250 Hour Lubrication Schedule
EVERY
250
OAL1980
2-12 31200926 G5-18A, 2505H, 25.5

2.6 THREAD LOCKING COMPOUND
JLG P/N Loctite® ND Industries Description

0100011 242™ Vibra-TITE™121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™140 High Strength (Red)
0100071 262™ Vibra-TITE™131 Medium - High Strength (Red)
Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
G5-18A, 2505H, 25.5 31200926 2-13

2.7 TORQUE CHARTS
2.7.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Stress Clamp Torque Torque ™ ™
Size TPI Bolt Dia (Loctite® 242 or 271 or ™
Area Load (Dry) Lubricated (Loctite® 262 or
Vibra-TITETM
Vibra-TITETM 131)
111 or 140)
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 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
2-14 31200926 G5-18A, 2505H, 25.5

2.7.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque ™ ™ ™
Tensile Stress (Loctite® 242T or 271 or Vibra- (Loctite® 262 or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area ™ ™
K=0.20 TITE 111 or 140) Vibra-TITE 131)
K=0.18 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
G5-18A, 2505H, 25.5 31200926 2-15


Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Torque ™ ™ ™
Tensile Stress (Loctite® 242 or 271 or Vibra- (Loctite® 262 or
Size TPI Bolt Dia Clamp Load (Dry)
Area ™ ™
K=0.17 TITE 111 or 140) Vibra-TITE 131)
K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
2-16 31200926 G5-18A, 2505H, 25.5


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque ™ ™ ™
Tensile Stress (Loctite® 242 or 271 or Vibra- (Loctite® 262 or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area ™ 111 or 140) ™ 131)
K=0.17 TITE Vibra-TITE
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 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
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
G5-18A, 2505H, 25.5 31200926 2-17


SOCKET HEAD CAP SCREWS
Torque Torque
™ ™ ™
Tensile Stress Clamp Load Torque (Loctite® 242 or 271 or Vibra- (Loctite® 262 or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 ™ 111 or 140) or Precoat® 85 ™ 131)
TITE Vibra-TITE
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
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 320 435 300 415 280 380
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
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.
2-18 31200926 G5-18A, 2505H, 25.5


Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
SOCKET HEAD CAP SCREWS
Torque Torque
™ ™ ™
Tensile Stress Clamp Load Torque (Loctite® 242 or 271 or Vibra- (Loctite® 262 or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 ™ ™
TITE 111 or 140) or Precoat® 85 Vibra-TITE 131)
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
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 320 435 300 415 280 380
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
G5-18A, 2505H, 25.5 31200926 2-19

2.7.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Tensile Stress Clamp Load Torque ™ ™ ™ ™
Size Pitch Torque (Lub) (Loctite® 262 or 271 or (Loctite® 242 or 271 or
Area See Note 4 (Dry or Loctite® 263TM) ™ ™
Vibra-TITE 131) Vibra-TITE 111 or 141)
Sq mm KN [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
2-20 31200926 G5-18A, 2505H, 25.5

2.7.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque
Torque (Lub or Loctite®
Clamp Load
™
(Loctite® 262 or
Size Pitch Tensile Stress Area ™ ™ ™
(Dry or Loctite® 263 ) 242 or 271 or
See Note 4 ™
K=0.20 ™ Vibra-TITE 131)
Vibra-TITE 111 or 140)
K=0.15
K=0.18
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 23 19
8 1.25 36.60 22.8 37 33 27
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
G5-18A, 2505H, 25.5 31200926 2-21


Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque (Lub or Loctite®
Torque ™
(Loctite® 262 or
™ ™
Clamp Load ™ 242 or 271 or
Size Pitch Tensile Stress Area (Dry or Loctite® 263 ) ™
See Note 4 ™ Vibra-TITE 131)
K=0.17 Vibra-TITE 111 or 140)
K=0.15
K=0.16

3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
2-22 31200926 G5-18A, 2505H, 25.5


Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Torque Torque
Torque (Lub or Loctite® ™
Clamp Load See ™ ™ ™ (Loctite® 262 or
Size Pitch Tensile Stress Area (Dry or Loctite® 263 242 or 271 or
Note 4 ™
Vibra-TITE 131)
K=0.17 Vibra-TITETM 111 or 140)
K=0.18 K=0.15
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 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 55
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 3 353 222.0 905 850 800
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 31200926 2-23

2.8 HYDRAULIC CONNECTION ASSEMBLY SAE - 45° flare per SAE J512
AND TORQUE SPECIFICATION
2.8.1 Definitions
a. Tapered Thread Types
NPTF - National tapered fuel (dry seal) per SAE J476/J512

MAE9030
ORFS - O-ring face seal per SAE J1453
MAE9000 MAE9040
BSPT - British standard pipe tapered per ISO7-1 MBTL - Metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS - Metric flareless bite type fitting, pressure rating S (high)
per ISO 8434, DIN 2353
MAE9050
MAE9010
BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types

b. Straight Thread Types, Tube and Hose Connections
JIC - 37° flare per SAE J514
MAE9060
MAE9020
2-24 31200926 G5-18A, 2505H, 25.5

c. Straight Thread Types, Port Connections d. Flange Connection Types

FL61 - Code 61 flange per SAE J518, ISO 6162
ORB - O-ring boss per SAE J1926, ISO 11926
FL62 - Code 62 flange per SAE J518, ISO 6162
MPP - Metric pipe parallel o-ring boss per SAE J2244,
ISO 6149, DIN 3852
MAE9090
e. Tightening Methods
MAE9070
Torque - Application of a twisting force to the applicable
connection by use of a precise measurement instrument
MFF - Metric flat face port per ISO 9974-1 (i.e. torque wrench).
BSPP - British standard parallel pipe per ISO 1179-1, Finger Tight (Hand Tight) - The point where the connector
DIN 3852-2 will no longer thread onto the mating part when tightened
by hand or fingers. Finger Tight is relative to user strength
and will have some variance. The average torque applied by
this method is 4 Nm (3 ft-lbs).
TFFT - Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by
hand (fingers) and applying an additional rotation counted
by a defined number of turns by use of a tool.
FFWR (Flat method) - Flats From Wrench Resistance;
Application of a preload to a connection by tightening to
the point of initial wrench resistance and turning the nut a
described number of flats. A flat is one side of the hexagonal
tube nut and equates to 1/6 of a turn.
f. Assembly and Torque Specifications

Prior to selecting the appropriate torque from the tables
MAE9080
within this section, it is necessary to properly identify the
connector being installed.
g. General Tube Type Fitting Assembly Instructions

1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling
or assembly. Nicks and scratches in sealing surfaces can
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting
attachment to ensure that the tube has not been
damaged.
G5-18A, 2505H, 25.5 31200926 2-25

3. The assembly process is one of the leading causes for 6. Refer to the appropriate section in this manual for more
contamination in air and hydraulic systems. specific instructions and procedures for each type of
Contamination can prevent proper tightening of fittings fitting connection.
and adapters from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as
necessary before reinstalling.
c. Sealing compounds should be applied where
specified; however, care should be taken not to
introduce sealant into the system.
d. Avoid applying sealant to the area of the threads
where the sealant will be forced into the system.
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants.
o-rings or washers are provided for sealing.
g. When replacing or installing an o-ring, care is to be
taken while transferring the o-ring over the threads
as it may become nicked or torn. When replacing an
o-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with o-rings, lubrication
shall be used to prevent scuffing or tearing of the
o-ring. Refer to Section 2.8.17, “O-ring Installation
(Replacement)”, for procedure.
4. Take care to identify the material of parts to apply the
correct torque values.
a. Verify the material designation in the table headings
b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
be as follows:
Aluminum and Brass - Reduce steel values by 35%
Stainless Steel - Use the upper limit for steel.
5. To achieve the specified torque, the torque wrench is to
be held perpendicular to the axis of rotation.
MAE9100
2-26 31200926 G5-18A, 2505H, 25.5

This Page Intentionally Left Blank
G5-18A, 2505H, 25.5 31200926 2-27

2.8.2 Assembly Instructions for American

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as Loctite 567, to and use the last turn for alignment.
the male pipe threads if not already applied. Ensure the
first 1 to 2 threads are uncovered to prevent system 5. Rotate male fitting the number of turns as per below
contamination. mentioned table. Refer to Section 2.8.15, “FFWR and
3. Assemble connection hand tight. TFFT Methods”, for procedure.
4. Mark fittings, male and female Note: TFFT values provided in below mentioned table are
applicable for the following material configurations:
a. Steel fittings with steel mating components
NOTICE b. Steel fittings with aluminum or brass mating
components
Over tightening may cause deformation of the pipe c. Aluminum or brass fittings with steel mating
fitting and damage to the joining fitting, flange or components
component may occur. d. Aluminum or brass fittings with aluminum or brass
mating components.
a. NPTF Pipe Thread
MAE9110
TYPE/FITTING IDENTIFICATION
Turns From Finger Tight
Thread Size ØA*
Material Dash Size (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
4 1/4 - 18 0.54 13.61 2 to 3
STEEL, ALUMINUM, OR 6 3/8 - 18 0.67 17.05 2 to 3
BRASS FITTINGS
8 1/2 - 14 0.84 21.22 2 to 3
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3
BRASS
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
MATING
COMPONENTS 20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.
2-28 31200926 G5-18A, 2505H, 25.5

2.8.3 Assembly Instructions for British

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as Loctite 567, to and use the last turn for alignment.
the male pipe threads if not already applied. Ensure the 5. Rotate male fitting the number of turns as per below
first 1 to 2 threads are uncovered to prevent system mention table.
contamination.
Note: TFFT values provided in below table are applicable for
3. Assemble connection hand tight.
the following material configurations:
4. Mark fittings, male and female.
a. Steel fittings with steel mating components
NOTICE b. Steel fittings with aluminum or brass mating

components
c. Aluminum or brass fittings with steel mating
Over tightening may cause deformation of the pipe
components
fitting and damage to the joining fitting, flange or
component may occur. d. Aluminum or brass fittings with aluminum or brass
mating components.
a. BSPT Pipe Thread
MAE9120
Turns From Finger Tight
Thread Size ØA* (TFFT)**
Material Dash Size
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
4 1/4 - 19 0.52 13.16 2 to 3
STEEL, ALUMINUM, OR
BRASS FITTINGS 6 3/8 - 19 0.66 16.66 2 to 3
WITH STEEL, 8 1/2 - 14 0.83 20.96 2 to 3
ALUMINUM, OR 12 3/4 - 14 1.04 26.44 2 to 3
BRASS 16 1 - 11 1.31 33.25 1.5 to 2.5
MATING
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
COMPONENTS
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.
G5-18A, 2505H, 25.5 31200926 2-29

2.8.4 Assembly Instructions for 37° (JIC) Flare 2. Align tube to fitting and start threads by hand.
Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
NOTICE
surface is smooth, free of rust, weld and brazing splatter, The torque method should NOT be used on lubricated or
splits, dirt, foreign matter, or burrs. If necessary, replace oily fittings. No lubrication or sealant is required. The
fitting or adapter. lubrication would cause increased clamping force and
cause fitting damage.
NOTICE 3. Torque assembly to value listed in below mentioned
table while using the Double Wrench Method.
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint Note: Torque values provided in below table are segregated
eventually leading to leakage. based on the material configuration of the connection.
a. 37° Flare (JIC) Thread - Steel
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS
WITH STEEL 8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
MATING
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.
2-30 31200926 G5-18A, 2505H, 25.5

b. 37° Flare (JIC) Thread - Aluminum Brass
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --

3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
ALUMINUM/BRASS 6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2

FITTINGS OR
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
ALUMINUM/BRASS
MATING 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
THREADS 14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

G5-18A, 2505H, 25.5 31200926 2-31

2.8.5 Assembly Instructions for 45° SAE Flare

Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter,
splits, dirt, foreign matter, or burrs. If necessary, replace
fitting or adapter.
NOTICE
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint
eventually leading to leakage.
2. Align tube to fitting.

3. Tighten fitting by hand until hand tight.
NOTICE
The torque method should NOT be used on lubricated or
oily fittings. No lubrication or sealant is required. The
lubrication would cause increased clamping force and
Torque fitting to value listed in below table while using the

Double Wrench Method outlined in this section.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
‘Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following material
configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
2-32 31200926 G5-18A, 2505H, 25.5

a. 45° Flare (SAE)
MAE9140
STEEL
TYPE/FITTING IDENTIFICATION TORQUE

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19

STEEL FITTINGS
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
WITH STEEL MATING
COMPONENTS; 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
UN-LUBRICATED
THREADS 10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
ALUMINUM BRASS

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
ALUMINUM/BRASS 4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12

FITTINGS OR 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20
ALUMINUM/BRASS
MATING 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
COMPONENTS;
UN-LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
G5-18A, 2505H, 25.5 31200926 2-33

2.8.6 Assembly Instructions for O-Ring Face

Seal (ORFS) Fittings
1. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement)”, for
procedure.
2. Ensure that surface is smooth, free of rust, weld and
brazing splatter, splits, dirt, foreign matter, or burrs. If
necessary, replace fitting or adapter.
NOTICE
Care to be taken when lubricating o-ring. Avoid adding
oil to the threaded connection of the fitting. The
3. Pre-lubricate the o-ring with hydraulic oil.

4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the o-ring. Hand
thread the nut onto the fitting body.
5. Torque nut to value listed in below mentioned table
while using the Double Wrench Method. Refer to
Section 2.8.15, “FFWR and TFFT Methods”, for procedure
if using the FFWR method.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following
material configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
2-34 31200926 G5-18A, 2505H, 25.5

a. O-ring Face Seal (ORFS)
MAE9150
STEEL

Thread
Dash ØA* ØB* [Ft-Lb] [Nm] Tube Swivel &
Material Size
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL FITTINGS 8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
WITH 10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
STEEL MATING
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
COMPONENTS;
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS
FLATS FROM
WRENCH
RESISTANCE
(F.F.W.R)**
Thread
ØA* ØB* [Ft-Lb] [Nm]
Dash Size Tube Swivel &
Material
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS 8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
FITTINGS OR
ALUMINUM/BRASS 10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENT;
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
UN-LUBRICATED
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

G5-18A, 2505H, 25.5 31200926 2-35

2.8.7 Assembly Instructions for DIN 24° Flare

Bite Type Fittings (MBTL and MBTS)
NOTICE
A non-square tube end can cause improperly seated
fittings and leakage.
6. Inspect the components to ensure free of
contamination, external damage, rust, splits, dirt,
foreign matter, or burrs. Ensure tube end is visibly
square. If necessary, replace fitting or tube.
7. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
8. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
9. Push the tube end into the coupling body.
10. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed while using the Double
Wrench Method. The tube must not turn with the nut.
2-36 31200926 G5-18A, 2505H, 25.5

a. DIN 24° CONE (MBTL & MBTS)
MAE9160
DIN 24° CONE FLARELESS BITE FITTING

(WITH OR WITHOUT O-RING)
Tube Thread Torque Flats From
ØA* ØB* C* ØD*
O.D. M Size [Ft-Lb] [Nm] Wrench
Material Type
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75

8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
FFWR is the recommended method of
10 M16 x 1.5 14.50 16.00 7.00 10.20 fitting assembly. 1.5 to 1.75
12 M18 x 1.5 16.50 18.00 7.00 12.20 Torque values are application specific 1.5 to 1.75
DIN 24° CONE
FLARELESS 15 M22 x 1.5 20.50 22.00 7.00 15.20 due to variability in the fitting supplier, 1.5 to 1.75
coating, lubrication, and other physical
BITE (MBTL) 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristic of the connection. 1.5 to 1.75
FITTING
22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
Consult Engineering on the
28 M36 x 2 33.90 36.00 7.50 28.20 generation of torque values for the 1.5 to 1.75
particular application.
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
STEEL Torque
Tube Thread Flats From
FITTINGS ØA* ØB* C* ØD*
O.D. M Size [Ft-Lb] [Nm] Wrench
WITH STEEL Type
Resistance
MATING
COMPONENTS (mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75

FFWR is the recommended method of
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75
fitting assembly.
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific 1.5 to 1.75
DIN 24° CONE
14 M22 x 1.5 20.50 22.00 8.00 14.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS
coating, lubrication, and other physical
BITE (MBTS) 16 M24 x 1.5 22.50 24.00 8.50 16.20 1.5 to 1.75
characteristics of the connection.
FITTING 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 Consult Engineering on the 1.5 to 1.75
generation of torque values for the
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
particular application.
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only.

G5-18A, 2505H, 25.5 31200926 2-37

2.8.8 Assembly Instructions for Bulkhead (BH)

Fittings
1. Ensure that threads and surface are free of rust, weld
and brazing splatter, splits, burrs or other foreign
material. If necessary, replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting while using the Double Wrench
Method.
2-38 31200926 G5-18A, 2505H, 25.5

a. Bulkhead Fittings (BH) - INCH
MAE9170
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Thread Torque
Material Type Dash Size Size [Ft-Lb] [Nm]
(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
O-RING FACE 10 1-14 85 90 94 115 122 127
SEAL (ORFS)
12 1 3/16-12 135 142 149 183 193 202
BULKHEAD
FITTING 14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Thread Torque
Type Dash Size Size [Ft-Lb] [Nm]
STEEL (UNF) Min Nom Max Min Nom Max
FITTINGS 3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
37° FLARE (JLIC) 10 7/8-14 85 90 94 115 122 127
BULKHEAD
12 1 1/16-12 135 142 149 183 193 202
FITTING
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
G5-18A, 2505H, 25.5 31200926 2-39

b. Bulkhead Fittings (BH) - METRIC
MAE9180
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Connecting Thread Torque
Material Type Tube O.D. M Size [Ft-Lb] [Nm]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE
FLARELESS BITE 15 M22 x 1.5 44 47 50 60 64 68
(MBTL) BULKHEAD 18 M26 x 1.5 70 75 80 95 102 108
FITTING
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
Connecting Thread Torque
STEEL Tube O.D. M Size
Type [Ft-Lb] [Nm]
FITTINGS
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
DIN 24° CONE
FLARELESS BITE 14 M22 x 1.5 44 47 50 60 64 68
(MBTS) BULKHEAD 16 M24 x 1.5 70 75 80 95 102 108
FITTING 20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
2-40 31200926 G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 31200926 2-41

2.8.9 Assembly Instructions for O-Ring Boss

(ORB) Fittings
1. Inspect components to ensure that male and female
port threads are free of rust, splits, dirt, foreign matter,
or burrs.
2. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement)”, for
procedure.
NOTICE

4. For non-adjustable and plugs, thread the fitting by hand
until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the straight thread
o-ring port and the type on the other side of the
fitting. The torque will be applied to the straight
thread o-ring port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the o-ring is not pinched and the
washer is seated flat on the counter bore of the port.
2-42 31200926 G5-18A, 2505H, 25.5

a. O-ring Boss (ORB) - Table 1 of 6
MAE9190
HEX TYPE PLUGS & STUD ENDS

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
NOTE: 1. * ØA Thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
G5-18A, 2505H, 25.5 31200926 2-43

b. O-ring Boss (ORB) - Table 2 of 6
MAE9190
STUD ENDS
WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-44 31200926 G5-18A, 2505H, 25.5

c. O-ring Boss (ORB) - Table 3 of 6
MAE9210
ADJUSTABLE STUD END

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

G5-18A, 2505H, 25.5 31200926 2-45

d. O-ring Boss (ORB) - Table 4 of 6
MAE9220
ADJUSTABLE STUD END

WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45
STEEL FITTINGS 6 9/16-18 0.56 14.28 35 37 39 46 50 53
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 20 21 21 27 28 28
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 23 24 24 31 33 33
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-46 31200926 G5-18A, 2505H, 25.5

e. O-ring Boss (ORB) - Table 5 of 6
MAE9230
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 14 15 16 19 20 22
STEEL FITTINGS 6 9/16-18 0.56 14.28 34 36 38 46 49 52
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9
5 1/2-20 0.50 12.70 9 10 10 12 14 14
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 22 24 25 30 33 34
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

G5-18A, 2505H, 25.5 31200926 2-47

f. O-ring Boss (ORB) - Table 6 of 6
MAE9240
ZERO LEAK GOLD®

HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
STEEL FITTINGS WITH
STEEL MATING 8 3/4-16 0.75 19.10 28 30 32 38 41 43
COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
THREADS
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 11 12 13 15 16 18
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MATING 10 7/8-14 0.87 22.22 46 48 50 62 65 68
COMPONENTS; 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50

2-48 31200926 G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 31200926 2-49

2.8.10 Assembly Instructions for Adjustable

Port End Metric Fittings
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If o-ring is not pre-installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement)”, for procedure.
NOTICE

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
a. The table headings identify the Metric port and the
type on the other side of the fitting. The torque will
be applied to the Metric port.
configurations:
components
components
mating components.
2-50 31200926 G5-18A, 2505H, 25.5

a. Metric Flat Face Port (MFF) L Series - Table 1 of 3
MAE9260
MAE9250
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH 37° (JIC) or L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END
Thread Connecting Torque Torque
Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
STEEL FITTINGS
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
WITH STEEL
MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
UN-LUBRICATED
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
THREADS
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694

M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
ALUMINUM/BRASS
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
FITTINGS OR M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
ALUMINUM/BRASS M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING
COMPONENTS; M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
UN-LUBRICATED M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
THREADS
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
G5-18A, 2505H, 25.5 31200926 2-51

b. Metric Flat Face Port (MFF) L Series - Table 2 of 3
MAE9280
MAE9270

IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)

M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FITTINGS
WITH STEEL M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
COMPONENTS; M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
UN-LUBRICATED M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
THREADS
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

(UNF) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
BRASS FITTINGS
OR ALUMINUM/ M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
COMPONENTS; M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
2-52 31200926 G5-18A, 2505H, 25.5

c. Metric Flat Face Port (MFF) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS
WITH L SERIES DIN (MBTL) SEALING RING)
IDENTIFICATION WITH L SERIES DIN (MBTL)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END
Thread Connecting Torque Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
STEEL FITTINGS
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
WITH STEEL
MATING M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
UN-LUBRICATED
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
BRASS FITTINGS
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALUMINUM/
BRASS M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPONENTS;
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LUBRICATED
THREADS M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
G5-18A, 2505H, 25.5 31200926 2-53

d. Metric Flat Face Port (MFF) S Series - Table 1 of 3
MAE9320 MAE9330

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
WITH STEEL
MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
COMPONENTS; M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
UN-LUBRICATED
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
THREADS
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
COMPONENTS;
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
2-54 31200926 G5-18A, 2505H, 25.5

e. Metric Flat Face Port (MFF) S Series - Table 2 of 3
MAE9350
MAE9340

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FITTINGS
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
WITH STEEL
MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS; M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
UN-LUBRICATED
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FITTINGS
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
OR ALUMINUM/
BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
COMPONENTS;
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
G5-18A, 2505H, 25.5 31200926 2-55

f. Metric Flat Face Port (MFF) S Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION WITH S SERIES DIN (MBTS)
OPPOSITE END

M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
STEEL FITTINGS
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
WITH STEEL
MATING M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
UN-LUBRICATED
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
ALUMINUM/
BRASS M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
FITTINGS OR M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
COMPONENTS; M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
UN-LUBRICATED M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
THREADS
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
2-56 31200926 G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 31200926 2-57

2.8.11 Assembly Instructions for Metric ISO

6149 Port Assembly Stud Ends
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement)”.
NOTICE

a. The table headings identify the Metric port and the
be applied to the Metric port.
configurations:
components
components
mating components.
2-58 31200926 G5-18A, 2505H, 25.5

a. Metric Pipe Parallel O-Ring Boss (MPP)
MAE9370 MAE9380
MAE9360
STUD ENDS WITH 37° (JIC) STUD ENDS WITH (ORFS)

TYPE/FITTING
OR L SERIES DIN (MBTL) OR S SERIES DIN (MBTS)
IDENTIFICATION
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
STEEL FITTINGS M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
MATING
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
COMPONENTS;
UN-LUBRICATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
THREADS M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/ M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
BRASS FITTINGS M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/ M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING
COMPONENTS; M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
UN-LUBRICATED M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
THREADS M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
G5-18A, 2505H, 25.5 31200926 2-59

2.8.12 Assembly Instructions for Adjustable

Port End (BSPP) Fittings
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement)”, for instructions.
NOTICE

a. The table headings identify the BSPP port and the
be applied to the BSPP port.
configurations:
components
components
mating components.
2-60 31200926 G5-18A, 2505H, 25.5

a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
MAE9390 MAE9400
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING STUD ENDS WITH 37° (JIC) or STUD ENDS
IDENTIFICATION L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
Torque Torque
Connecting
BSPP
Tube O.D.
Material Thread [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
COMPONENTS; G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
UN-LUBRICATED G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
THREADS G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
BRASS
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING
COMPONENTS; G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
UN-LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
NOTE: ** Non typical for JLG Straight Male Stud Fittings, reference only.
G5-18A, 2505H, 25.5 31200926 2-61

b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
MAE9410 MAE9420
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH 37° (JIC) OR STUD ENDS WITH 37° (JIC) OR
IDENTIFICATION
L SERIES DIN (MBTL) OPPOSITE END L SERIES DIN (MBTL) OPPOSITE END

BSPP
G Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
UN-LUBRICATED G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
BRASS
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING
COMPONENTS; G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
2-62 31200926 G5-18A, 2505H, 25.5

c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS WITH
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION S SERIES DIN (MBTS)
OPPOSITE END
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
WITH STEEL
MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
UN-LUBRICATED
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
THREADS
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
ALUMINUM/
BRASS G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
FITTINGS OR G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS
MATING G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
COMPONENTS; G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
UN-LUBRICATED G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
THREADS
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321
G5-18A, 2505H, 25.5 31200926 2-63

d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
MAE9430 MAE9440
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH (ORFS) OR STUD ENDS WITH (ORFS) OR
IDENTIFICATION
S SERIES DIN (MBTS) OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END
BSPP Connecting Torque Torque

G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
STEEL FITTINGS
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
WITH STEEL
MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS; G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
UN-LUBRICATED
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
THREADS
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Connecting Torque Torque
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
BRASS FITTINGS
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
OR ALUMINUM/
BRASS G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
MATING G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
COMPONENTS;
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
2-64 31200926 G5-18A, 2505H, 25.5

e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3
MAE9460
MAE9450
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING

TYPE/FITTING STUD ENDS AND HEX TYPE PLUGS RING) STUD ENDS & ADJUSTABLE
IDENTIFICATION WITH (ORFS) or S SERIES DIN (MBTS) STUD ENDS WITH (ORFS) OR
OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END

BSPP
G Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
STEEL FITTINGS
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
WITH STEEL
MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
COMPONENTS; G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
UN-LUBRICATED
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/ G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
OR ALUMINUM/
BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
COMPONENTS;
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
NOTE: * Typical for JLG Straight Male Stud Fittings.

*** Typical for JLG Adjustable Fittings.
G5-18A, 2505H, 25.5 31200926 2-65

f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9290 MAE9300
MAE9470
BANJO FITTINGS HIGH PRESSURE BANJO

TYPE/FITTING
WITH S SERIES DIN (MBTS) FITTINGS WITH S SERIES JIS/BSPP O-RING ONLY
IDENTIFICATION
OPPOSITE END DIN (MBTS) OPPOSITE END

BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77 Fitting type not typically
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 specified on Caterpillar
WITH STEEL
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133 applications.
MATING
COMPONENTS; G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Refer to the specific
UN-LUBRICATED
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure
THREADS
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353 in this Service Manual.
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/ G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50 Fitting type not typically
BRASS FITTINGS
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 specified on Caterpillar
OR ALUMINUM/
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS
MATING G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the
COMPONENTS;
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 specific procedure in
UN-LUBRICATED
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229 this Service Manual.
THREADS
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
2-66 31200926 G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 31200926 2-67

2.8.13 Assembly Instructions for Flange

Connections (FL61 and FL62)
1. Ensure sealing surfaces are free of rust, splits, scratches,
dirt, foreign matter, or burrs.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp
halves.
5. Tighten all bolts by hand.
6. Torque bolts in diagonal sequence in two or more
increments to the torque listed.
2-68 31200926 G5-18A, 2505H, 25.5

a. Flange Code (FL61 & FL62) - Inch Fasteners
MAE9480
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
Fastener Torque for Fastener Torque for

Inch Bolt Flanges Equipped with Flanges Equipped with
Flange Flange
A* Thread GRADE 5 Screws GRADE 8 Screws
Type SAE Size
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
(FL61) 40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Inch Bolt Fastener Torque for Flanges Fastener Torque for Flanges
Flange Flange Equipped with GRADE 5 Screws Equipped with GRADE 8 Screws
A* Thread
Type SAE Size
Size
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66
CODE 62 16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
SPLIT
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
FLANGE
(FL62) 20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
NOTE: * A dimension for reference only.
G5-18A, 2505H, 25.5 31200926 2-69

b. Flange Code (FL61 & FL62) - Metric Fasteners
MAE9480
TYPE/FITTING STEEL 4-BOLT FLANGE SAE J518

IDENTIFICATION (INCH FASTENERS)
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE CLASS 8.8 Screws CLASS 10.9 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
FLANGE
(FL61) 40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE GRADE 5 Screws GRADE 8 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77
CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
FLANGE
(FL62) 20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
NOTE: * A dimension for reference only.
2-70 31200926 G5-18A, 2505H, 25.5

2.8.14 Double Wrench Method

To prevent undesired hose or connector rotation, two
wrenches must be used; one torque wrench and one
back- up wrench. If two wrenches are not used,
inadvertent component rotation may occur which
absorbs torque and causes improper joint load and leads
to leaks. For hose connections, the ‘layline’ printed on the
hose is a good indicator of proper hose installation. A
twisted lay-line usually indicates the hose is twisted.
Double Wrench Method to Prevent Hose Twist
MAE9490
G5-18A, 2505H, 25.5 31200926 2-71

2.8.15 FFWR and TFFT Methods 2.8.16 Adjustable Stud End Assembly
1. FFWR (Flats from Wrench Resistance Method) For Adjustable Stud End Connections; the following
a. Tighten the swivel nut to the mating fitting until no assembly steps are to be performed:
lateral movement of the swivel nut can be detected; a. Lubricate the o-ring with a light coat of hydraulic oil.
finger tight condition.
b. Position #1 – The o-ring should be located in the
b. Mark a dot on one of the swivel hex nut flats and groove adjacent to the face of the back-up washer.
another dot in line on the connecting tube adapter. The washer and o-ring should be positioned at the
c. Use the double wrench method per Appendix A, extreme top end of the groove as shown.
turn the swivel nut to tighten. The nut is to be c. Position #2 – Position the locknut to just touch the
rotated clockwise the number of hex flats. back-up washer as shown. The locknut in this
d. After the connection has been properly tightened, position will eliminate potential back up washer.
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has 2.8.17 O-ring Installation (Replacement)
been properly tightened.
Care must be taken when installing o-rings over threads dur-
FFWR Method
ing replacement or installation. o-rings could become
nicked or torn. A damaged o-ring could lead to leakage
problems.
1. Inspect o-ring for tears or nicks. If any are found replace
o-ring.
2. Ensure proper o-ring to be installed. Many o-rings look
the same but are of different material, different
hardness, or are slightly different diameters or widths.
MAE9500
3. Use a thread protector when replacing o-rings on
fittings.
2. TFFT (Turns from Finger Tight Method) 4. In ORB; ensure o-ring is properly seated in groove. On
straight threads, ensure o-ring is seated all the way past
a. Tighten the swivel nut to the mating fitting until no
the threads prior to installation.
lateral movement of the swivel nut can be detected;
finger tight condition. 5. Inspect o-ring for any visible nicks or tears. Replace if
b. Mark a dot on one of the swivel hex nut flats and found.
another dot in line on the connecting tube adapter.
c. Use the double wrench method per Appendix A,
turn the swivel nut to tighten. The nut is to be
rotated clockwise the number of turns.
d. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has
been properly tightened.
2-72 31200926 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.4 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.5 Tilt and Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.6 Tilt and Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.7 Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.8 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6.1 Quick Attach Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6.2 Quick Attach Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.8 Boom Prop (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.8.1 Prop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.8.2 Prop Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.9 Emergency Boom Lowering Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.9.1 Equipment and Supplies Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.9.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
G5-18A, 2505H, 25.5 31200926 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.
FIRST BOOM
SECTION
PIVOT PIN
SECOND BOOM
SECTION
COMPENSATING
LIFT/LOWER CYLINDER
CYLINDER
TILT
CYLINDER
EXTEND/RETRACT
CYLINDER
MY8380
AUXILIARY HYDRAULIC
QUICK CONNECTS
3-2 31200926 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 in
DO NOT service the machine without following all safety (N) NEUTRAL.
precautions as outlined in Section 1 “Safety Practices”, of
4. Engage park brake and shut engine OFF.
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 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 or any MY8570
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 compensating
Read, understand and follow these instructions. cylinder.
During service of boom, perform following:
1. Check wear pads.
(Refer to Section 3.5.1, “Wear Pad Inspection”)
3
2. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.5, “Lubrication Schedule”)
3. Check for proper operation by operating all boom 4
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following MY8580
procedures explain removal/installation of complete boom

or removal/installation of individual boom sections.
G5-18A, 2505H, 25.5 31200926 3-3

Boom
10. Lower the boom to a position that allows for the SN 0160076806 to Present including 0160076010,
removal of rod end pin (3) connecting lift/lower cylinder 0160076011, 0160076012
to boom.
5
11. Support boom by placing a sling(s) around boom head. 6
Support lift/lower cylinder and remove lock bolt (4) and
rod end pin (3). Lower lift/lower cylinder onto frame
rails.
12. Properly disconnect battery. Refer to Section 9.8 7
“Battery”, for procedure.
13. Label and disconnect tilt and (if equipped) auxiliary
hydraulic hoses attached to machine at tubes on top of
boom. Plug and cap hose ends to prevent dirt and
debris from entering hydraulic system.
14. Label and disconnect extend/retract hydraulic hoses at
tubes on side of boom. Plug and cap hose ends to
prevent dirt and debris from entering hydraulic system. MAE2790
15. If equipped, disconnect the LSI boom proximity sensor

at rear of first boom section. 16. Lower boom to a level position and place a suitable
Note: Tag or identify each hose to the corresponding fitting it support under rear of boom. Reposition slings to each
was removed from. end of boom.
Prior to SN 0160076806 excluding 0160076010, 17. Remove capscrew (5) and locknut (6) securing boom
0160076011, 0160076012 pivot pin (7) and remove boom pivot pin.
18. Lift complete boom off machine and set on level
5 ground or supports being careful not to damage tubes
6 on bottom of boom.
MY8590
3-4 31200926 G5-18A, 2505H, 25.5

Boom
3.4.2 Complete Boom Installation 10. Uncap and reconnect extend/retract cylinder fittings
and plugs to extend/retract cylinder tubes and tighten
Note: Lubrication of boom wear surfaces with grease is
until wrench-tight. Mark fitting, then torque to
recommended to keep boom wear surfaces lubricated properly.
specification. Refer to Section 2.8, “Hydraulic
Lubrication of boom wear surfaces is also recommended when
Connection Assembly and Torque Specification”.
machine is stored, to help prevent rusting. Refer to Section 2.3,
“Fluids, Lubricants and Capacities”. 11. Uncap and reconnect tilt hoses and (if equipped)
auxiliary hoses. Attach both sets to their appropriate
1. Park machine on a hard, level surface. fittings until wrench-tight. Mark fitting, then torque to
2. Place transmission in (N) NEUTRAL. specification. Refer to Section 2.8, “Hydraulic
3. Engage park brake and shut engine OFF. Connection Assembly and Torque Specification”.

and steering wheel.
Note: Grease the boom pivot bore, compensating cylinder rod
ends, lift/lower cylinder rod end and pins before installing. 8
6. Balance boom assembly using suitable slings and 9
carefully guide the boom into position for attachment
to frame.
7. Align frame pivot bore with the boom assembly pivot
bore. Install boom pivot pin (7).
8. Install capscrew (5). Apply locking compound and
torque locknut (6) to 66 lb-ft (90 Nm).
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).
Note: Raising boom up or down with sling may be necessary MY8570
so boom, compensating and lift/lower cylinder bores can be 12. Raise boom to height that allows for installation of
aligned for easier pin installation. compensating cylinder, pin (8) and lock bolt (9). Apply
locking compound and torque to 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 as
required.
17. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
18. Close and secure engine cover.
19. Remove Do Not Operate Tags from both ignition key
switch and the steering wheel.
20. Install previously removed attachment to quick attach
assembly.
G5-18A, 2505H, 25.5 31200926 3-5

Boom
3.4.3 Second Boom Section Removal 15. Support front of boom by placing a sling behind boom
head.
16. Pull second boom section out of first boom section
2. Be sure there is enough room in front of machine to
approximately 6 - 8 in (15 - 20 cm).
allow boom sections to be removed.
17. Pull tilt hoses and (if equipped) auxiliary hydraulic hoses
3. Park machine on a hard, level surface.
through rear of boom.
18. Remove top, side and bottom wear pads from front of
(N) NEUTRAL.
first boom section.
Note: Tag each pad, backing plate, shim and bolts from each
6. Place a Do Not Operate Tag on both ignition key switch location.
and steering wheel.
Note: The use of two slings will allow for better stability.
7. Properly disconnect battery. Refer to Section 9.8
“Battery”, for procedure. 19. Pull second boom section halfway out of first boom
8. Open engine cover. Allow system fluids to cool. section, reposition sling(s), balancing second boom
section and remove from first boom section.
9. Remove quick attach assembly. Refer to Section 3.6.1,
“Quick Attach Assembly Removal”. 20. Place second boom section on suitable stands to begin
tear down.
10. Label and disconnect tilt hoses and (if equipped)
auxiliary hydraulic hoses attached to machine at boom 21. Inspect boom and welds. Consult local JLG Dealer if
head. Plug and cap hose ends to prevent dirt and debris structural damage is detected.
from entering hydraulic system. 22. Inspect hoses, hardware, wear pads, mounting points
and other components visible with first boom section.
Note: Tag or identify each hose to corresponding fitting it was
Replace any item if damaged.
removed from.
23. Inspect all wear pads for wear.
11. Label and disconnect extend/retract hydraulic tubes on (Refer to Section 3.5.1, “Wear Pad Inspection”)
extend/retract cylinder at the rear of boom. Plug and
cap hose ends to prevent dirt and debris from entering
hydraulic system.
12. Remove top and side wear pads from rear of second
boom section.
Note: Tag each pad, backing plate, shim and bolts from each
location.
10
11
MY1960
13. Remove lock bolt and nut (10) from rear of

extend/retract cylinder.
14. Remove extend/retract cylinder mounting pin (11).
3-6 31200926 G5-18A, 2505H, 25.5

Boom
3.4.4 Second Boom Section Installation 12. Start engine and operate all boom functions several
times to bleed any air out of hydraulic system. Check for
Note: Lubrication of boom wear surfaces with grease is
fluid leaks. Check hydraulic fluid level in tank and add
recommended to keep boom wear surfaces lubricated properly.
fluid as required.
“Fluids, Lubricants and Capacities”.
1. If previously removed, install extend/retract cylinder
into rear of second boom section. Pin and clip barrel
end of cylinder in place. 12
2. Install wear pads, shims and bolts to their proper

location at front inside of first boom section.
DO NOT tighten wear pads at this time.
3. Feed the tilt cylinder hoses and if equipped, the
auxiliary hoses through the channel above the extend/
retract cylinder.
MY2000
4. Using suitable sling(s), balance second boom section,
lift and carefully guide boom into place. 13. Check clearance (12) between the tilt hoses (and if
equipped) auxiliary hoses and the front of the extend/
retract cylinder trunnion. There should be
approximately 1/2 in (12,7 mm) of clearance.
14. If adjustment is needed, loosen the tilt tubes (and if
equipped) auxiliary tubes. Move tubes to achieve the
10 proper clearance.
around the machine.
11
16. Close and secure the engine cover.
MY1960
5. Install extend/retract cylinder mounting pin (11). assembly.
6. Install lock bolt and nut (10) at rear of
3.4.5 Tilt and Auxiliary Hose Removal
extend/retract cylinder.
1. Remove attachment from the quick coupler assembly.
7. Install wear pads, shims and bolts previously removed
Refer to Operation and Maintenance Manual.
from rear of second boom section.
DO NOT tighten the wear pads at this time. 2. Allow sufficient room in front of the machine to allow
for the second boom section removal.
8. Uncap and reconnect extend/retract cylinder fittings
and plugs from extend/retract cylinder tubes and 3. Park machine on a hard, level surface. Level boom, and
tighten until wrench-tight. Mark fitting, then torque to extend boom approximately 2 ft (609mm). Place
specification. Refer to Section 2.8, “Hydraulic transmission in (N) NEUTRAL and engage park brake.
Connection Assembly and Torque Specification”. Shut engine off.
9. Uncap and reconnect tilt hoses and (if equipped) 4. Place a Do Not Operate Tag on both ignition key switch
auxiliary hoses. Attach both sets to their appropriate and steering wheel.
fittings until wrench-tight. Mark fitting, then torque to 5. Open engine cover. Allow system fluids to cool.
specification. Refer to Section 2.8, “Hydraulic
6. Properly disconnect battery.
Connection Assembly and Torque Specification”.
10. Adjust and shim each wear pad as needed.
11. Properly connect battery. Refer to Section 9.8 “Battery”,
for procedure.
G5-18A, 2505H, 25.5 31200926 3-7
Boom
9. Remove the extend/retract cylinder retaining clips and

mounting pins (3) from the side of the second boom
section.
Note: Tag each wear pad, spacer, and shim hardware for each
location.
10. Remove the top (4) and both side (5) wear pads, shim(s),
and backing plates from the front of the first boom
section.
11 11. Attach lifting straps to the front of the second boom
section. Raise the second boom section and remove the
2 bottom wear pads, shim(s) and backing plates (6) from
1
10
the front of the first boom section.
9
12. Pull the second boom section (7) approximately 3/4 out
of the first boom section (8). Lower the second boom
section onto a suitable support. Reposition the lifting
straps.
13. Remove the second boom section (7) and place on
suitable supports.
14. Label and disconnect the tilt cylinder hoses (9) and
auxiliary hoses (10) at the boom head. Cap and/or plug
7. Place a suitable receptacle under the front of the first all hoses and fittings to prevent dirt and debris from
boom section. entering the hydraulic system.
8. Label and disconnect the tilt cylinder (right side) hoses 15. Remove the tilt cylinder hoses (9) and auxiliary hoses
(1) and auxiliary (left side) hoses (2) under the first (10) from the rear of the second boom section.
boom section. Cap and/or plug all hoses and fittings to
prevent dirt and debris from entering the hydraulic 3.4.6 Tilt and Auxiliary Hose Installation
system.
1. Connect the tilt cylinder hoses (9) and auxiliary hoses
Note: Loss of hydraulic fluid is limited to amount of fluid (10) to tilt cylinder/aux bulkhead.
trapped in each hose.
2. Wrap new hoses under rear of second boom section
(11).
4 3. Insert second boom section (7) approximately 2 ft
(609mm) into first boom section (8).
5 Note: Raising the barrel end of the extend/retract
cylinder may be required for clearance.
4. Support second boom section assembly.
7
5. Reposition straps, and guide second boom section into
8
first boom section.
6 6. Reinstall extend/retract cylinder barrel pin (3).
3
7. Connect the tilt (1) and auxiliary (2) hoses at bottom of
first boom section.
8. Reinstall wear pads and shims.
9. Reinstall attachment.
10. Properly connect battery.
11. Check for hydraulic leaks. Check hydraulic fluid level.
Add hydraulic fluid if necessary.
3-8 31200926 G5-18A, 2505H, 25.5

Boom
13. Remove the Do Not Operate tags from both the ignition
key switch and the steering wheel.
15
3.4.7 Extend/Retract Cylinder Removal

Note: Boom must be properly aligned (level) with access hole
at rear of frame to allow removal of extend/retract cylinder
barrel mounting pin.
2. Be sure there is enough room in front of machine to
allow boom sections to be removed. 14
(N) NEUTRAL.
MY2670
and steering wheel.
11. Loosen and remove hose clamps and cover plate (14)
7. Open engine cover and properly disconnect battery.
from rear of boom assembly.
Refer to Section 9.8 “Battery”, for procedure.
12. Remove any miscellaneous parts such as mirror if they
will interfere with removal of cylinder.
9. Remove the quick attach assembly. Refer to Section
13. Label and disconnect tilt and (if equipped) auxiliary
3.6.1, “Quick Attach Assembly Removal”.
hydraulic hoses attached to machine on top of
boom (15). Plug and cap hose ends to prevent dirt and
13
MY2680
10. Remove cylinder rod eye retaining clips and mounting

pin (13) at side of second boom section.
G5-18A, 2505H, 25.5 31200926 3-9

Boom
3.4.8 Extend/Retract Cylinder Installation

1. Carefully install the extend/retract cylinder into rear of
boom using a suitable sling.
2. Line up barrel end of cylinder with pin bores on first
boom section.
18
Note: The tilt hoses and (if equipped) the auxiliary hoses may
need to be moved during installation of the extend/retract
cylinder.
3. Install mounting pin (19), spacers and washers through
frame access hole on chassis and first boom section
19
bore and cylinder barrel. Secure with hardware (18)
removed earlier.
4. Remove plugs in bottom of extend/retract cylinder and
17 install previously removed fittings (17).
16 5. Uncap and connect tubes (16) to previously labeled
MY8610 fittings at extend/retract cylinder. Apply locking
compound to fittings.
14. Loosen and remove both extend/retract cylinder 6. Uncap and reconnect tilt hoses and (if equipped)
tubes (16) at rear of first boom section. Plug tube ends auxiliary hoses (15) to their appropriate fittings until
to prevent dirt and debris from entering hydraulic wrench-tight. Mark the fitting and torque to
system. specification. Refer to Section 2.8, “Hydraulic
15. Loosen and remove both fittings (17) from bottom of Connection Assembly and Torque Specification”.
extend/retract cylinder barrel. Plug openings in extend/ 7. Install cover plate (14) and hose clamps at rear of boom
retract cylinder barrel. assembly.
16. Loosen and remove hardware (18) securing on cylinder 8. Reinstall any miscellaneous parts, such as mirror, if
barrel mounting pin. removed previously.
17. Remove cylinder barrel mounting pin (19). 9. Properly connect battery. Refer to Section 9.8 “Battery”,
Note location of spacers and washers. for procedure.
18. Attach a sling or other suitable lifting device to extend/ 10. Start machine and extend the extend/retract cylinder
retract cylinder and carefully pull cylinder free from until rod eye of cylinder aligns with pin bore in second
machine through rear of boom/chassis. boom section.
Note: The tilt hoses and if equipped, auxiliary hoses may need 11. Shut the engine OFF.
to be moved during removal of extend/retract cylinder.
12. Install mounting pin through side of second boom
section (13) and secure with retaining clips.
13. Start machine and cycle extend/retract cylinder to
bleed any air out of hydraulic system.
14. Check for fluid leaks or any alignment problems.
15. Check the hydraulic fluid level in tank and add fluid as
required.
around the machine.
assembly.
3-10 31200926 G5-18A, 2505H, 25.5

Boom
3.5 BOOM WEAR PADS

A total of 14 wear pads are installed on the boom.
4
Twelve of fourteen wear pads on this boom are flat
rectangular wear pads with metal inserts. Two wear pads on
bottom of second section boom are channeled for tilt hose 3
and auxiliary hose clearance.
2
3.5.1 Wear Pad Inspection
1
MAM1390
• Assemble as shown using spacer (2) with holes before

any shim (3 is used.
1 • If required, a shim (3) must inserted between the
spacer (2) and wear pad support plate, block or boom
section (4).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
each side.
MAE2840
• Maintain a total boom section clearance of
0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and
Inspect all wear pads for wear. If angle indicators (1) on end
vertical directions.
of wear pads are visible, wear pads can be reused. If the wear
pads show uneven wear (front to back), they should be
replaced. Replace wear pads as a set if worn or damaged. A
3.5.2 Wear Pad Installation and Lubrication

B
Note: Inspect all wear pads. Replace as necessary.
The following wear pad procedure must be followed to MY3620
insure proper wear pad installation:
Note: MUST clean wear pad inserts and mounting bolts of any • The length of wear pad bolt depends on number of
shims, spacers and washers being used.
grease, oil or other contaminates before applying locking
compound and installing mounting bolts. • The thickness of each threaded wear pad insert is
0.312 in (7,92 mm) (A).
• Apply locking compound to all the wear pad mounting • The bolt length should be determined by measuring
bolts. distance from face of insert to face of boom (B)
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 each
wear pad bolt except where noted otherwise.
DO NOT use more than two hardened washers.
• Use only one hardened washer if mounting bolts
are recessed.
• Wear Pad Bolt Torque:
3/8-24 Bolt, 32 - 37 lb-ft (43 - 50 Nm)
3/8-24 Hollow Bolt, 15 - 17 lb-ft (20 - 23 Nm)
1/2-20 Bolt, 76 - 86 lb-ft (103 - 116 Nm)
1/2-20 Hollow Bolt, 45 - 50 lb-ft (61 - 68 Nm)
G5-18A, 2505H, 25.5 31200926 3-11
Boom
• Torque wear pad bolts after shimming is completed. 3.6 QUICK ATTACH ASSEMBLY
• Lubricate face and pockets of each wear pad after being
installed.
3.6.1 Quick Attach Assembly Removal
3.5.3 Boom Wear Pad Lubrication 1. Park machine on a hard, level surface.
After replacing any wear pads or after prolonged periods of 2. Fully retract boom, lower boom, place transmission in
inoperation, Lubrication of boom wear surfaces with grease is (N) NEUTRAL.
recommended to keep boom wear surfaces lubricated properly. 3. Engage park brake and shut engine OFF.
and steering wheel.
“Fluids, Lubricants and Capacities”.
5. Properly disconnect battery. Refer to Section 9.8
Note: The first shim under the pad needs to contain holes, “Battery”, for procedure.
instead of slots.
6. Open engine cover. Allow system fluids to cool.
4
5
2
3
MY2660
7. If equipped with a hydraulic quick attach device,

remove both hydraulic hoses (1) from valve on left side
of boom head. Plug and cap hose ends to prevent dirt
and debris from entering system.
8. Remove the lock bolt (2) holding tilt cylinder rod
end pin (3) to quick attach assembly. Remove pin.
9. Support quick attach assembly. Remove lock bolt (4)
holding quick attach pin (5) to quick attach assembly.
Remove pin.
10. Inspect pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
11. Replace pins if damaged or beyond repair.
3-12 31200926 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 centered
attached to carriage. If the following criteria is not met, forks
in boom head.
must be removed from service immediately.
2. Coat quick attach pivot pin (5) 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 (4). Torque to
72 lb-ft (97 Nm).
3
3. Align quick attach assembly with tilt cylinder rod end
and insert tilt cylinder pin (3). Align tilt cylinder pin and 6
quick attach assembly. Install lock bolt (2). Torque to 7 4
5
72 lb-ft (97 Nm).
4. If equipped, uncap and reconnect hydraulic quick 2
attach assembly device hoses (1) to valve on left side of 1
boom head. 6
around machine.
6. Properly connect battery. Refer to Section 9.8 “Battery”,
for procedure. 5 9
8. Remove a Do Not Operate Tag on both ignition key 8 MH6460
switch and steering wheel.

1. Inspect forks (1) for cracks, paying special attention to
heel (2) and mounting tubes (3).
2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
Yearly Inspection
1. Straightness of the upper face of blade (5) and the front
face of shank (6) should not exceed 0.5 percent of the
length of blade or height of shank.
2. Angle (7) between upper face of blade and front face of
shank should not exceed 93 degrees.
3. Thickness of blade (5) and shank (6) 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 (8) is adequate for the intended
loads.
5. Fork markings should be legible, re-stamp if required.
6. Compare fork tips (9) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent of
length of blade (8).
G5-18A, 2505H, 25.5 31200926 3-13

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

EQUIPMENT DAMAGE. DO NOT operate with the boom
WARNING 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 before 3.8.2 Prop Removal
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 in (N) NEUTRAL, engage the park brake 2. Remove the o-rings (2) and boom prop (1) from the
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.
3-14 31200926 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 capacity to
WARNING 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 the NOTICE
extend/retract cylinder first, lower the lift cylinder the
minimum amount necessary and resume retraction of EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply
the extend/retract cylinder as soon as possible. hydraulic oil must be compatible with hydraulic oil shown
in Section 2.3, “Fluids, Lubricants and Capacities”.
Hoses:
WARNING • Two Hydraulic Hoses - Approximately 10 ft (3,0 m)
Properly support the boom before attempting to proceed each, with a minimum I.D. of 0.375 in. (9,5 mm) and
with the emergency boom lowering procedure. a minimum rating of 4000 psi (275,8 bar).
Fittings:
• Two 1 in. (25,4 mm) - 14 ORFS Caps
WARNING • Two 1 in. (25,4 mm) - 14 ORFS Plugs
If possible, safely remove and/or secure the load on the Note: Machine extend/retract and lift/lower hoses are
machine before starting the boom lowering procedure. If -14 ORFS. The adaptor size may vary depending on the hose
load cannot be removed, the machine load chart MUST ends of the auxiliary hydraulic power supply.
be followed.
3.9.2 Lowering Procedure
a. Retract the boom as follows:

1. Place a suitable receptacle under hose connections.
0160076011, 0160076012
1&2
MAP0040
VIEW FROM LEFT SIDE
G5-18A, 2505H, 25.5 31200926 3-15

Boom
SN 0160076806 to Present including 0160076010, b. Lower the boom as follows:

0160076011, 0160076012
1. Place a suitable receptacle under main control valve.
1&2
4
3
MY3000
MAE2810
VIEW FROM LEFT SIDE 2. Label and disconnect lift/lower cylinder hoses
2. Locate the extend/retract cylinder connection (1 and 2) (3 and 4) from main control valve. Install plugs in hoses
along the left side of the boom where the hoses from to prevent fluid loss. Cap all fittings and openings to
the valve connect to the steel tube. keep dirt and debris from entering hydraulic system.
3. Label and disconnect hoses from steel tubes along left Note: Loss of hydraulic oil is limited to amount trapped within
side of boom. Install plugs in hoses to prevent fluid loss. each hose.
Cap all fittings and openings to keep dirt and debris 3. Using hoses and fittings specified, connect hoses
from entering the hydraulic system. between auxiliary hydraulic power supply and hoses
Note: Loss of hydraulic oil is limited to amount trapped within removed from main control valve lift/lower section of
each hose. affected machine. Hose (4) is supply (lower) and
hose (3) is return. Connect hoses in proper order to
4. Using hoses and fittings specified previously, connect ensure that boom is lowered, not raised.
jumper hoses between auxiliary hydraulic power supply
and steel tubes (1 and 2) connected to extend/retract 4. Use auxiliary power supply to retract lift cylinder.
cylinder of affected machine. Ensure that supply and 5. After boom has been lowered, loosen and remove
return lines are installed in proper order to ensure jumper hoses and reconnect lift/lower cylinder hoses at
cylinder is retracted, not extended. main control valve.
5. Use the auxiliary power supply to retract the 6. Transfer any hydraulic oil into a suitable, covered
extend/retract cylinder. container, and label the container as “Used Oil”. Dispose
6. Loosen and remove the jumper hoses and reconnect of used oil at an approved recycling facility.
extend/retract cylinder hoses. 7. Clean up all debris, hydraulic fluid, etc., in, on, near and
7. Transfer any hydraulic oil into a suitable, covered around the machine.
container, and label the container as “Used Oil”. Dispose
of used oil at an approved recycling facility.
around machine.
3-16 31200926 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 retract. 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections 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 when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.5.2, “Wear Pad
Installation and Lubrication”.
4. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. (Refer to Section 2.5, “Lubrication
Schedule”) Replace worn pins as
needed.
2. Worn bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals (Refer to
Section 2.5, “Lubrication
Schedule”).
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
and/or connection leaks. 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 31200926 3-17

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 rusted 3. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
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”.
3-18 31200926 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 System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.4.9 Heater and A/C System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.10 Air Filter System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
G5-18A, 2505H, 25.5 31200926 4-1

Cab
4.1 OPERATOR CAB COMPONENT

TERMINOLOGY
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 POWER

(2505H & 25.5) OUTLET
JOYSTICK
ACCESSORY CONTROL
LEVER (IF EQUIPPED)
FRAME LEVEL
HORN INDICATOR
BUTTON LONGITUDINAL
LEVEL INDICATOR
(AUS)
POWER
STEERING
OUTLET
WHEEL
INSTRUMENT
PANEL
PARK BRAKE SWITCH

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

(IF EQUIPPED)
TILT STEERING COLUMN

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

(2505H & 25.5)
4-2 31200926 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 Section 1, “Safety Practices”, of 1. Park machine on a hard, level surface.
this manual. 2. Fully retract boom, lower boom, place transmission in
(N) NEUTRAL.
4.3 OPERATOR CAB 3. Engage park brake and shut engine OFF.
4.3.1 Operator Cab Description and steering wheel.
The welded metal cab features a modular design, allowing for a 5. Properly disconnect battery. Refer to Section 9.8,
relatively quick, simple exchange of entire cab and/or “Battery”, for procedure.
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
structures (ROPS/FOPS) for operator.
1 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. 2
To help ensure optimum safety, protection and

performance, replace cab if it is damaged. Refer to
appropriate parts manual for ordering information.
The cab contains seat, operating controls, numerous panels, MAH0430
steering and brake components and more.
7. Carefully pry center button (1) out of steering wheel.
Covers and mirrors on machine exist for safety, protection
and appearance. They are relatively simple to remove and 8. Mark steering wheel and shaft to ensure proper
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 wheel (3)
from splined shaft.
The cab serial number decal is located inside cab, under the
seat. Information specified on serial number plate includes
b. Steering Wheel Installation
cab model number, cab serial number and other data. Write
this information down in a convenient location to use in cab 1. Install steering wheel (3) onto splined steering column
correspondence. shaft.
2. Secure steering wheel with nut (2).
3. Press center button (1) onto steering wheel.
4. Properly connect battery. Refer to Section 9.8, “Battery”,
for procedure.
6. Remove a Do Not Operate Tag on both ignition key
G5-18A, 2505H, 25.5 31200926 4-3

Cab
4.4.2 Steering Column/Valve Replacement 7. Remove steering wheel (4) (Refer to Section 4.4.1,
“Steering Wheel”), transmission control lever (5) and
a. Steering Column and Valve Removal accessory control lever (6) (if equipped).
1. Park machine on a hard, level surface. 8. Loosen and remove steering column cover.
2. Fully retract boom, lower boom, place transmission in 9. Loosen and remove dash cover.
(N) NEUTRAL. 10. Label, disconnect and cap hydraulic hoses and fittings
3. Engage park brake and shut engine OFF. on steering orbital valve (7).
4. Place a Do Not Operate Tag on both ignition key switch 11. Remove four hex-flange capscrews (8) (three if machine
and steering wheel. is equipped with tilt column) connecting orbital valve to
steering column.
5. Properly disconnect battery. Refer to Section 9.8,
“Battery”, for procedure. 12. Pull steering column assembly and orbital valve from
machine cab.
Prior to SN 0160076806 excluding 0160076010, Note: DO NOT disassemble the steering orbital valve. The
0160076011, 0160076012 steering orbital valve is not serviceable and must be replaced in
its entirety, if defective.
4 b. Steering Column and Valve Installation
6 1. Install four hex-flange capscrews (three if machine is

equipped with tilt column) through steering column,
mounting bracket and into top of orbital valve.
5
Note: ALWAYS use new o-rings when servicing the machine.
2. Uncap and install new o-rings into fittings.
7 Lubricate o-rings with clean hydraulic oil.
8 3. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.
4. Install dash cover.
5. Install steering column cover.
MY2440
6. Install steering wheel (Refer to Section 4.4.1, “Steering
Wheel”), accessory control lever and transmission
SN 0160076806 to Present including 0160076010,
control lever.
0160076011, 0160076012
for procedure.
4
8. Carefully examine all connections one last time before
engine start-up. Rectify any faulty conditions.
6 9. Start engine and check operation of all controls. Check
for fluid leaks. Check hydraulic fluid level in tank and
add fluid as required.
5
around the machine.
7 12. Remove a Do Not Operate Tag on both ignition key
8
c. Power Steering Test
MAE2860
Conduct a pressure check of the steering hydraulic circuits at
the test port on the implement pump. Refer to Section 8.6.5,
“Steering Pressure Checking”.
4-4 31200926 G5-18A, 2505H, 25.5
Cab
4.4.3 Brake Pedal and Valve 8. Remove hardware (9).

9. Remove pin (10) and return spring securing service
a. Brake Valve Removal brake pedal to cab.
Refer to Section 8.11.2, a. “Service Brake Valve Removal”, for 10. Remove service brake pedal from cab.
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 Installation”, within cab.
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 (10).
4. Install hardware (9) securing pin.
(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 switch 7. Properly connect battery. Refer to Section 9.8, “Battery”,
and steering wheel. for procedure.
5. Properly disconnect battery. Refer to Section 9.8, 8. Close and secure engine cover.
“Battery”, for procedure. 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.
9
10
MY8860
G5-18A, 2505H, 25.5 31200926 4-5

Cab
4.4.4 Accelerator Pedal Replacement b. Accelerator Pedal Installation

1. Reconnect sensor (12) 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 in 3. Install hardware (11) securing pedal assembly
(N) NEUTRAL. to mount.
3. Engage park brake and shut engine OFF. 4. Properly connect the battery. Refer to Section 9.8,
4. Place a Do Not Operate Tag on both ignition key switch “Battery”, for procedure.
and steering wheel. 5. Close and secure engine cover.
5. Properly disconnect battery. Refer to Section 9.8, 6. Remove a Do Not Operate Tag on both ignition key
“Battery”, for procedure. switch and steering wheel.
11
12
11
MY8870
7. Remove hardware (11) securing pedal assembly to cab

frame.
8. Disconnect sensor (12) from pedal assembly.
9. Remove accelerator pedal assembly from cab.
4-6 31200926 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 9.10.1, “Windshield Wiper Motor”, for
1. Park machine on a hard, level surface. removal and installation information.
(N) NEUTRAL. 4.4.7 Windshield Washer Assembly
(if equipped)
Refer to Section 9.10.3, “Windshield Washer Reservoir and
Pump”, for removal and installation information.
and steering wheel.
7. Support the boom by installing the lift cylinder lock or a
suitable support.
14
15
13
MY2410
8. Label, disconnect and cap hydraulic hoses and electrical

connections (13) to joystick.
9. Lift rubber boot (14) from base of joystick and remove
capscrews (15).
10. Remove joystick.
b. Joystick Installation
1. Uncap and reconnect previously labeled hydraulic
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.
for procedure.
8. Start engine and test joystick for proper functions.
G5-18A, 2505H, 25.5 31200926 4-7

Cab
4.4.8 Heater System (if equipped) SN 0160076806 to Present including 0160076010,

0160076011, 0160076012
a. Removal
(N) NEUTRAL.
and steering wheel.
7. Place a suitable container beneath the radiator petcock
8. Slowly turn the coolant surge tank cap and allow any
pressure to escape.
9. Place a funnel at base of radiator to channel drained MAE4080
coolant into container. 16 17

10. Open radiator petcock and allow coolant to drain.
14. Remove front cover (16) to expose heater/defroster
11. Close the radiator petcock. element.
12. Transfer coolant into a suitable, covered container, and 15. Loosen hose clamps and disconnect the two
label as “Used Coolant”. heater hoses.
13. Dispose of used coolant at an approved recycling 16. Remove capscrews, nuts and lockwashers securing
facility. heater assembly to cab.
Note: If equipped with Air Conditioning, contact the local JLG 17. Carefully pull out heater assembly (17). Label and
dealer or certified air conditioning service center for proper disconnect wiring harness connections at blower.
draining of the air conditioner system. 18. Remove heater assembly.
Note: Label all hoses to ensure correct installation.
b. Installation
0160076011, 0160076012 1. Install heater assembly (17) to original orientation.
2. Connect wiring harness connections at blower.
3. Install capscrews, nuts and lockwashers to secure heater
assembly to cab.
4. Reconnect heater hoses.
5. Refill cooling system at recovery tank with a 50/50
mixture of ethylene glycol and water allowing time for
coolant to fill engine block. See Section 2.3, “Fluids,
Lubricants and Capacities”, for system capacities.
Note: If equipped with Air Conditioning, contact the local JLG
dealer or certified air conditioning service center for proper
charging of the air conditioner system. Refer to Section 2.3.2,
“Capacities”, for refrigerant type and capacity.
6. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
MY2430
16 17
4-8 31200926 G5-18A, 2505H, 25.5

Cab
7. Start engine, run it briefly at low idle and check machine Prior to SN 0160076806 excluding 0160076010,
for any visual sign of fluid leakage. STOP the machine 0160076011, 0160076012
immediately if any leakage is noted, and make any
necessary repairs before continuing.
8. Install front cover (16) in cab.
9. Check coolant level. Add or remove fluid as required.
4.4.9 Heater and A/C System (if equipped)
a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place
the travel select lever in the (N) NEUTRAL position,
engage the parking brake, and shut the engine OFF.
MY2431
16
switch and steering wheel, stating that the machine
should not be operated. SN 0160076806 to Present including 0160076010,
3. Open the engine cover. Allow the system fluids to cool. 0160076011, 0160076012
4. Properly disconnect the battery. Refer to Section 9.8,
6. Place a suitable container beneath the radiator petcock
pressure to escape.
8. Place a funnel at base of radiator to channel drained
coolant into container.
9. Open radiator petcock and allow coolant to drain.
10. Close the radiator petcock.
11. Transfer coolant into a suitable, covered container, and
label as “Used Coolant”.
12. Dispose of used coolant at an approved recycling
facility.
Note: If equipped with Air Conditioning, contact the local JLG MAE6060
dealer or certified air conditioning service center for proper

16
draining of the air conditioner system.
Note: Label all hoses to ensure correct installation. 13. Remove front cover (16) to expose heater/defroster
element.
G5-18A, 2505H, 25.5 31200926 4-9

Cab
b. Installation
19
1. Install cab condenser assembly (19) to cab roof. Secure
18 with previously removed hardware.
2. Connect previously labeled electrical connections to
the condenser assembly (19).
3. Connect previously labeled hoses (18) to condenser
assembly (19).
4. Position the heater assembly to its original orientation
in the cab. Secure with previous hardware.
5. Connect the previously labeled electrical connections.
6. Connect the previously labeled heater hoses (21) to
their appropriate locations.
7. Connect the previously labeled A/C hoses (23) to their
appropriate locations.
8. Install the seat riser weldment.
9. Install the front plate to the seat riser weldment.
10. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluids,
20 Lubricants and Capacities”.
20 11. Fill air conditioning system completely with refrigerant.
23 Refer Section 2.3, “Fluids, Lubricants and Capacities”, for
21
refrigerant type and capacity.
22
Note: If machine is equipped with air conditioning, air
conditioning system must be charged by local distributor or
24 certified air conditioning service center.
12. Properly connect the battery. Refer Section 9.8,
13. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.
MAE6020
Note: STOP engine immediately if any leakage is noted, and
14. Label and disconnect tubes (18) attached to the make any necessary repairs before continuing.
condenser assembly (19).
14. Wait for engine to cool and check coolant level. Add
15. Label and disconnect all electrical connections attached coolant as required to bring coolant to proper level.
to the condenser assembly (19).
15. Install protective covers.
16. Remove bolts securing the condenser assembly (19) to
cab roof. Remove condenser assembly from rear of the 16. If equipped, install windshield wiper assembly.
cab roof. 17. Close and secure the engine cover.
17. Loosen the hose clamps and disconnect the heater air Remove Do Not Operate Tag from ignition key switch and
duct hoses (20). steering wheel.
18. Loose the hose clamps securing the heater hoses (21).
4.4.10 Air Filter System (if equipped)
19. Label and remove both heater hoses.
20. Label and disconnect any electrical connections (22).
21. Label and disconnect two AC hoses (23).
(N) NEUTRAL.
22. Remove the bolts (24) securing the heater assembly to
the cab. Remove the heater assembly.
4-10 31200926 G5-18A, 2505H, 25.5
Cab
4. Place a Do Not Operate Tag on both ignition key switch 4.5 CAB REMOVAL
and steering wheel.
“Battery”, for procedure. WARNING
6. Open engine cover. Allow system fluids to cool. The protection offered by this ROPS/FOPS will be
Prior to SN 0160076806 excluding 0160076010, impaired if subjected to any modification or structural
0160076011, 0160076012 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 any questions about
suitability or condition of a cab.
26 Note: Remove and label cab components as needed before
25 removing cab from machine. Label, disconnect and cap
hydraulic hoses. Transfer cab parts to replacement cab after
MY9020 replacement cab is securely mounted on machine.
SN 0160076806 to Present including 0160076010, 1. Park machine on a hard, level surface.
0160076011, 0160076012
(N) NEUTRAL.
and steering wheel.
7. If equipped with a cab heater, Refer to Section 4.4.8, b.
26 “Installation”.
8. Working underneath cab, label, disconnect and cap all
25 hydraulic hoses at cab fittings.
MAE4070
9. Cap all fittings and openings to keep dirt & debris from
entering hydraulic system.
7. Remove access panel (25).
10. Label and disconnect cab harness connectors. Move
8. Remove cab air filter (26) and inspect. If required, harnesses clear of cab to prevent damage during cab
replace with new filter. removal.
9. Place filter back under seat and secure. 11. Install four lifting eye bolts with a minimal lifting
10. Replace and secure access panel. capacity of 800 lb (363 kg) in existing holes at top
corners (1) of cab.
for procedure. 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.
13. Remove hardware (2), securing cab to frame.
G5-18A, 2505H, 25.5 31200926 4-11

Cab
4.6 CAB INSTALLATION

1 1. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and
1 side clearance for cab installation.
2. Attach a sling with minimal lifting capacity of
800 lb (363 kg) through previously installed eye bolts.
3. Use a hoist or overhead crane and sling attached to cab.
Carefully begin to align cab with mounting holes in
frame.
4. Stop and check that wiring, hydraulic hoses, cables, etc.,
will not be pinched or damaged as cab is 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).
2
MY2420 7. Torque upper cab bolts to 340 lb-ft (461 Nm).
8. Torque lower cab bolts to 530 lb-ft (719 Nm).
14. Remove mirrors and all other cab components as
9. Remove eye bolts from top corners (1) of cab.
needed, if not previously removed.
10. Uncap and reconnect hydraulic hoses at cab locations.
15. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift cab 11. Install cab-to-wiring harness connectors on side of the
and remove it from frame. cab.
16. Readjust position of sling as needed to help balance cab 12. Uncap and connect heater hoses to engine.
during removal. 13. Secure with hose clamps.
17. When cab is completely clear of machine, carefully 14. If equipped with a cab heater, Refer to Section 4.4.8,
lower it to ground. “Heater System (if equipped)”.
18. Block up or support cab so that it does not move or fall. 15. Properly connect battery. Refer Section 9.8, “Battery”,
Assure that no personnel enter cab while it is being for procedure.
removed from machine.
16. Carefully examine all cab components, fasteners, etc.,
19. Inspect condition of fittings, clamps, hydraulic hoses, one last time before engine start-up. Rectify any faulty
etc. Replace parts as indicated by their condition. conditions.
20. Inspect and replace other machine parts that 17. Start engine and check operation of all controls.
are exposed with cab removed. Repair or replace
18. Check for hydraulic fluid leaks.
as required.
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.
4-12 31200926 G5-18A, 2505H, 25.5

Cab
21. Turn engine off and wait for engine to cool and check
coolant level. Add coolant as required to bring coolant
to proper level.
22. Install protective cover to front of cab.
23. Install mirrors and all other components as needed, if
removed.
24. Unblock wheels.
26. Start engine and test joystick for proper functions.
WARNING
Avoid breathing exhaust fumes, and prevent engine
operation from becoming a cause of toxic emissions.
G5-18A, 2505H, 25.5 31200926 4-13

Cab
4-14 31200926 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
5.4.8 Steering System Purge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.4 Drive Shaft Cleaning and Drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.8.1 Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.9.1 Equipment and Supplies Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.9.2 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
G5-18A, 2505H, 25.5 31200926 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
of the major assemblies of the axles, drive shafts, wheels and
tires. The following illustration identifies the components
that are referred to throughout this section.
FRONT AXLE
ASSEMBLY
DRIVE
SHAFT
FRONT STEERING REAR STEERING

CYLINDER CYLINDER
FRONT AXLE
WHEEL HUBS (2)
REAR AXLE
ASSEMBLY
MY8880
REAR AXLE
WHEEL HUBS (2)
5-2 31200926 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 emulsion cleaners
WARNING 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
precautions as outlined in Section 1, “Safety Practices”, of
contamination in the lubricant can cause gear and bearing
this manual.
failure. Remove old gasket material from all surfaces.
DRYING: Use clean, lintless towels to dry components after
5.3 GENERAL INFORMATION cleaning. DO NOT dry bearings by spinning them with
compressed air; this can damage mating surfaces due to lack
Before performing any inspection, maintenance or service
of lubrication. After drying, coat components with oil or a
operation, thoroughly clean the unit. The axles and drive
rust-preventive chemical to help protect them from
shafts should be checked and repaired only by experienced
corrosion. If storing components for a prolonged period, wrap
service technicians who are aware of all safety instructions
them in wax paper.
and particular component features.
PERIODIC OPERATION REQUIREMENT: Every two weeks,
Use suitable products to thoroughly clean all disassembled
drive the machine far enough to cause the drive-train
mechanical parts to help prevent personal injury to the
components to make several complete revolutions. This will
worker and prevent damage to the parts. Carefully inspect
help ensure that internal components receive lubrication to
the integrity of all moving parts (bearings, yokes, tubes,
minimize deterioration caused by environmental factors
gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as
such as high humidity.
they are subject to major stress and wear.
SUBMERSION: If the machine has been exposed to water
5.4 AXLE ASSEMBLIES deep enough to cover the hubs, disassemble the wheel ends
and inspect for water damage and contamination. If the
carrier housing was submerged in water, especially if the
5.4.1 Axle Serial Number Plate water level was above the vent tube (breather), drain the axle
The front and rear axle serial number plate is located on the and inspect internal parts for water damage and
inside of each axle on the right side of the center section. contamination. Before assembling and refilling the unit with
Information on the serial number plate is required in the specified lubricant(s), clean, examine and replace
correspondence regarding the axle. 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 PN 31200419
• Rear Axle Manual PN 31200981
G5-18A, 2505H, 25.5 31200926 5-3

5.4.5 Axle Removal
WARNING 2
3
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 drive pump, 5
MY8890
parking brake mechanism and a limited-slip feature; the rear
axle has none of these. The following steps outline a typical 4 4
axle removal procedure, suitable for either the front or the
8. If axle will be disassembled after removal, place a
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 and
remove the axle, thoroughly clean the machine. Avoid allow axle oil to drain into receptacle. Transfer used axle
spraying water or cleaning solution on the stabilizer oil into a suitable covered container, and label container
solenoids and other electrical components. If using a steam as “Used Oil”. Dispose of used oil at an approved
cleaner, seal all openings before steam cleaning. recycling facility.
Note: Clear the work area of all debris, unnecessary 9. Label, disconnect and cap steering and brake lines at
personnel, etc. Allow sufficient space to raise the machine and axle. Wipe up any spilled oil.
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.
(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 will
4. Place a Do Not Operate Tag on both ignition key switch remain in place during axle removal.
and steering wheel.
12. Support axle that is being removed with a suitable jack,
5. Properly disconnect battery. Refer to Section 9.8, hoist or overhead crane and sling. DO NOT raise axle or
“Battery”, for procedure. machine.
6. Open engine cover. Allow system fluids to cool. 13. Mark and remove both wheel and tire assemblies from
7. If the axle will be disassembled after removal, the oil will the axle that is being removed. (Refer to Section 5.6.1,
have to be drained. Loosen the breather to release “Removing Wheel and Tire Assembly from Machine”).
possible internal pressure, then tighten breather with a Note: The wheel and tire assemblies must be re-installed later
torque wrench to 9 lb-ft (12 Nm). with the directional tread pattern “arrows” facing in the
direction of forward travel.
1 5
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 axle.
Balance axle and prevent it from tipping, turning or
falling while removing it from beneath machine. Place
MY2091 the axle on a suitable support or holding stand.
4
5-4 31200926 G5-18A, 2505H, 25.5

5.4.6 Axle Installation 12. Remove blocks from front and rear of both tires on
other axle.
1. Before proceeding, ensure that the machine will remain
in place during axle installation. Block the front and rear 13. Uncap and reconnect steering and brake lines at their
of both tires on the axle that is already installed on the axle fittings. Refer to Section 8.11.2, “Service Brake
machine. Valve”, for brake bleeding procedures.
2. If applicable, raise the machine using a suitable jack or 14. Check hydraulic reservoir oil level.
hoist. Place suitable supports beneath the frame and 15. Properly connect battery. Refer to Section 9.8, “Battery”,
lower the machine onto the supports, allowing enough for procedure.
room for axle installation. Ensure that the machine will
16. Close and secure the engine covers.
remain in place during axle installation.
17. Start engine. Turn steering wheel several times lock to
3. Using a suitable jack, hoist or overhead crane and sling,
lock and check function of brakes. Check for hydraulic
remove the axle from its support or holding stand.
Balance the axle and prevent it from tipping, turning or leaks, and tighten or repair as necessary.
falling while positioning it beneath the machine. 18. Remove Do Not Operate Tag on both ignition key
DO NOT raise or otherwise disturb the machine while switch and steering wheel.
installing the axle. Keep the axle supported and
balanced on the jack, hoist or 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 2.3,
“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 2.3, “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.
11. Carefully raise machine using a suitable jack or hoist.
Remove supports from beneath frame and lower
machine to ground.
G5-18A, 2505H, 25.5 31200926 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 2.3, “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 2.3, “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 2.3, “Fluids,
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
traveling. damaged. 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) worn 2. Repair or replace universal joints

or damaged. as needed.
3. Drive shaft damaged/unbalanced. 3. Replace drive shaft as needed.
5-6 31200926 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 coupling

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

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

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 housing(s) 7. Replace housing(s) as needed.

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 housing 2. Replace o-ring.

(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 damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.
G5-18A, 2505H, 25.5 31200926 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 2.3, “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 2.3, “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 cylinder

internally. as needed.
10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
engaged. 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. Refer
machine or braking power to the appropriate Axle Repair
reduced. 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 31200926 G5-18A, 2505H, 25.5

5.4.8 Steering System Purge Procedure wheel fully to the left, then repeat steps 4-6 before
continuing.
1. Start the machine. Warm the engine and hydraulic
system to operating temperatures. Cycle all 7. Select 4-Wheel Circle Steer (1) mode, and turn the
hydraulic functions several times to purge air from steering wheel fully to the left, continuing a hard turn
the system. for 2 seconds at the stop to purge air from the
system.
2. Park the machine on a firm, level surface, fully
retract and lower the boom, and place the
transmission control lever in (N) NEUTRAL. Engage
the parking brake. Maintain a high idle throughout
this procedure.
Note: The rear wheels should be right, the front wheels should
be left.
8. Select 2-Wheel Front Steer (2) mode, and turn the
steering wheel fully to the right, then fully to the left,
continuing a hard turn for 2 seconds at the stops in
3. Select 2-Wheel Front Steer (2) mode, and turn the each direction to purge air from the system. Repeat
steering wheel fully to the right, then fully to the left, this cycle 2 times.
continuing a hard turn for 2 seconds after the stop in 9. The rear wheels should be fully right as shown
each direction to purge air from the system. Repeat above. If not, remain in 2-Wheel Front Steer (2)
this cycle 5 times. mode, and turn the steering wheel fully to the right,
then repeat steps 7-9 before continuing.
10. Repeat steps 5-10 five times to completely purge all
air from the system.
11. Select 4-Wheel Circle Steer (1) mode. Turn the
steering wheel fully to the right, then fully to the left,
continuing a hard turn for 2 seconds at the stops in
Note: The rear wheels should be forward, the front wheels each direction to purge air from the system. Repeat
should be left. this cycle 5 times.
4. Select 4-Wheel Circle Steer (1) mode, and turn the 12. Align all four wheels forward.
steering wheel fully to the right, continuing a hard 13. Select 4-Wheel Crab Steer (3) mode. Turn the
turn for 2 seconds after the stop to purge air from the steering wheel fully to the right, then fully to the left,
system. continuing a hard turn for 2 seconds at the stops in
5. Select 2-Wheel Front Steer (2) mode, and turn the each direction to purge air from the system. Repeat
steering wheel fully to the left, then fully to the right, this cycle 5 times.
continuing a hard turn for 2 seconds after the stops 14. Repeat steps 3-13 to complete this Steering System
in each direction to purge air from the system. Purge Procedure.
Repeat this cycle 2 times.
Note: Align all four wheels forward before driving machine.

Note: The rear wheels should be left, the front wheels
should be right.
6. The rear wheels should be fully left. If not, remain in
2-Wheel Front Steer (2) mode, and turn the steering
G5-18A, 2505H, 25.5 31200926 5-9
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 assembly 4
(universal joints, or U-joints). A few moments spent doing
this can help prevent further problems and down time later.
2
Inspect area where the drive shaft flange yoke and slip yoke
mount to the drive shaft. Attempt to turn drive shaft in both
directions. Look for excessive looseness, missing parts, cracks 2
or other damage. Worn or damaged drive shaft and cross and
bearing assembly may cause an excessive amount of
1
vibration or noise. 3
MY8900
Note: Any bolt removed from the drive shaft assembly MUST TO FRONT AXLE
be replaced. Do Not re-torque.
10. Remove hardware (1) securing drive shaft to rear axle
5.5.2 Drive Shaft Maintenance flange.
11. Remove hardware (2) securing drive shaft to front
Refer to Section 2.5, “Lubrication Schedule”, for information
axle flange.
regarding the lubrication of the grease fittings on the drive
shafts. 12. Remove drive shaft assembly (3).
5.5.3 Drive Shaft Removal 5.5.4 Drive Shaft Cleaning and Drying
1. Park machine on a hard, level surface. 1. Disassemble and clean all parts. Allow to dry.
2. Fully retract boom, lower boom, place transmission in 2. Remove any burrs or rough spots from all machined
(N) NEUTRAL. surfaces. Re-clean and dry as required.
3. Engage park brake and shut engine OFF. 5.5.5 Drive Shaft Installation
4. Place a Do Not Operate Tag on both ignition key switch 1. Raise drive shaft assembly (3) into position. The
and steering wheel. slip-yoke (4) end of drive shaft mounts toward rear axle.
5. Properly disconnect battery. Refer to Section 9.8, If reinstalling a drive shaft previously removed, align
“Battery”, for procedure. flange yokes according to alignment marks made during
removal.
2. Apply locking compound to all mounting bolts.
7. Block the wheels.
3. Install hardware securing drive shaft to front axle.
8. The drive shaft assembly is a balanced assembly. Mark
Torque capscrews to 102 lb-ft (139 Nm).
yoke and axle, transmission and shaft and slip yoke so
that these components can be returned to their original 4. Install hardware securing slip-yoke to rear axle. Torque
positions when reinstalled. capscrews to 102 lb-ft (139 Nm).
9. Yokes at both ends of drive shaft must be in same plane 5. Properly connect the battery. Refer to Section 9.8,
to help prevent excessive vibration. “Battery”, for procedure.
6. Unblock the wheels.
7. Close and secure the engine covers.
8. Remove the Do Not Operate Tags from both the ignition
key and the steering wheel.
5-10 31200926 G5-18A, 2505H, 25.5

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 original.
directional tread pattern “arrows” (1) facing in the direction
• Wheel diameter, width and offset dimensions equal to of forward travel.
the original.
• Approved for the application by the tire manufacturer 5.6.1 Removing Wheel and Tire Assembly from
(including inflation pressure and maximum tire load). Machine
The rims installed have been designed for stability 1. Park the machine on a firm, level surface, fully retract
requirements which consist of track width, tire pressure and the boom, lower the boom, place the transmission in
load capacity. Size changes such as rim width, center piece (N) NEUTRAL, engage the park brake and shut the
location, larger or smaller diameter, etc., without written engine OFF.
factory recommendations, may result in unsafe condition 2. Place a Do Not Operate Tag on both the ignition key
regarding stability. switch and steering wheel, stating that the machine
Foam filled tires have a positive effect on the weight, stability should not be operated.
and handling characteristics of the machine, especially 3. Loosen but DO NOT remove the lug nuts on the wheel
under load. The use of hydrofill as a tire-fill substance is not and tire assembly to be removed.
recommended because of possible environmental impact.
4. Place a suitable jack under the axle pad closest to the
Large-bore valve stems are used to help expedite tire wheel being removed. Raise the machine and position a
inflation and deflation. An inner tube may be used if a tire suitable support beneath the axle. Allow sufficient room
does not provide an airtight seal. Check tire inflation to lower the machine onto the support and to remove
pressures when the tires are cold. When mounting a tire on the wheel and tire assembly.
the wheel, the tire must be mounted on the wheel respective
5. Lower the machine onto the support.
of the directional tread pattern of the tire; this produces a left
or right tire and wheel assembly. 6. Remove lug nuts and washers in an alternating pattern.
7. Remove the wheel and tire assembly from the machine.
G5-18A, 2505H, 25.5 31200926 5-11

5.6.2 Installing Wheel and Tire Assembly onto 5.7 STEERING ANGLE ADJUSTMENT
Machine
Detailed axle service instructions are provided in the Axle
Note: The wheel and tire assemblies must be installed with the
Disassembly & Assembly Manual (PN 31200451).
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 (PN 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.
5-12 31200926 G5-18A, 2505H, 25.5

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 repair the NOTICE
machine, and move it under its own power.
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply
Towing is only possible by using the “towing” feature built
hydraulic oil must be compatible with hydraulic oil shown
into hydrostatic pump and disengaging park brake on the
in Section 2.3, “Fluids, Lubricants and Capacities”.
front axle.
Auxiliary Hydraulic Power Supply:
• Maximum towing distance is 200 ft (60 m).
• Portable hydraulic unit with capability of
• Maximum towing speed is 5 mph (8 kmh).
producing 300 psi (20,7 bar) minimum
• Maximum towing grade is 25%. pressure to release park brake.
DO NOT attempt to tow a machine that is loaded or boom/ Hose:
attachment is raised above 1,2 m (4 ft). • One Hydraulic Hose – Approximately 5 ft (1,5 m),
with a minimum I.D. of 0.25 in (6,3 mm) and a
WARNING Fittings:
minimum rating of 250 psi (17 bar).
MACHINE HAS NO TOWING BRAKES. Towing vehicle

must be able to control machine at all times. On highway • One 9/16-18 UNF (-6) ORFS Cap
towing is NOT permitted. • One 9/16-18 UNF (-6) ORFS Plug
Note: Machine axle fittings are 9/16-18 UNF (-6) ORFS. The
WARNING adaptor size may vary depending on the hose end of the
auxiliary hydraulic power supply.
BLOCK ALL FOUR WHEELS TO PREVENT MACHINE
FROM MACHINE ROLL AWAY. Failure to follow
instructions could cause death or serious injury.
G5-18A, 2505H, 25.5 31200926 5-13

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 supply
MY8910 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.
5-14 31200926 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 31200926 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY
of the major assemblies of the transmission. The following
TOP FILL
PORT
HYDROSTATIC
TRANSMISSION
FORWARD
RELIEF VALVE
SHUTTLE
VALVE
REVERSE
RELIEF VALVE
DIRECTIONAL
CONTROL VALVE
VIEW FROM BOTTOM WITH

PLATE REMOVED MY8920
6-2 31200926 G5-18A, 2505H, 25.5

Transmission
6.2 SAFETY INFORMATION 6.5 TRANSMISSION REPLACEMENT

Note: Contact the local JLG Dealer if internal transmission
WARNING 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
this manual.
the replacement process. Avoid spraying water or cleaning
solution onto or near the transmission shift solenoids and
6.3 TRANSMISSION DESCRIPTION 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 in
specifications contact an authorized Rexroth Repair center. (N) NEUTRAL.
More information can be obtained from the serial number 3. Engage park brake and shut engine OFF.
plate directly mounted on the transmission. Information
specified on the serial number plate includes the
and steering wheel.
transmission model number, the transmission serial number
and other data. Information on the serial number plate is 5. Properly disconnect battery. Refer to Section 9.8,
required in correspondence regarding the transmission. “Battery”, for procedure.
6.4 TRANSMISSION SPECIFICATIONS 7. Remove the air cleaner assembly.
8. Remove cooling system, Refer to Section 7.2, “Engine
6.4.1 Transmission Maintenance Cooling System”.
The transmission is a hydraulic component and requires the 9. Drain the hydraulic oil reservoir. Refer to Section 8.8.2,
same maintenance as the hydraulic system. Refer to Section “Hydraulic Oil Reservoir Draining”.
2.4, “Maintenance Schedule”.
10. Label, disconnect and cap all hydraulic hoses attached
Performance criteria is based on full throttle engine speed to transmission and implement pump.
unless otherwise specified or not applicable.
11. Cap all fittings and openings to keep dirt and debris
from entering hydraulic system.
12. Remove front fender support bar.
13. Label and disconnect all electrical connections attached
to transmission.
14. Wipe up any spilled hydraulic oil.
15. Vertically secure transmission and implement pump
with a lifting strap or chain. Use a suitable hoist or
overhead crane. Operate hoist or crane to remove slack
from chain, but DO NOT raise transmission at this time.
16. Remove two bolts that attach transmission to engine.
WARNING
The transmission may move while hoisting it out of the
chassis. Carefully move the transmission and adjust the
sling as needed. Keep fingers, hands, legs and other body
parts clear of the transmission.
G5-18A, 2505H, 25.5 31200926 6-3

Transmission
17. Carefully remove transmission and pump from the 13. Retract and level boom, recheck level of the fluid in the
machine. Avoid causing damage to transmission or reservoir.
surrounding parts. 14. Add oil as necessary to bring fluid level up until it
18. Lift transmission and pump clear of machine, and lower reaches FULL mark on reservoir. Recheck oil level when
it onto suitable supports or secure it to a stand built it reaches operating temperature 180–200° F (83–94° C).
especially for transmission or engine service. Secure 15. Recheck all drain plugs, lines, connections, etc., for leaks,
transmission and pump so that it will not move or fall. and tighten where necessary.
6.5.2 Transmission Disassembly 16. Close and secure the engine covers.
Contact an authorized Rexroth Repair center for transmission
disassembly, internal inspection, service, repair and
assembly procedures.
6.5.3 Transmission Installation
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.
7. Install cooling system. Refer to Section 7.2, “Engine
Cooling System”.
8. Fill hydraulic reservoir with clean, fresh oil and bleed
system. DO NOT overfill.
9. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
10. Check hydraulic oil level and add oil as required.
NOTICE
DO NOT use flushing compounds for cleaning purposes.
11. Run engine for two minutes at idle to help bleed any air
from hydraulic system.
12. Operate all boom functions to ensure any air is removed
from hydraulic system.
6-4 31200926 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.2 Fuel/Hydraulic Tank - Prior to SN 0160076806 excluding 0160076010, 0160076011,
0160076012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.3 Fuel Tank - SN 0160076806 to Present including 0160076010, 0160076011,
0160076012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.4.4 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.5.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.5.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.7.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7.3 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
G5-18A, 2505H, 25.5 31200926 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
engine. Information contained in the serial number is
WARNING required in correspondence with the engine manufacturer.
7.1.3 Specifications and Maintenance
Information
this manual.
For engine, coolant and oil specifications, and maintenance
information, refer to Section 2, “General Information and
WARNING Specifications”.
Engine fuel lines are pressurized. DO NOT attempt
repairs unless specific training has been completed.
7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that after
maintenance, service and repair of the engine, engine
operation does not violate local regulations.
Note: Detailed engine service instructions (covering
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 31200926 G5-18A, 2505H, 25.5

Engine
7.1.4 Component Terminology

To understand safety, operation and maintenance
information presented in this section, it is necessary that
operator/mechanic be familiar with names and locations of
engine components. The following illustration identifies
components that are referred to throughout this section.
THERMOSTAT
FUEL PUMP
OIL FILTER
FUEL FILTER
ALTERNATOR
TURBOCHARGER
STARTER
MY8930
G5-18A, 2505H, 25.5 31200926 7-3

Engine
7.2 ENGINE COOLING SYSTEM
7.2.1 Surge Tank Cap

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 coolant and a
hot-running engine.
7.2.2 Radiator/Oil Cooler Replacement

Before considering radiator or oil cooler replacement for
other than obvious damage, conduct a cooling system
pressure test check the coolant specific gravity, coolant level,
fan belt tension and dash panel temperature indicator.
• If the engine runs hot, check the temperature of the
upper radiator hose.
• If the hose is not hot, the thermostat may be stuck in
the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012

7
4
6
1
10
10 5 9 8
2
MY8970
7-4 31200926 G5-18A, 2505H, 25.5

Engine
SN 0160076806 to Present including 0160076010, 0160076011, 0160076012

7
4
6
1
2 10
MAE2870
10 5 9 8
a. Radiator/Oil Cooler Removal 13. Disconnect the ECM connectors and remove any nylon
ties that may be securing the wire harness mounted to
1. Park the machine on a firm, level surface, fully retract
the right front fender.
the boom, raise and support the boom, place the
transmission in (N) NEUTRAL, engage the park brake 14. Remove the right front fender (3).
and shut the engine OFF. Note: It may be required to remove the right front tire to access
2. Place a Do Not Operate Tag on both the ignition key hydraulic hose fittings.
switch and the steering wheel, stating that the machine
should not be operated.
pressure to escape (4).
3. Open the engine cover. Allow the system fluids to cool.
16. Place a suitable container beneath the radiator
4. Thoroughly clean the engine and surrounding area, petcock (5).
including all hoses and fittings before proceeding.
17. Place a funnel at the base of the radiator to channel the
5. Open the battery cover. drained coolant into the container. Open the radiator
6. Properly disconnect the battery. Refer to Section 9.8, petcock and drain the coolant into the funnel. Transfer
“Battery”, for procedure. the fluid into a properly labeled container. Dispose of
properly if coolant needs to be replaced. Close the
7. Support or secure the hood assembly.
radiator petcock.
8. Remove the mounting nuts from the rod end of each
18. Remove air dam (6) to gain access to the cooling
hood gas strut.
package lifting eye mounts.
9. Remove the two bolts and washers securing each hinge
19. Loosen the mounting bolts and move the surge tank (4)
from the hood side of the hood. Mark each bolt location
to access the cooling package lifting eye mounts.
before removing to aid in aligning the hood during
reassembly. 20. Remove the top radiator hose (7) and hose from the
surge tank attached to the radiator. Cap all fittings and
10. Remove the hood assembly.
openings to keep dirt & debris from entering the
11. Remove the inside firewall plate (1) to access the back cooling system.
side of the cooling package.
21. Place a suitable container beneath the hydraulic oil
12. Remove the engine pod side skirt (2) and belly pan. cooler fittings. Transfer any hydraulic oil into a properly
labeled container. Dispose of properly.
G5-18A, 2505H, 25.5 31200926 7-5

Engine
22. Disconnect and cap the hydraulic hose (8) attached to b. Cooler/Fan Motor Removal
the radiator/oil cooler assembly. Allow hydraulic oil to
drain from the hydraulic oil cooler. Cap all fittings and 14
hydraulic system.
23. Disconnect the hydraulic cooler temperature sensor (9).
24. Loosen and remove the four mounting nuts and
rebound washers (10) from the radiator assembly.
25. Connect a lifting strap to the radiator/oil cooler 14
assembly lifting eyes. 14
26. Slowly lift the radiator assembly to gain access to the

fan side, hydraulic oil cooler out hose connections and
the bottom radiator hose.
14
MY8940
1. Turn the radiator/cooler assembly over and place on a

secure location.
2. Remove the four bolts (14) securing the fan
motor/guard to the radiator/cooler shroud.
MY9000
13 11 12
27. Disconnect the connector on the fan solenoid(s).
Loosen and remove the fan solenoid(s) (11).
28. Label, disconnect and cap the three hydraulic hoses
attached to the fan motor (12). Cap all fittings and
openings to keep dirt and debris from entering the
hydraulic system. 15
29. Loosen and remove the lower hydraulic oil cooler hose.
Cap all fittings and openings to keep dirt & debris from
entering the hydraulic system.
30. Remove the bottom radiator hose (13). Cap all fittings
and openings to keep dirt & debris from entering the MY8950
cooling system.
3. Turn the fan motor/guard over to access the fan
31. Slowly remove the radiator/oil cooler from the machine. assembly.
4. Loosen and remove the center bolt and washer (15)
securing the fan to the motor shaft.
Note: Retain the key located on the fan motor shaft.
7-6 31200926 G5-18A, 2505H, 25.5

Engine
7. Install previously removed bottom radiator hose.

8. Connect the electrical connector to the fan solenoid(s).
9. Connect the electrical connector to the hydraulic
16 temperature sensor.
10. Install the previously removed rebound washers and
nuts securing the radiator assembly. Torque the
mounting nuts to 31 - 34 lb-ft (23 - 25 Nm).
11. Install the previously removed surge tank.
16 12. Install the previously removed top radiator hose.
13. Connect the previously removed surge tank hose to the
radiator.
MY8960 14. Re-fill the surge tank/radiator with approximately
2.7 gal (9.9 L) of a 50/50 mixture of ethylene glycol and
5. Turn the fan motor/guard over to access the two fan
water.
motor mounting bolts (16).
15. Install the previously removed air dam.
6. Loosen and remove both mounting bolts securing the
fan motor to the fan guard. 16. Install the previously removed inside firewall plate.
7. Remove the fan motor as necessary. 17. Install the previously removed right front fender. Do not
tighten mounting bolts at this time.
c. Cooler/Fan Motor Installation 18. Connect the ECM connectors and secure the wire
1. Apply Loctite® 242 to all mounting bolts.
TM harness.
2. Install the fan motor to the fan guard. The fan motor can 19. Properly connect the battery. Refer Section 9.8,
only be installed one way. “Battery”, for procedure.
3. Install the two previously removed mounting bolts and 20. Remove any boom support.
torque to 31 - 35 lb-ft (41 - 47 Nm). 21. Run the engine to operating temperature. Visually
4. Verify the key is in place on the fan motor shaft and check for leaks with the engine running. Check the
install the previously removed fan. Install the fan coolant level in the surge tank and fill, or drain, as
mounting washer and bolt. Torque to necessary. Check the hydraulic oil level in the tank and
10.75 lb-ft (15 Nm). add hydraulic oil as required.
5. Install the fan motor assembly to the fan shroud. Install Note: Refer to Section 8.11.11, “Variable Speed Fan Valve”, for
and torque the mounting bolts to 27 lb-ft (37 Nm). detailed testing information.
22. Retract and raise boom. Install previously removed
d. Radiator/Oil Cooler Installation boom support. Shut engine OFF.
1. Connect a lifting strap to the radiator/oil cooler Note: If previously removed, install the right front tire and
lifting eyes. torque lug nuts to 220 lb-ft (300 Nm).
2. Slowly lower the radiator assembly to connect the
23. Install the previously removed engine pod side skirt and
previously removed hydraulic fan hoses, hydraulic oil
belly pan. Tighten all mounting bolts, including the
cooler out hoses and the bottom radiator hose.
right front fender mounting bolts.
3. Remove any caps and/or plugs and install the
24. Install the hood and secure with the previously
previously removed hoses.
removed mounting bolts.
4. Install the previously removed fan solenoid(s).
25. Install each gas strut and secure with the previously
Note: Verify the fan solenoid(s) retaining nut is installed with removed mounting nuts.
the recess FACING the solenoid. 26. Adjust hood as needed.
5. Lower the radiator/oil cooler assembly into place. 27. Close and secure the engine cover.
6. Remove any caps and/or plugs and install the 28. Install and secure the battery cover.
previously removed hydraulic cooler outlet hose.
29. Remove previously installed boom support.
G5-18A, 2505H, 25.5 31200926 7-7

Engine
30. Remove the Do Not Operate Tags from both the ignition 7.4.2 Fuel/Hydraulic Tank - Prior to
key and the steering wheel. SN 0160076806 excluding 0160076010,
0160076011, 0160076012
7.3 ENGINE ELECTRICAL SYSTEM
a. Cleaning and Drying
The engine electrical system, including the starter, alternator
If contaminated fuel, hydraulic oil or foreign material is in the
and primary wiring, is described in Section 9, “ Electrical
tank, the tank can usually be cleaned.
System”.
Note: If a leak is suspected between the fuel and hydraulic oil
7.4 FUEL SYSTEM tank, contact the local JLG dealer.
To clean the fuel/hydraulic oil tank:
7.4.1 Diesel Fuel 1. Have a dry chemical (Class B) fire extinguisher near the
Fuel represents a major portion of machine operating costs work area.
and therefore must be used efficiently. ALWAYS use a 2. Depending on which side of the tank is contaminated
premium brand of high-quality, clean diesel fuel. Low cost, (fuel or hydraulic oil), remove the fuel or oil tank drain
inferior fuel can lead to poor performance and expensive plug, and safely drain any fuel or hydraulic oil into a
engine repair. suitable container. Dispose of fuel or hydraulic oil
Refer to Section 2.3, “Fluids, Lubricants and Capacities”, for properly.
approved fuel specifications. 3. Clean the fuel/hydraulic oil tank with a high-pressure
washer, or flush the tank with hot water for five minutes
and drain the water. Dispose of contaminated water
properly.
4. For the fuel tank side, add a diesel fuel emulsifying
agent to the tank. Refer to the manufacturer’s
instructions for the correct emulsifying agent-to-water
mixture ratio. Refill the tank with water, and 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.
b. 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
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 to the exterior and look for bubbles to appear
at the cracked or damaged area.
c. Disassembly and Assembly

The fuel/hydraulic oil reservoir is a one piece-unit integral to
the chassis frame and cannot be disassembled.
7-8 31200926 G5-18A, 2505H, 25.5

Engine
7.4.3 Fuel Tank - SN 0160076806 to Present b. Cleaning and Drying

including 0160076010, 0160076011, If contaminated fuel or foreign material is in the tank, the
0160076012 tank can usually be cleaned.
a. Fuel Tank Removal To clean the fuel tank:
1. Park machine on a firm, level surface, level machine, 1. Have a dry chemical (Class B) fire extinguisher near the
fully retract boom, lower boom, place transmission in work area.
(N) NEUTRAL, engage parking brake, and shut engine 2. Remove the fuel drain plug, and safely drain any fuel
OFF. into a suitable container. Dispose of fuel properly.
2. Place a Do Not Operate Tag on both ignition key switch 3. Clean the fuel tank with a high-pressure washer, or flush
and steering wheel. the tank with hot water for five minutes and drain the
3. Open engine cover. Allow system fluids to cool. water. Dispose of contaminated water properly.
4. Properly disconnect battery. Refer Section 9.8, “Battery”, 4. Add a diesel fuel emulsifying agent to the tank. Refer to
for procedure. the manufacturer’s instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the tank
Note: If replacing the tank, remove all internal and external with water, and agitate the mixture for 10 minutes.
components from the old tank, and retain for use on the Drain the tank completely. Dispose of contaminated
replacement tank. water properly.
Note: Have a dry chemical (Class B) fire extinguisher near the 5. Refill the fuel tank with water until it overflows.
work area. Completely flush the tank with water. Empty the fuel
5. Remove the hydraulic oil reservoir. Refer to
Section 8.8.4, “Hydraulic Oil Reservoir Removal/
c. Inspection
Installation (SN 0160076806 to Present including
0160076010, 0160076011, 0160076012)”, for procedure. 1. Inspect the fuel tank thoroughly for any cracks, slices,
leaks or other damage.
2. Plug all openings except one elbow fitting. Install the
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
at the cracked or damaged area.
d. Fuel Tank Installation

1. Install the fuel tank to the frame with previously
removed hardware.
2. Fill fuel tank according to specifications. Refer to Section
2.3, “Fluids, Lubricants and Capacities”.
1 3. Check fuel tank for leaks.
4. Install the hydraulic oil reservoir. Refer to Section 8.8.4,
MAE5450 “Hydraulic Oil Reservoir Removal/ Installation (SN
0160076806 to Present including 0160076010,
6. Remove drain plug from fuel tank (1) and drain fuel into 0160076011, 0160076012)”, for procedure.
an approved and suitable container. Dispose of fuel 5. Properly connect battery. Refer Section 9.8, “Battery”,
properly. for procedure.
7. Install the fuel tank drain plug. 6. Close and secure engine cover.
8. Remove hardware securing fuel tank (2) to frame. 7. Remove Do Not Operate Tag from ignition key switch
9. Remove fuel tank from frame. and steering wheel.
G5-18A, 2505H, 25.5 31200926 7-9

Engine
7.4.4 After Fuel System Service 7.5 ENGINE EXHAUST SYSTEM

1. Drain and flush the fuel tank if it was contaminated.
2. Fill the fuel tank with fresh, clean diesel fuel as required. 7.5.1 Exhaust System Removal
Note: If bleeding of the fuel system is required, contact the 1. Park the machine on a firm, level surface, level the
local JLG dealer. machine, fully retract the boom, lower the boom, place
the travel select lever in the (N) NEUTRAL position,
engage the parking brake, and shut the engine OFF.
switch and steering wheel, stating that the machine
3. Open the engine cover. Allow the system fluids to cool.
ULS
LS
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.
7-10 31200926 G5-18A, 2505H, 25.5

Engine
7.5.2 Exhaust System Installation 7.6 AIR CLEANER ASSEMBLY

Note: Keep all clamps loosened until entire exhaust system is in
place.
Note: Replace the nuts and the exhaust studs on the
CAUTION
turbocharger if damaged. NEVER run the engine with only the inner safety element
installed.
1. Install the exhaust assembly in place at the
turbocharger with the previously used hardware. Note: Refer to the machine Operation & Safety Manual
Torque the flange nuts (2) on the turbo charger to for the correct element change procedure.
22 ±5 lb-ft (30 ±7 Nm).
2. Install the muffler brackets (1) to the frame brackets 7.6.1 Air Cleaner Assembly Removal
with the previously used hardware. 1. Park the machine on a firm, level surface, level the
3. Adjust the muffler, exhaust and tail pipes for proper machine, fully retract the boom, lower the boom, place
clearance then tighten all clamps. the travel select lever in the (N) NEUTRAL position,
4. Properly connect the battery. Refer to Section 9.8, engage the parking brake, and shut the engine OFF.
“Battery”, for procedure. 2. Place a Do Not Operate Tag on both the ignition key
5. Start engine and check for exhaust leaks at all exhaust switch and steering wheel, stating that the machine
connections. Adjust or repair as needed. should not be operated.
6. Close and secure the engine cover. 3. Open the engine cover. Allow the system fluids to cool.
7. Remove the Do Not Operate Tags from both the ignition 4. Properly disconnect the battery. Refer to Section 9.8,
key and the steering wheel. “Battery”, for procedure.
0160076011, 0160076012
1
4
2
MY9011
G5-18A, 2505H, 25.5 31200926 7-11

Engine
SN 0160076806 to Present including 0160076010, 7.6.2 Air Cleaner Assembly Installation

0160076011, 0160076012
1
1. Install the air cleaner assembly (2) to the air cleaner
mounting plate with the previously used hardware (4).
2
Hand torque mounting bolts to
10 - 12 lb-ft (13,5 - 16,3 Nm).
2. Place the loosened clamp (3) over the air intake elbow
and install elbow on the air cleaner assembly.
3. Adjust and tighten clamp before starting the machine.
4. Install air intake adapter duct (1) to air cleaner
assembly (2) and tighten the clamp bolt.
5. Properly connect the battery. Refer to Section 9.8,
3 6. Close and secure the engine cover.
4 7. Remove the Do Not Operate Tags from both the ignition
MAE3040
5. Loosen the clamp bolt and remove air intake adapter

duct (1) from air cleaner assembly (2).
6. Loosen clamp (3) securing air intake elbow to air cleaner
assembly. Pull the air intake elbow off the air cleaner.
7. Remove the hardware securing the air cleaner to the air
cleaner mounting plate (4). Remove the air cleaner
assembly (2).
7-12 31200926 G5-18A, 2505H, 25.5

Engine
7.7 ENGINE REPLACEMENT

3
MY8970
2

3
2
MAE2870
2
G5-18A, 2505H, 25.5 31200926 7-13

Engine
7.7.1 Engine Removal 7.7.2 Engine Disassembly, Inspection and

Service
the boom, lower the boom, place the transmission in Engine disassembly, internal inspection, service, repair and
(N) NEUTRAL, engage the park brake and shut the assembly procedures are covered in the Deutz Engine
engine OFF. manual. Several special engine service tools are required to
2. Place a Do Not Operate Tag on both the ignition key properly service the Deutz engine. Contact the local JLG dealer
switch and the steering wheel, stating that the machine for further information.
should not be operated. Note: If the engine is being replaced, there may be external
3. Open the engine cover. Allow the system fluids to cool. components that will be required to be transferred from the original
engine to the replacement engine depending upon who you
4. Thoroughly clean the engine and surrounding area, purchase the new engine from and the configuration of your
including all hoses and fittings before proceeding. replacement engine. Refer to the appropriate JLG user manual for
5. Properly disconnect the battery. Refer to Section 9.8, detailed procedures that cover the transfer of original engine
“Battery”, for procedure. components to the replacement engine.
6. Remove the radiator/oil cooler assembly. Refer to
Section 7.2.2, “Radiator/Oil Cooler Replacement”, for 7.7.3 Engine Installation
detailed removal instructions. Note: Refer to Section 2.2, “Specifications”, for specific fastener
7. Drain hydraulic reservoir. Refer to Section 8.8.2, torque specifications.
“Hydraulic Oil Reservoir Draining”. 1. Position engine (3) in engine compartment being sure
8. Remove the air cleaner assembly. Refer to Section 7.6.1, to line up the four motor mount holes. Replace bolts
“Air Cleaner Assembly Removal”, for detailed removal and torque to 185 lb-ft (251 Nm).
instructions. 2. Reattach any previously labeled wire connections on
9. Remove the exhaust system. Refer to Section 7.5.1, the engine and transmission.
“Exhaust System Removal”, for detailed removal 3. Install the hydraulic and fuel filters, and radiator/oil
instructions. cooler assembly bracket assembly (2).
10. Loosen and remove the rear fender (1). 4. Install the previously removed rear fender (1).
11. Label, disconnect and cap all hydraulic hoses attached 5. Remove the plugs and connect all previously labeled
to engine and transmission, cap all fittings and plug fuel lines.
hoses to keep dirt & debris from entering hydraulic
system. 6. Install the exhaust assembly. Refer to Section 7.5.2,
“Exhaust System Installation”, for detailed installation
12. Label, disconnect and cap all fuel lines. Install a plug in instructions.
the end of each line.
7. Install the air cleaner assembly. Refer to Section 7.6.2,
13. Remove hydraulic and fuel filters, and radiator/oil cooler “Air Cleaner Assembly Installation”, for detailed
assembly bracket assembly (2). installation instructions.
14. Label and disconnect all wire connections on the 8. Install the radiator/oil cooler assembly. Refer to Section
engine and transmission. 7.2.2, “Radiator/Oil Cooler Replacement”, for detailed
15. Secure the engine (3) with a lifting strap or chain from installation instructions.
the appropriate lifting points. Use a suitable hoist or 9. Uncap and reconnect all hydraulic hoses and fittings to
overhead crane. the engine and transmission. Keep hoses free of dirt &
16. Remove the four motor mount bolts that attach the debris.
engine to the frame. 10. Refill the hydraulic reservoir (Refer to the appropriate
17. Carefully lift the engine from the machine. Avoid Operation & Safety Manual for information concerning
causing damage to the surrounding parts. the hydraulic oil and filter change).
18. Lift the engine clear of the machine, and lower it onto 11. Properly connect the battery. Refer to Section 9.8,
suitable supports or stand. Secure the engine so that it “Battery”, for procedure.
will not move or fall. 12. Check that all hydraulic, electrical, cooling, fuel and
exhaust system connections are correct and connected
tightly.
7-14 31200926 G5-18A, 2505H, 25.5

Engine
13. Run engine to normal operating temperature then shut off

the engine. While the engine is cooling, check for leaks.
14. Allow the engine to cool. Check the radiator coolant
level, and top off with a 50/50 mixture of ethylene glycol
and water. Replace the radiator cap.
NOTICE
During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steering
wheel.
• Keep the transmission in NEUTRAL (N).
15. Check for leaks from the engine, main hydraulic pump and
lines, transmission, hydraulic reservoir and fuel tank.
Check the levels of all fluids and lubricants. Fill as
required.
16. Purge the hydraulic system of air by operating all boom
functions through their entire range of motion several
times. Check the hydraulic oil level.
17. Check for proper operation of all components.
18. Turn the engine OFF.
19. Install the belly pan.
20. Install the engine cover. Close and secure the cover.
G5-18A, 2505H, 25.5 31200926 7-15

Engine
7-16 31200926 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
8.7.1 G5-18A (Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012)
........................................................................... 8-7
8.7.2 G5-18A (SN 0160076806 to Present including 0160076010, 0160076011, 0160076012)
........................................................................... 8-9
8.7.3 2505H & 25.5 (Prior to SN 0160076806 excluding 0160076010, 0160076011,
0160076012). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.4 2505H & 25.5 (SN 0160076806 to Present including 0160076010, 0160076011,
0160076012). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.8.1 Pressurized Hydraulic Oil Fill Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.8.2 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.8.3 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.9 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.9.1 Implement Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.9.2 Implement Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.9.3 Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
G5-18A, 2505H, 25.5 31200926 8-1

Hydraulic System
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.10.1 Front Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.10.2 Front Drive Motor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.11.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.11.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.11.3 Park Brake Valve (G5-18A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.11.4 Hand Brake Valve (2505H & 25.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.11.5 Steering Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.11.6 Pilot Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.11.7 Inching Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.11.8 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.11.9 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.11.10 Quick Attach Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
8.11.11 Variable Speed Fan Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.12 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.12.1 General Cylinder Removal Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.12.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.12.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
8.12.4 Cylinder Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.12.5 General Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.12.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.12.7 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.12.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8-2 31200926 G5-18A, 2505H, 25.5

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
hydraulic components of the machine. The following
COMPENSATING
CYLINDER
HYDRAULIC RESERVOIR
MAIN CONTROL AND LIFT/LOWER CYLINDER
VALVE (UNDER BOOM)
EXTEND/RETRACT
CYLINDER
TILT
CYLINDER
HYDRAULIC
FILTER
HYDROSTATIC
DRIVE PUMP
IMPLEMENT
PUMP
MAE4050
STEERING FRONT AXLE

CYLINDER DRIVE MOTOR
G5-18A, 2505H, 25.5 31200926 8-3

Hydraulic System
8.2 SAFETY INFORMATION frequently. Always use OEM filters to assure the necessary
filtration requirements are met.
Some hydraulic functions are actuated by interfacing with
WARNING electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
DO NOT service the machine without following all safety properly, check the electrical aspect of the malfunctioning
precautions as outlined in Section 1, “Safety Practices”, of circuit also. Refer to Section 9.4, “Electrical System
this manual. Schematics”.
8.3 GENERAL INFORMATION 8.4 SPECIFICATIONS

Petroleum-based hydraulic fluids are used in this machine. Refer to Section 2, “Specifications”, for hydraulic system
The temperature of hydraulic fluid increases during the specifications.
operation of various hydraulic functions. A heated
petroleum-based hydraulic fluid presents a fire hazard, 8.5 HOSES, TUBE LINES, FITTINGS, ETC.
especially when an ignition source is present.
Accordingly, periodically inspect all hydraulic system There are numerous hydraulic hoses, tubes, fittings, etc. used
components, hoses, tubes, lines, fittings, etc. Carefully on this machine. Periodically inspect all of these and carefully
examine any deterioration and determine whether any examine any signs of wear, abrasion and/or deterioration.
further use of the component would constitute a hazard. If in Determine whether any further use of the component would
doubt, replace the component. constitute a hazard. If in doubt, replace the component.
Whenever you disconnect a hydraulic line, coupler, fitting or
other component, slowly and cautiously loosen the part 8.5.1 Replacement Considerations
involved. A hissing sound or slow seepage of hydraulic fluid Conditions including, but not limited to, the following are
may occur in most cases. After the hissing sound has ceased, sufficient for considering component replacement:
continue removing the part. Any escaping oil should be 1. Any evidence of hydraulic fluid leakage at the surface of
directed into an appropriate container. Cap or otherwise a flexible hose or its junction with the metal and
block off the part to prevent further fluid seepage. couplings.
Hydraulic system maintenance will, at times, require that the 2. Any blistering or abnormal deformation to the outer
engine be operated. Always follow safety precautions. covering of a hydraulic hose.
A major cause of hydraulic component failure is 3. Hydraulic oil leakage at any threaded or clamped joint
contamination. Keeping the hydraulic fluid as clean as that cannot be eliminated by normal tightening or
possible will help avoid downtime and repairs. Dirty or other recommended procedures.
contaminated hydraulic oil can damage internal
components and void the manufacturer’s warranty. When 4. Evidence of excessive abrasion or scrubbing on the
servicing the system, cap or plug hydraulic fittings, hoses and outer surface of a hose, rigid tube, or hydraulic fitting.
tube assemblies. Plug all cylinder ports, valves and the Modification must be made to eliminate the
hydraulic reservoir, and pump openings until installation interference of the elements in contact with one
occurs. Protect threads from contamination and damage. another, or to otherwise protect the components from
contact with one another. Slightly moving a hose or
Manufacture’s recommended hydraulic oil cleanliness levels adjusting a plastic tie wrap may often be all that is
are based on the three digit ISO code for 4 micron/6 micron/ necessary to eliminate interference; evaluate each
14 micron particle sizes found in one ml of fluid (reference situation and proceed as required by the individual
ISO 4406: 199(E). The acceptable level is 19/17/14 or below; circumstances.
anything higher requires system cleaning and filter
replacement.
8.5.2 Hose, Tube, Line and Fitting Replacement
Note: The human eye can only distinguish particles down to Before removing a hydraulic hose or component, always
40 microns. mark or otherwise label the related parts and the exact
Refer to Section 2, “General Information and Specifications”, location of the hose or component to aid in proper
for the appropriate maintenance intervals based on hours of reinstallation. Hydraulic fluid is a good cleaner and can
operation, but if your equipment is exposed to extremely remove most liquid-ink type markings, so make sure the
dirty or hostile conditions service may be required more mark or label will remain intact. Alternative methods to using
8-4 31200926 G5-18A, 2505H, 25.5

Hydraulic System
markers include color-coded tie wraps, number-tag sets, 6. As a last resort, adjust the appropriate relief valve, if
alpha-numeric stampings or markings, and suitably labeled applicable. Turning the adjustment screw clockwise will
pieces of tape. Select an appropriate marking method for the increase the pressure; turning the screw
conditions and proceed accordingly. counterclockwise will decrease the pressure.
NEVER replace a hydraulic hose or other component with a
part not specifically designed for this machine. Use only 8.6.2 Main Control Valve Pressure Checking
factory approved parts for best performance and safety.
Removal and replacement of hoses, tube lines, fittings, etc.
usually involves straightforward procedures. When
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 1
or interference with any rotating members. Install
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 MY8640
1. Attach 5000 psi (345 bar) gauge to the test port (1) at
8.6.1 Pressure Checks and Adjustments
the rear of the implement pump to check the system
In general, follow the steps below whenever conducting pressure. Make sure the gauge is visible from inside the
pressure checks and performing adjustments: cab.
1. Park the machine on a firm, level surface. Engage the 2. Refer to Section 8, “Hydraulic Pressure Diagnosis”, for
park brake, place the transmission in (N) NEUTRAL, place start up procedure. Check the main control pressure
the neutral lock lever in the (N) NEUTRAL LOCK position, with the park brake on and the service brake off at full
level the boom and turn the engine OFF. throttle. Retract a boom circuit function until the
2. Pressure tee fittings are conveniently located in each cylinder bottoms. The main control valve pressure
hydraulic circuit. Install a pressure gauge capable of should be 3585 - 3665 psi (247 - 252,7 bar) at full
measuring at least 10% more pressure than that which throttle. Repeat for each boom circuit to verify the
the circuit being checked operates under. correct main control valve pressure.
3. Start the engine. Operate machine functions several
times to allow hydraulic oil to reach operating
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
2
readings are taken. MY2110
5. Check the pressure gauge reading. It should read as

3. If a pressure adjustment is required, adjust the main
described in the appropriate section. If the reading is
relief cartridge (2) on the main control valve. Recheck
not as specified, turn the engine OFF and check other
pressure after any adjustment has been made.
components in the system. Verify that all related
hydraulic components and electrical switches, sensors,
solenoids, etc. are operating correctly.
G5-18A, 2505H, 25.5 31200926 8-5

Hydraulic System
8.6.3 Charge Pressure Checking 8.6.5 Steering Pressure Checking
5
3 6
MY8640
MY8650
1. Attach a pressure gauge to the test fitting (5) at the rear
1. Attach a pressure gauge to the test port (3) on the of the implement pump. The pressure reading should
hydrostatic transmission (4) to check the system be 2490 - 2590 psi (171,7 - 178,6 bar) with the steering
pressure. The pressure should be wheel fully turned to the steering stop in one direction.
350 - 410 psi (24,1 - 28,2 bar) with the engine at low idle. 2. There is no adjustment for steering pressure.
2. The charge pressure relief valve is preset at the factory
and is not adjustable. 8.6.6 Fan Speed Pressure and Direction
Checking
8.6.4 Boom Function Pressure Checking 1. Place a piece of paper over the face of the radiator core.
1. Attach 5000 psi (345 bar) gauge to the test port (5) at If the paper is held in place, the fan is rotating in the
the rear of the implement pump to check the system right direction.
pressure. Make sure the gauge is visible from inside the 2. Attach a pressure gauge to the test fitting (6) at the rear
cab. of the implement pump.
2. See Section 8, “Hydraulic Pressure Diagnosis” for start 3. If the machine is equipped with either the variable fan
up procedure. Check the boom function pressure with option or the variable, reversing fan option; run the
the park brake on and the service brake off at full engine at high idle and measure the fan speed using a
throttle. Retract each boom circuit function until the suitable portable stroboscope adjustable to fractional
cylinder bottoms. Each circuit function pressure should RPM, and with the ability to distinguish actual RPM from
be 3585 - 3665 psi (247 - 252,7 bar) at full throttle. 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 main 4. Connect the JLG Analyzer and activate the Test Mode to
control valve is 125 psi (13,3 bar) HIGHER than the drive the fan to the maximum fan RPM.
3450 - 3550 psi (237,8 - 244,7 bar) of each individual valve 5. The pressure reading should be 2400 psi (166 bar) at
section function. DO NOT adjust the main control valve relief high idle.
pressure below 3585 - 3665 psi (247 - 252,7 bar).
To check individual valve section pressures, install a tee 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 31200926 G5-18A, 2505H, 25.5

8.7
8.7.1
8 7 6 5 4 3 2 1
H H
G5-18A, 2505H, 25.5

CYLINDER, TILT CYLINDER, CROWD
CYLINDER, LIFT
JOYSTICK
T P
FRONT AUX
G G
1 2 3 4
FRONT AXLE
PARK BRAKE
HYDRAULIC SCHEMATIC
VALVE, MAIN CONTROL 1b 1B 1A 2b 2B 2A 3b 3B 3A 4b 4B 4A

T VALVE, PILOT SELECT VALVE, PARK
T
F BRAKE RELEASE F
JS4
241 BAR
P T2
JS2
TELE AUX TILT
1a 2a 3a 4a
3A 3B P2 P1 P3 P4 P5 P6
FRONT AXLE
SERVICE BRAKE
MASTER CYLINDER
E E
R
LS CF EF B
VALVE, PRIORITY
P INCHING VALVE
31200926
T P
D D
FILTER, CHARGE
3.45 BAR
b a
STANDARD-VARIABLE T1 R PS Yst MH Fa
STEERING SPEED FAN DRIVE
ORBITAL A X1
VALVE, STEER L R 11 CC
X2 G
MB
SELECT
DR
B T1 U
B
DRIVE
A MOTOR
C B Vg min
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
REAR STEERING
OPTION-VAR SPEED &
FRONT STEERING
REVERSING FAN DRIVE
P T A
T2 G S MA
11 CC
DRIVE
PUMP
FILTER, RETURN B DR M1 Sa
B B
3.45 BAR
A A
G5-18A (Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012)
Hydraulic System
8 7 6 5 4 3 2 1
MAE3650C
8-7
8-8
8 7 6 5 4 3 2 1
H H
AUXILIARY OPTIONS
REAR AUX FRONT AUX
FRONT AUX
1ST 2ND
G G
REAR AUX
Hydraulic System
VALVE,
DIVERTER
VALVE,
DIVERTER
VALVE,
DIVERTER
F F
3B 3A
3B 3A
E OPTIONAL REAR AUX/WITH E

OPTIONAL REAR
ELECTRIC SECOND FRONT AUX
AUXILIARY
31200926
D D
FRONT AUX
1ST 2ND
C C
VALVE,
DIVERTER
B B
3B 3A
OPTIONAL SECOND
FRONT AUXILIARY
A A
-ELECTRIC-
8 7 6 5 4 3 2 1
MAE3660C
G5-18A, 2505H, 25.5

8.7.2
G5-18A, 2505H, 25.5

1 2 3 4 5 6 7 8
CYLINDER, TILT CYLINDER, CROWD
CYLINDER, LIFT
JOYSTICK
D T P D
FRONT AUX
1 2 3 4
FRONT AXLE
PARK BRAKE

T VALVE, PILOT SELECT VALVE, PARK
T
BRAKE RELEASE
JS4
241 BAR
P T2
JS2
TELE AUX TILT
C 1a 2a 3a 4a C
3A 3B P2 P1 P3 P4 P5 P6
MASTER CYLINDER
R
LS CF EF B
VALVE, PRIORITY
31200926
P
FRONT AXLE
SERVICE BRAKE
FILTER, CHARGE
3.45 BAR
B B
b a
ORBITAL A X1
VALVE, STEER 11 CC
X2 G
L 230 bar R
MB
SELECT
DR
B T1 U
B
DRIVE
A MOTOR
B Vg min
11 CC 31.8 14.3
IMPLEMENT
CC CC PUMP Vg max
2.41 BAR
DR A
B
CYLINDER
CYLINDER
T
170 bar LS P 26.2 BAR
A T2
REAR STEERING
OPTION-VAR SPEED &
FRONT STEERING
REVERSING FAN DRIVE
A
T2 G S MA
11 CC
DRIVE
PUMP
A 3.45 BAR
A
1 2 3 4 5 6 7 8
MAE5280A
G5-18A (SN 0160076806 to Present including 0160076010, 0160076011, 0160076012)
Hydraulic System
8-9
8-10
1 2 3 4 5 6 7 8
AUXILIARY OPTIONS
D D
REAR AUX FRONT AUX
FRONT AUX
1ST 2ND
Hydraulic System
REAR AUX
VALVE,
DIVERTER
VALVE,
DIVERTER
VALVE,
DIVERTER
3B 3A
3B 3A
C C
OPTIONAL REAR AUX/WITH

OPTIONAL REAR
ELECTRIC SECOND FRONT AUX
AUXILIARY
31200926
FROM BRAKE
B B
MASTER CYLINDER
FRONT AUX
Y
1ST 2ND
T P
VALVE,
DIVERTER
FROM DRIVE
PUMP(PS)
3B 3A
A A
OPTIONAL SECOND INCHING VALVE OPTION
FRONT AUXILIARY
-ELECTRIC-
1 2 3 4 5 6 7 8
MAE3030A
G5-18A, 2505H, 25.5

8 7 6 5 4 3 2 1
8.7.3
CYLINDER, LIFT CYLINDER, TILT CYLINDER, CROWD
G5-18A, 2505H, 25.5

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

T VALVE, PILOT SELECT
T MPJS3 JS3 JS1
R R
0.047" JS4
F 2 3 1 F
241 BAR
P T2
JS2
LIFT TELE AUX TILT
LIFT LIFT AUX CROWD
1a 2a 3a 4a 3A 3B P8 P7 P2 P1 P3 P4 P5 P6
FRONT AXLE
SERVICE BRAKE
MASTER CYLINDER
E E
R
LS CF EF B
VALVE, PRIORITY
P INCHING VALVE
31200926
T P
D D
FILTER, CHARGE
3.45 BAR
b a
ORBITAL A X1
VALVE, STEER L R 11 CC
X2 G
MB
SELECT 235 bar
DR
B T1 U
B
C C
DRIVE
A MOTOR
B Vg min
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
REAR STEERING
175 bar OPTION-VAR SPEED &
FRONT STEERING
REVERSING FAN DRIVE
P T A
T2 G S MA
11 CC
DRIVE
PUMP
B B
3.45 BAR
A A
Hydraulic System
8 7 6 5 4 3 2 1
2505H & 25.5 (Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012)
8-11
8-12
8 7 6 5 4 3 2 1
H H
FRONT AUX AUXILIARY OPTIONS

1ST 2ND
REAR AUX FRONT AUX

REAR AUX
G G
VALVE,
DIVERTER
Hydraulic System
TRAILER BRAKE CONNECTION
VALVE,
DIVERTER
VALVE,
DIVERTER
F F
3B 3A B
3B 3A
FROM SERVICE BRAKE
E E
OPTIONAL REAR OPTIONAL REAR AUX/WITH L
ELECTRIC SECOND FRONT AUX TO IMPLEMENT VALVE
AUXILIARY
P P1
31200926
D D
STEERING
FRONT AUX
1ST 2ND
C LS CF EF C
VALVE,
DIVERTER
P
VALVE, PRIORITY
PUMP
IMPLEMENT
B B
OPTIONAL TRAILER BRAKE

OPTIONAL SECOND
FRONT AUXILIARY
A A
-ELECTRIC-
MAL2730C
8 7 6 5 4 3 2 1
G5-18A, 2505H, 25.5

8.7.4
G5-18A, 2505H, 25.5

1 2 3 4 5 6 7 8
CYLINDER, LIFT CYLINDER, TILT CYLINDER, CROWD
JOYSTICK
D T P D
FRONT AUX
FRONT AXLE
PARK BRAKE
1 2 3 4
SENSOR, PILOT
PRESSURE
VALVE, PARK BRAKE RELEASE

T VALVE, PILOT SELECT
T MPJS3 JS3 JS1
0.047" JS4
241 BAR
P T2
JS2
LIFT TELE AUX TILT
1a 2a 3a 4a 3A 3B P8 P7 P2 P1 P3 P4 P5 P6
C C
MASTER CYLINDER
R
LS CF EF B
VALVE, PRIORITY
P
FRONT AXLE
SERVICE BRAKE
31200926
FILTER, CHARGE
3.45 BAR
b a
B ORBITAL A X1 B
VALVE, STEER 11 CC
X2 G
L 230 bar R
MB
SELECT
DR
B T1 U
B
DRIVE
A MOTOR
B Vg min
11 CC 31.8 14.3
IMPLEMENT
CC CC PUMP Vg max
2.41 BAR
DR A
B
CYLINDER
CYLINDER
T LS P A T2
170 bar 26.2 BAR
REAR STEERING
OPTION-VAR SPEED &
FRONT STEERING
REVERSING FAN DRIVE
A
T2 G S MA
11 CC
DRIVE
PUMP
3.45 BAR
A A
1 2 3 4 5 6 7 8
MAE5270A
Hydraulic System
2505H & 25.5 (SN 0160076806 to Present including 0160076010, 0160076011, 0160076012)
8-13
8-14
1 2 3 4 5 6 7 8
FRONT AUX AUXILIARY OPTIONS

1ST 2ND
D D
REAR AUX FRONT AUX
REAR AUX
Hydraulic System
VALVE,
DIVERTER
VALVE,
DIVERTER
VALVE,
DIVERTER
TRAILER BRAKE CONNECTION
3B 3A
3B 3A
C FROM SERVICE BRAKE

C
OPTIONAL REAR OPTIONAL REAR AUX/WITH

L
AUXILIARY ELECTRIC SECOND FRONT AUX TO IMPLEMENT VALVE
P P1
31200926
STEERING
FROM BRAKE
B MASTER CYLINDER B
FRONT AUX
Y
LS CF EF
1ST 2ND
P OPTIONAL TRAILER BRAKE

VALVE, PRIORITY
PUMP
IMPLEMENT
T P
VALVE,
DIVERTER
FROM DRIVE
PUMP(PS)
A A
OPTIONAL SECOND
INCHING VALVE OPTION
FRONT AUXILIARY
-ELECTRIC-
1 2 3 4 5 6 7 8
MAE3020A
G5-18A, 2505H, 25.5

Hydraulic System
8.8 HYDRAULIC RESERVOIR 7. Wipe up any spilled hydraulic oil.
Prior to SN 0160076806 excluding 0160076010, 8.8.3 Hydraulic Oil Reservoir Filling

0160076011, 0160076012: The hydraulic reservoir and fuel
1. Be sure the reservoir is clean and free of all debris.
tank are part of the frame. For this reason, neither tank can be
removed. For cleaning instructions, refer to Section 7.4.2, 2. Install new hydraulic oil filters.
“Fuel/Hydraulic Tank - Prior to SN 0160076806 excluding 3. Fill the reservoir with Cat HDO oil. Refer to Section 2.3,
0160076010, 0160076011, 0160076012”. “Fluids, Lubricants and Capacities”.
SN 0160076806 to Present including 0160076010, 4. Properly connect the battery. Refer to Section 9,
0160076011, 0160076012: The hydraulic reservoir is “Battery”, for procedure.
located on the frame.
5. Close and secure the battery and engine covers.
Occasionally, fluid may seep, leak or be more forcefully
expelled from the filter head when system pressure exceeds
the rating of the filter head or filler cap. If the return filter
becomes plugged, return hydraulic oil will bypass the filter 7. Start the machine. Run engine to normal operating
when pressure reaches 22 psi (1,5 bar) and return to the temperature. Operate all hydraulic functions.
reservoir unfiltered.
8.8.4 Hydraulic Oil Reservoir Removal/
Carefully examine fluid seepage or leaks from the hydraulic
Installation (SN 0160076806 to Present
reservoir to determine the exact cause. Clean the reservoir
including 0160076010, 0160076011,
and note where any seepage occurs.
0160076012)
Leaks from a cracked or damaged reservoir require that the
reservoir be flushed completely with water and repaired by a If it is determined that the hydraulic oil reservoir must be
certified welder using approved techniques. If these removed, the hydraulic oil must be drained before the
conditions cannot be met, the reservoir must be replaced in reservoir is removed. Always dispose of hydraulic oil
its entirety. Contact the local JLG dealer should reservoir properly.
welding be required.
a. Reservoir Removal
8.8.1 Pressurized Hydraulic Oil Fill Cap 1. Park the machine on a firm, level surface, level the
The fill cap will allow the hydraulic oil reservoir to pressurize machine, fully retract the boom, lower the boom, place
to 2 psi (0,14 bar). Inspect the condition of the cap seal to the transmission in (N) NEUTRAL, engage the park brake
maintain proper reservoir pressure. and shut the engine OFF.
8.8.2 Hydraulic Oil Reservoir Draining switch and the steering wheel.
1. Park the machine on a firm, level surface, fully retract 3. Open the engine cover. Allow the system fluids to cool.
the boom, support the boom, place the transmission in 4. Properly disconnect the battery. Refer to Section 9.8,
(N) NEUTRAL, engage the park brake and shut the “Battery”, for procedure.
engine OFF.
5. Remove the cab assembly. Refer to Section 4.5, “Cab
2. Place a Do Not Operate Tag on both the ignition key Removal”, for procedure.
6. Remove the oil cooler assembly. Refer to Section 7.2.2,
“Radiator/Oil Cooler Replacement”, for procedure.
3. Open the battery and engine covers. Allow the system
7. Remove the boom assembly. Refer to Section 3.4.1,
fluids to cool.
“Complete Boom Removal”, for procedure.
8. Drain the hydraulic oil reservoir. Refer Section 8.8.2,
“Hydraulic Oil Reservoir Draining”.
5. Remove the drain plug at the bottom of the hydraulic
9. Label, disconnect and cap all hydraulic hoses attached
oil reservoir.
to the hydraulic oil reservoir. Cap all fittings and
6. Transfer the used hydraulic oil into a suitable, covered openings to keep dirt and debris from entering the
container, and label as “Used Oil”. Dispose of used oil at hydraulic system.
an approved recycling facility. Clean and reinstall the
drain plug.
G5-18A, 2505H, 25.5 31200926 8-15
Hydraulic System
To clean the hydraulic oil tank:

1. Have a dry chemical (Class B) fire extinguisher near the
work area.
2 2. Remove the fuel or oil tank drain plug, and safely drain
any fuel or hydraulic oil into a suitable container.
Dispose of fuel or hydraulic oil properly.
3. Clean the hydraulic oil tank with a high-pressure
washer, or flush the tank with hot water for five minutes
and drain the water. Dispose of contaminated water
properly.
1
4. Add a diesel fuel emulsifying agent to the tank. Refer to
the manufacturer’s instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the tank
with water, and 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
MAE5430
10. Remove the hardware (1) securing hydraulic c. Inspection

reservoir (2) to frame.
1. Inspect the hydraulic oil tank thoroughly for any cracks,
Note: If required, label, disconnect and cap any hydraulic slices, leaks or other damage.
hoses and/or electrical wires attached to the frame that would 2. Plug all openings except one elbow fitting. Install the
provide additional clearance in the removal of hydraulic tank. elbow fitting, and apply approximately
Cap fittings and openings to keep dirt and debris from entering 1 - 1.5 psi (0.07 - 0.10 bar) of air pressure through the
the hydraulic systems. elbow. Check the tank for leaks by applying a soap
b. Cleaning and Drying at the cracked or damaged area.
If contaminated hydraulic oil or foreign material is in the
tank, the tank can usually be cleaned. d. Reservoir Installation
1. Place the hydraulic oil reservoir (2) into its original
orientation.
2. Secure the hydraulic oil reservoir (2) to the frame with
the previously removed hardware (1).
3. Loosely install the proper mounting hardware, the
washers must be set on a flat surface.
4. Hydraulic tank must be positioned against the cab side
of the frame.
5. Tighten and torque the mounting hardware on the cab
side of the frame.
6. Tighten and torque the mounting hardware on the top
of the tank.
7. Install the shims between the tank and frame.
8. Tighten and torque the mounting hardware on the
engine side of the frame.
8-16 31200926 G5-18A, 2505H, 25.5

Hydraulic System
9. Uncap and connect the previously labeled hydraulic 6. Drain the hydraulic oil reservoir. Refer to Section 8.8.2,
hoses to their appropriate locations. Be sure all lines are “Hydraulic Oil Reservoir Draining”.
free of kinks and sharp bends.
10. Fill the reservoir with oil until oil level is visible in the
gauge window. Refer to Section 2.3, “Fluids, Lubricants
and Capacities”. 2
11. Check the hydraulic oil reservoir for leaks.
12. Install the boom assembly. Refer to Section 3.4.2,
“Complete Boom Installation” for procedure.
13. Install the oil cooler assembly. Refer to Section 7.2.2,
“Radiator/Oil Cooler Replacement”, for procedure.
14. Install the cab assembly. Refer to Section 4.6, “Cab
Installation”, for procedure.
15. Properly connect the battery. Refer Section 9.8,
MY8640
“Battery”, for procedure. 2 1
7. Thoroughly clean the pump (1) and surrounding area,
17. Start machine and check all hydraulic functions for including all hoses and fittings before proceeding.
proper operation. Check for any hydraulic oil leaks. Shut
8. From under the machine, label, disconnect and cap all
machine OFF and check hydraulic oil level. If oil is warm,
hydraulic hoses attached to the pump, cap all fittings
oil level should be visible in the gauge window. Add
and plug hoses to keep dirt & debris from entering the
hydraulic oil if necessary.
hydraulic system.
18. Remove the Do Not Operate Tag from the ignition key
9. Remove the two bolts and washers (2) securing the
pump in place.
8.9 HYDRAULIC SYSTEM PUMP 8.9.2 Implement Pump Installation

1. Position pump in the mounting position.
8.9.1 Implement Pump Removal
Note: Use new o-rings where required. Never reuse o-rings.
1. Park the machine on a firm, level surface, fully retract the
boom, support the boom, place the transmission in 2. Use the two previously removed bolts and washers to
(N) NEUTRAL, engage the park brake and shut the engine secure the pump into place. Torque to 64 lb-ft (87 Nm).
OFF. 3. Uncap and reconnect previously labeled hydraulic
2. Place a Do Not Operate Tag on both the ignition key hoses to their proper locations.
switch and the steering wheel, stating that the machine 4. Fill the hydraulic reservoir with clean, filtered hydraulic
should not be operated. oil.
3. Open the battery and engine covers. Allow the system 5. Prime the pump by filling the case drain port with fresh,
fluids to cool. filtered hydraulic oil from a clean container before
4. Properly disconnect the battery. Refer to Section 9, installing the case drain connector and hose.
“Battery”, for procedure. 6. Check all routing of hoses and tubing for sharp bends or
5. Loosen and remove the belly pan and front fender. interference with any rotating members. All tube and
hose clamps must be tight.
7. Properly connect the battery. Refer to Section 9,
8. Start the engine and run at approximately one-third to
one-half throttle for about one minute without moving
the machine or operating any hydraulic functions.
9. Inspect for leaks and check all fluid levels.
10. Install the front fender and belly pan.
G5-18A, 2505H, 25.5 31200926 8-17

Hydraulic System
11. Close and secure the battery and engine covers. 8.10 FRONT DRIVE MOTOR
key and the steering wheel. For internal service instructions and detailed specifications,
contact the local JLG Dealer.
Note: Check for leaks and repair as required before continuing.
13. Close and secure the engine covers. 8.10.1 Front Drive Motor Removal
14. Remove the Do Not Operate Tags from both the ignition 1. Park the machine on a firm, level surface, fully retract
key and the steering wheel. the boom, lower the boom, place the transmission in
(N) NEUTRAL, engage the park brake and shut the
8.9.3 Pump Test engine OFF.
1. Perform a flow meter test on the pump. 2. Place a Do Not Operate Tag on both the ignition key
2. Check the system functions. should not be operated.
fluids to cool.
4. Properly disconnect the battery. Refer to Section 9,
5. Drain the hydraulic reservoir or attach a vacuum
adapter fitting to the reservoir fill tube to reduce oil
spillage.
6. Label and disconnect all hydraulic hoses attached to the
pump, cap all fittings and plug hoses to keep dirt &
2
3
1
MY8660
7. Disconnect the electrical connector (1) on the

proportional valve.
8. Support the motor and remove the four bolts (2)
securing the motor to the front axle.
8-18 31200926 G5-18A, 2505H, 25.5

Hydraulic System
8.10.2 Front Drive Motor Installation 8.11 CONTROL VALVES

1. Install the motor onto the front axle and secure with the
four previously removed bolts (2). Torque to 8.11.1 Main Control Valve
72 lb-ft (97 Nm). Use only new seals.
The main control valve is mounted on the rear of the
2. Uncap and reconnect the previously labeled hydraulic machine behind the rear access panel.
3. Fill the motor with hydraulic fluid through the fill
plug (3) before starting the machine.
4. Refill the hydraulic reservoir and inspect for leaks
around the machine.
5. Properly connect the battery. Refer to Section 9, 6
one-half throttle for about one minute without moving 1
MY2110 5
7. Inspect for leaks and check all fluid levels.
8. Close and secure the battery and engine covers. FRONT OF MACHINE 2 3 4
The main control valve assembly consists of various working
sections with their own valve assemblies, each providing a
specific hydraulic function. The section assemblies are the
left-hand end cover (1), lift/lower (2), tilt (3), auxiliary (4),
crowd (5) and right-hand end cover (6) sections.
a. Main Control Valve Removal

the boom, lower the boom, place the transmission in
engine OFF.
fluids to cool.
4. Properly disconnect the battery. Refer to Section 9,
5. Remove the rear panel. Allow the hydraulic fluid to cool.
6. Thoroughly clean the main control valve and
surrounding area, including all hoses and fittings,
before proceeding.
7. Place a suitable container to catch hydraulic fluid
drainage beneath the frame.
8. Label, disconnect and cap all the hydraulic hoses
attached to the main control valve. Cap all fittings and
hydraulic system.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
G5-18A, 2505H, 25.5 31200926 8-19

Hydraulic System
10. Remove the four bolts securing the main control valve e. Main Control Valve Assembly
to the frame bracket.
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
parts to help ensure proper sealing and operation. Lubricate
b. Main Control Valve Disassembly
seals and o-rings with clean hydraulic oil.
1. To disassemble the individual sections of the main
control valve, remove the nuts from the end of the tie Assemble each Valve Section
rods. Pull the tie rods out through the sections.
1. Reassemble any plugs, check valves, compensator
2. Disassemble each section assembly as required. valves, anti-cavitation valves, shock valves or hydraulic
Some sections include a pre-adjusted relief valve that remote positioners from individual valve sections if
regulates pressure in a specific circuit. equipped.
2. Install the end covers onto Lift/Lower and Crowd
NOTICE sections.
Assemble the Main Control Valve

DO NOT adjust any of the relief valve assemblies!
Tampering with a relief valve will irrevocably alter pressure 1. Place all three tie rods with the washers and nuts through
in the affected circuit, requiring re-calibration or a new relief the end main control valve section.
valve. 2. Stand the end main control valve section on end.
3. Install proper o-rings on the inner face of the end main
Disassemble each Valve Section
control valve section. Align the Crowd section over the
1. Carefully separate the end cover section from the lift/lower three tie rods and slide onto the end main control valve
section. section.
2. Remove the o-rings from between the two sections. 4. Using proper o-rings and load sense shuttle, repeat step
3. Carefully separate each remaining section and remove three for the remaining sections.
all o-rings and seals. 5. Install the washers and nuts on the tie rods and torque
4. Remove any plugs, check valves, compensator valves, to 18.5 lb-ft (25 Nm).
anti-cavitation valves, shock valves or the rectangular
hydraulic remote positioners from each individual valve f. Main Control Valve Installation
section if equipped. 1. Loosely install the four main control valve mounting
5. Keep all parts being removed from individual valve bolts through bracket on the rear of the machine.
sections tagged and kept together. 2. Install the main control valve onto the bracket, aligning
the bolts with the holes in the end sections of the main
c. Main Control Valve Parts Cleaning control valve. Slide the main control valve into position,
Clean all components with a suitable cleaner, such as and tighten the bolts.
trichlorethylene, before continuing. Blow dry. 3. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a clean
d. Main Control Valve Parts Inspection container, before attaching the hoses.
Inspect all parts and internal passageways for wear, damage, 4. Use new oiled o-rings as required. Uncap and reattach
etc. If inner surfaces of any component DO NOT display an and secure all hoses, clamps, etc. to the main control
ultra-smooth, polished finish, or are damaged in any way, valve.
replace the damaged part. Often, dirty hydraulic fluid causes 5. Check the routing of all hoses, wiring and tubing for
failure of internal seals, damage to the polished surfaces sharp bends or interference with any rotating members,
within the component, and wear of and/or harm to other and install tie wraps and/or protective conduit as
parts. required. Tighten all tube and hose clamps.
8-20 31200926 G5-18A, 2505H, 25.5

Hydraulic System

one-half throttle for about one minute without moving
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF. 7
around the machine, work area and tools. 9
10. Install the rear panel.

8
g. Main Control Valve Test
MY2161
Conduct a pressure check of the hydraulic system in its 6. Label, disconnect and cap the hydraulic hoses
entirety. Adjust pressure(s) as required. Refer to Section 8.6.2, connected to the service brake valve (7). Cap all fittings
“Main Control Valve Pressure Checking”. and openings to keep dirt & debris from entering the
brake system.
8.11.2 Service Brake Valve
7. Remove the pin and clip (8) securing the service brake
The service brake valve is at the base of the steering column rod to the brake pedal assembly.
support, concealed by the lower dash cover.
8. Remove the two bolts and washers (9) securing the
The service brakes themselves are part of the front axle. Refer to service brake valve to the steering column support.
Section 5, “Brakes”, for further information.
Note: DO NOT disassemble the service brake valve. The service
a. Service Brake Valve Removal brake valve is not serviceable and must be replaced in its
entirety, if defective.
the boom, lower the boom, place the transmission in b. Service Brake Valve Installation
engine OFF. 1. Install the service brake valve to the steering column
support with the previously removed hardware (9).
2. Place a Do Not Operate Tag on both the ignition key Torque as required.
should not be operated. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
fluids to cool.
4. Properly disconnect the battery. Refer to Section 9, 2. Use new oiled o-rings as required. Uncap and reconnect
“Battery”, for procedure. the previously labeled hydraulic hoses to the
appropriate locations.
5. Remove the necessary dash panels.
3. Install the pin and clip (8) securing the service brake rod
to the brake pedal assembly.
4. Check the routing of all hoses, 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.
5. Fill the brake reservoir with Mobil 424 10W-30 hydraulic
oil.
G5-18A, 2505H, 25.5 31200926 8-21

Hydraulic System
7. Start the engine and run at approximately one-third to 3. DO NOT open the brake bleeder without holding the
one-half throttle for about one minute, without moving tubing firmly on the bleeder. There is pressure at the
the machine or operating any hydraulic functions. brakes. Have an assistant depress the brake pedal.
8. Inspect the service brake valve and connections for Carefully open the bleeder with a 12 mm wrench. Close
leaks, and check the brake oil level. Shut the engine OFF. the brake bleeder when air bubbles no longer appear in
the oil. Release the brake pedal. Remove the tubing
9. Replace the necessary dash panels. from the brake bleeder.
10. Wipe up any hydraulic oil spillage in, on, near and 4. If bleeding the service brake circuit, install a vacuum
around the machine, work area and tools. pump on the brake reservoir and remove the remainder
11. Close and secure the battery and engine covers. of the trapped air from the brake system.
12. Remove the Do Not Operate Tags from both the ignition 5. The inching valve may also require bleeding, refer to
key and the steering wheel. Section 8.11.7, “Inching Valve”.
6. Check brake fluid level and add fluid if necessary. Refer
c. Service Brake Bleeding Procedure to Section 2.3, “Fluids, Lubricants and Capacities”.
10
d. Brake Performance Test
1. Press down on the service brake pedal. The pedal
should NOT travel to the cab floor. Start the machine,
shift into forward, release the park brake and slowly
accelerate. Apply the service brake carefully noting the
performance of the service brake system. If the service
brakes do not safely stop the machine, repeat the
service brake bleeding procedure.
MY2050
8.11.3 Park Brake Valve (G5-18A)
The park brake valve is located in the cab, below the seat.
Carefully bleed the brake lines as soon as the brake valve is
installed on the machine. Air in the system will not allow the a. Park Brake Valve Removal
brakes to apply properly. There are two brake bleeder
locations (10) on the front axle. The outside bleeder is used 1. Park the machine on a firm, level surface, fully retract
for the park brake circuit. The inside bleeder is used for the the boom, lower the boom, place the transmission in
service brake circuit. Work with an assistant to perform this (N) NEUTRAL, engage the park brake and shut the
procedure. engine OFF.
1. Place the transmission in (N) NEUTRAL, engage the park 2. Place a Do Not Operate Tag on both the ignition key
brake, and start the engine.Raise the boom to access switch and the steering wheel, stating that the machine
the brake bleeders. Support boom and turn off engine. should not be operated.
2. Remove the plastic cap from the brake bleeder. Attach 3. Open the battery and engine covers. Allow the system
one end of a length of transparent tubing over the fluids to cool.
brake bleeder. Place the other end of this tubing in a 4. Properly disconnect the battery. Refer to Section 9,
suitable transparent container that is partially filled with “Battery”, for procedure.
hydraulic oil. The end of the tubing must be below the
5. Remove the four capscrews holding the cover below
oil level in the container.
the seat. The park brake valve is mounted on the
backside of the cover.
6. Label, disconnect and cap the hydraulic hoses on each
side and bottom of the park brake valve. Disconnect
and cap all hoses, fittings, etc.
7. Remove the two capscrews, and two lockwashers
mounting the park brake valve to the cover.
8-22 31200926 G5-18A, 2505H, 25.5

Hydraulic System
b. Park Brake Valve Disassembly, Cleaning, Inspection 5. Start the engine and run at approximately one-third to
and Assembly one-half throttle for about one minute, without moving
1. Place the park brake valve on a suitable work surface.
6. Inspect the park brake valve and connections for leaks,
and check the level of the hydraulic fluid in the reservoir.
11 Shut the engine OFF.
7. Install the park brake/cover with the four capscrews.
12
around the machine, work area and tools.
MY2150
2. Remove the solenoid valve (11) and cartridge (12) from
the park brake housing. d. Park Brake Valve Test.
3. 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 idle.
4. Inspect the solenoid cartridges for proper operation. The parking brake will not allow the machine to move.
Check by shifting the spool to ensure that it is 2. If further troubleshooting is required, refer to
functioning properly. Check that the spring is intact. Section 8.7, “Hydraulic Schematic” or Section 9.4,
Inspect the cartridge interior for contamination. “Electrical System Schematics”.
5. Inspect internal passageways of the park brake
manifold and valve for wear, damage, etc. If inner 8.11.4 Hand Brake Valve (2505H & 25.5)
surfaces of the manifold DO NOT display an The hand brake valve is located in the cab, beside the seat.
ultra-smooth, polished finish, or components are
damaged in any way, replace the manifold or a. Hand Brake Valve Removal
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished 1. Park the machine on a firm, level surface, fully retract
surfaces within the unit. the boom, lower the boom, place the transmission in
(N) NEUTRAL, engage the hand brake and shut the
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new engine OFF.
seals and o-rings with clean hydraulic oil. 2. Place a Do Not Operate Tag on both the ignition key
6. Install the solenoid valves and cartridges in the park brake should not be operated.
housing.
fluids to cool.
c. Park Brake Valve Installation
1. Install the park brake valve with the two lockwashers “Battery”, for procedure.
and two capscrews to the cover.
5. Remove the two capscrews holding the cover below the
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new seat. The hand brake valve is mounted on the mounting
parts to help ensure proper sealing and operation. Lubricate plate attached to the seat base.
6. Label, disconnect and cap the hydraulic hoses on each
2. Use new oiled o-rings as required. Uncap, reattach and side and bottom of the hand brake valve. Disconnect
secure the three hoses. and cap all hoses, fittings, etc.
3. Check the routing of all hoses for sharp bends or 7. Remove the four capscrews and lockwashers mounting
interference with any rotating members, and install tie the hand brake valve to the mounting plate.
wraps and/or protective conduit as required.
G5-18A, 2505H, 25.5 31200926 8-23

Hydraulic System
b. Hand Brake Valve Disassembly, Cleaning, Inspection 7. Install the hand brake cover with the two capscrews.
and Assembly 8. Wipe up any hydraulic fluid spillage in, on, near and
1. Place the hand brake valve on a suitable work surface. around the machine, work area and tools.
d. Hand Brake Valve Test

1. Start the machine and engage the shift lever to the
forward position. Slowly depress the throttle to mid idle.
The hand brake will not allow the machine to move.
2. If further troubleshooting is required, refer to
Section 8.7, “Hydraulic Schematic” or Section 9.4,
MU7710 “Electrical System Schematics”.
2. Clean all components with a suitable cleaner before
8.11.5 Steering Orbital Valve
inspection.
Refer to Section 4.4.2, “Steering Column/Valve
3. Inspect internal passageways of the hand brake
Replacement”, for details.
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an
ultra-smooth, polished finish, or components are 8.11.6 Pilot Select Valve
damaged in any way, replace the manifold or The pilot select valve is attached to a manifold mounted on a
appropriate part. Often, dirty hydraulic fluid causes mounting plate inside the frame in front of the comp
failure of internal seals and damage to the polished cylinder.
surfaces within the unit. 16 17
15
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new 14
c. Hand Brake Valve Installation

1. Install the Hand brake valve with the four lockwashers
and capscrews to the mounting plate.
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new 15
parts to help ensure proper sealing and operation. Lubricate 14
17
seals and o-rings with clean hydraulic oil. 13 16 MU7720
ANSI
13 CE & AUS
2. Use new oiled o-rings as required. Uncap, reattach and
secure the three hoses. Verify the correct operation of the pilot select valve
3. Check the routing of all hoses for sharp bends or solenoids: boom lift/lower (13), auxiliary (14), tilt (15), boom
interference with any rotating members, and install tie extend/retract (16) and front auxiliary (17) before
wraps and/or protective conduit as required. considering replacement of the valve. The housing of the
pilot select valve is not serviceable and must be replaced if
4. Properly connect the battery. Refer to Section 9,
defective.
one-half throttle for about one minute, without moving
6. Inspect the hand brake valve and connections for leaks,
and check the level of the hydraulic fluid in the reservoir.
Shut the engine OFF.
8-24 31200926 G5-18A, 2505H, 25.5

Hydraulic System
a. Pilot Select Valve Removal c. Pilot Select Valve Installation

1. Park the machine on a firm, level surface, fully retract 1. Attach the pilot select manifold valve to the mounting
the boom, lower the boom, place the transmission in plate on the frame using the socket head capscrews.
(N) NEUTRAL, engage the park brake and shut the 2. Connect the hydraulic hoses, fittings, solenoid wire
engine OFF. terminal leads, etc., to the pilot select valve.
2. Place a Do Not Operate Tag on both the ignition key 3. Check the routing of all hoses, wiring and tubing for
switch and the steering wheel, stating that the machine sharp bends or interference with any rotating members,
should not be operated. and install tie wraps and/or protective conduit as
3. Open the battery and engine covers. Allow the system required. Tighten all tube and hose clamps.
fluids to cool. 4. Properly connect the battery. Refer to Section 9.8,
4. Properly disconnect the battery. Refer to Section 9.8, “Battery”, for procedure.
“Battery”, for procedure. 5. Start the engine and run at approximately 1/3-1/2
5. Label or otherwise mark the hydraulic hoses in relation throttle for about one minute, without moving the
to the pilot select valve. Disconnect and cap all hoses, machine or operating any hydraulic functions.
fittings, solenoid wire terminal leads, etc. 6. Inspect for leaks and check the level of the hydraulic
6. Remove the capscrews that attach the valve to the fluid in the reservoir. Shut the engine OFF.
frame. 7. Wipe up any hydraulic fluid spillage in, on, near and
7. Remove the pilot select valve from the machine. Wipe around the machine, work area and tools.
up any hydraulic fluid spillage in, on, near and around 8. Close and secure the battery and engine covers.
the machine.
b. Pilot Select Valve Disassembly, Cleaning, Inspection key and the steering wheel.
and Assembly
d. Pilot Select Valve Test
1. Place the pilot select assembly on a suitable work
surface. 1. Check boom lift/lower, auxiliary and tilt for proper
function.
2. Remove the solenoid valves and cartridges (13, 14 &15)
from the steer select housing. 2. If further troubleshooting is required, refer to
3. Clean all components with a suitable cleaner before “Electrical System Schematics”, for details.
inspection.
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
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.
6. Install the solenoid valves and cartridges in the pilot select
housing.
G5-18A, 2505H, 25.5 31200926 8-25

Hydraulic System
8.11.7 Inching Valve SN 0160076806 to Present including 0160076010,

0160076011, 0160076012
The inching valve is attached at the front of the frame directly
above the steer select valve.
Verify the correct operation of the inching valve before
considering replacement of the valve. The housing of the
inching valve is not serviceable and must be replaced if 18
defective.
a. Inching Valve Removal

MAE3050
engine OFF.
2. Remove the cartridge (18) from the inching valve
housing.
should not be operated. 3. Clean all components with a suitable cleaner before
inspection.
fluids to cool. 4. Inspect the cartridge 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. Label or otherwise mark the hydraulic hoses in relation
5. Inspect internal passageways of the inching valve for
to the inching valve. Disconnect and cap all hoses,
wear, damage, etc. If inner surfaces of the manifold DO
fittings, etc.
NOT display an ultra-smooth, polished finish, or
6. Remove the capscrews that attach the valve to the components are damaged in any way, replace the
frame. manifold or appropriate part. Often, dirty hydraulic fluid
7. Remove the inching valve from the machine. Wipe up causes failure of internal seals and damage to the
any hydraulic fluid spillage in, on, near and around the polished surfaces within the unit.
machine. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
b. Inching Valve Disassembly, Cleaning, Inspection and seals and o-rings with clean hydraulic oil.
Assembly
6. Install the cartridge in the inching valve housing.
1. Place the inching valve assembly on a suitable work
surface. c. Inching Valve Installation
1. Attach the inching valve to the mounting plate on the
0160076011, 0160076012
frame using the socket head capscrews.
2. Connect the hydraulic hoses, fittings, etc., to the inching
valve.
3. Check the routing of all hoses and wiring for sharp
bends or interference with any rotating members, and
install tie wraps and/or protective conduit as required.
18 Tighten all hose clamps.
MY2330
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.
8-26 31200926 G5-18A, 2505H, 25.5

Hydraulic System
6. Inspect for leaks and check the level of the hydraulic hydraulic oil. The end of the tubing must be below the
fluid in the reservoir. Shut the engine OFF. oil level in the container.
Note: Check for leaks and repair as required before continuing. 3. DO NOT open the bleeder without holding the tubing
Add hydraulic fluid to the reservoir as needed. firmly on the bleeder. Have an assistant depress the
brake pedal. Carefully open the bleeder with a 10 mm
7. Wipe up any hydraulic fluid spillage in, on, near and wrench. Close the bleeder when air bubbles no longer
around the machine, work area and tools. appear in the oil. Release the brake pedal. Remove the
8. Close and secure the battery and engine covers. tubing from the bleeder.
9. Remove the Do Not Operate Tags from both the ignition 4. If brake system bleeding is required, refer to Section
key and the steering wheel. 8.11.2, “Service Brake Valve”.
5. Check brake fluid level and add fluid if necessary. Refer
d. Inching Valve Bleeding Procedure to Section 2.3, “Fluids, Lubricants and Capacities”.
Carefully bleed the inching valve as soon as the inching valve
is installed on the machine. Air in the system will not allow e. Inching Test
the brakes to apply properly. There is one bleeder location on 1. Start the machine, engage the shift lever to the forward
the inching valve. Work with an assistant to perform this position and release the parking brake. Slowly depress
procedure. the throttle to 1/2 throttle. Slowly apply the service
1. Place the transmission in (N) NEUTRAL, engage the park brake. The machine will slow, but still maintain forward
brake, start the engine and lower the boom. Turn off movement. Continuing to depress the service brake will
engine. disengage the inching brake and engage the service
Prior to SN 0160076806 excluding 0160076010, brakes.
0160076011, 0160076012 2. If further troubleshooting is required, refer to Section
8.7, “Hydraulic Schematic”.
19
MY2330
SN 0160076806 to Present including 0160076010,

0160076011, 0160076012
19
MAE3050
2. Remove the cap (19) from the inching brake bleeder.

Attach one end of a length of transparent tubing over
the bleeder. Place the other end of this tubing in a
suitable transparent container that is partially filled with
G5-18A, 2505H, 25.5 31200926 8-27

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., with new
Verify the correct operation of the priority valve before parts to help ensure proper sealing and operation. Lubricate
considering replacement of the valve. The priority valve must seals and o-rings with clean hydraulic oil.
be replaced if defective. 4. Install the previously labeled fittings in the priority valve
housing.
a. Priority Valve Removal
1. Park the machine on a firm, level surface, fully retract c. Priority Valve Installation
the boom, lower the boom, place the transmission in 1. Attach the priority valve to the mounting plate on the
(N) NEUTRAL, engage the park brake and shut the frame using the socket head capscrews.
engine OFF.
2. Connect the hydraulic hoses, fittings, etc., to the priority
2. Place a Do Not Operate Tag on both the ignition key valve.
3. Check the routing of all hoses for sharp bends or
interference with any rotating members, and install tie
3. Open the battery and engine covers. Allow the system wraps and/or protective conduit as required. Tighten all
fluids to cool. hose clamps.
4. Properly disconnect the battery. Refer to Section 9.8, 4. Properly connect the battery. Refer to Section 9.8,
“Battery”, for procedure. “Battery”, for procedure.
20 5. Start the engine and run at approximately 1/3-1/2
fluid in the reservoir. Shut the engine OFF.
Add hydraulic fluid to the reservoir as needed.
20
MY2971
5. Label or otherwise mark the hydraulic hoses in relation d. Priority Valve Test
to the priority valve. Disconnect and cap all hoses,
fittings, etc. 1. Start the machine and slowly depress the throttle to 1/2
throttle. Turn the steering and engage a boom function.
6. Remove the capscrews that attach the valve to the
The steering will continue to respond along with the
frame.
engaged boom function.
7. Remove the priority valve from the machine. Wipe up
2. If further troubleshooting is required, refer to Section
any hydraulic fluid spillage in, on, near and around the
8.7, “Hydraulic Schematic”.
machine.
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 (20) from the priority
valve housing.
8-28 31200926 G5-18A, 2505H, 25.5

Hydraulic System
8.11.9 Steer Select Valve b. Steer Select Valve and Manifold Disassembly,
Cleaning, Inspection and Assembly
The steer select valve is attached to inside the frame near the
front drive motor. 1. Place the steer select assembly on a suitable work
Verify the correct operation of the steer select valve surface.
solenoids before considering replacement of the valve. The 2. Separate the steer select valve from the manifold by
housing of the steer select valve is not serviceable and must removing the capscrews. Discard the old o-rings.
be replaced if defective. 3. Remove the solenoid valves and cartridges (21) from
the steer select housing.
a. Steer Select Manifold and Valve Removal
1. Park the machine on a firm, level surface, fully retract inspection.
5. Inspect the solenoid cartridges for proper operation.
engine OFF.
functioning properly. Check that the spring is intact.
2. Place a Do Not Operate Tag on both the ignition key Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select
3. Open the battery and engine covers. Allow the system surfaces of the manifold DO NOT display an ultra-
fluids to cool. smooth, polished finish, or components are damaged in
4. Properly disconnect the battery. Refer to Section 9.8, any way, replace the manifold or appropriate part.
“Battery”, for procedure. Often, dirty hydraulic fluid causes failure of internal
seals and damage to the polished surfaces within the
unit.
7. Install the solenoid valves and cartridges in the steer select
21 housing.
8. Attach the steer select valve to the manifold using new,
21 oiled o-rings and socket head capscrews.
c. Steer Select Manifold and Valve Installation

1. Attach the steer select manifold and valve to the
MY2180
mounting plate on the frame using the socket head
capscrews.
5. Label or otherwise mark the hydraulic hoses in relation 2. Connect the hydraulic hoses, fittings, solenoid wire
to the steer select manifold. Disconnect and cap all terminal leads, etc., to the steer select valve and
hoses, fittings, solenoid wire terminal leads, etc. manifold.
6. Remove the capscrews that attach the manifold to the 3. Check the routing of all hoses, wiring and tubing for
frame. sharp bends or interference with any rotating members,
7. Remove the steer select manifold with attached steer and install tie wraps and/or protective conduit as
select valve from the machine. Wipe up any hydraulic required. Tighten all tube and hose clamps.
fluid spillage in, on, near and around the machine. 4. Properly connect the battery. Refer to Section 9.8,
G5-18A, 2505H, 25.5 31200926 8-29

Hydraulic System

8. Close and secure the battery and engine covers. 22
d. Steering Test
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.
23
3. Select the 2-wheel steer mode and turn the steering
wheel until the left front wheel is aligned with the
frame.
MY8670
4. With the wheel now aligned, select the desired steer
mode. 5. Label or otherwise mark the hydraulic hoses in relation
5. If further troubleshooting is required, refer to Section to the quick attach valve (22). Disconnect and cap all
8.6.5, “Steering Pressure Checking” Section 8.7, hoses, fittings, solenoid wire terminal leads, etc.
“Hydraulic Schematic” or Section 9.4, “Electrical System 6. Remove the quick attach valve from the machine. Wipe
Schematics”. up any hydraulic fluid spillage in, on, near and around
the machine.
8.11.10 Quick Attach Valve
The quick attach valve is located on the left side of the boom b. Quick Attach Valve Disassembly, Cleaning,
head. Inspection and Assembly
Verify the correct operation of the quick attach valve 1. Place the quick attach valve assembly on a suitable
solenoid before considering replacement of the valve. The work surface.
housing of the quick attach valve is not serviceable and must 2. Remove the solenoid valve and cartridge (23) from the
be replaced if defective. quick attach valve housing.
a. Quick Attach Valve Removal
inspection.
1. Park the machine on a firm, level surface, fully retract 4. Inspect the solenoid cartridge for proper operation.
the boom, raise the boom, place the transmission in (N) Check by shifting the spool to ensure that it is
NEUTRAL, engage the park brake and shut the engine functioning properly. Check that the spring is intact.
OFF. Inspect the cartridge interior for contamination.
2. Place a Do Not Operate Tag on both the ignition key 5. Inspect internal passageways of the decompression
switch and the steering wheel, stating that the machine valve for wear, damage, etc. If inner surfaces of the
should not be operated. manifold DO NOT display an ultra-smooth, polished
3. Open the battery and engine covers. Allow the system finish, or components are damaged in any way, replace
fluids to cool. the manifold or appropriate part. Often, dirty hydraulic
4. Properly disconnect the battery. Refer Section 9, fluid causes failure of internal seals and damage to the
“Battery”, for procedure. polished surfaces within the unit.
6. Install the solenoid valve and cartridge in the quick attach
valve housing.
8-30 31200926 G5-18A, 2505H, 25.5

Hydraulic System
c. Quick Attach Installation 5. Properly disconnect the battery. Refer to Section 9.8,
1. Attach the quick attach valve to the fittings on the
boom head. 6. Refer to Section 7.2.2, “Radiator/Oil Cooler
Replacement”, for detailed removal instructions.
2. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the quick attach.
VARIABLE SPEED FAN
3. Properly connect the battery. Refer to Section 9.8, (IF EQUIPPED)
fluid in the reservoir. Shut the engine OFF. 24

25
VARIABLE SPEED
around the machine, work area and tools. REVERSING FAN
(IF EQUIPPED)
d. Quick Attach Valve Test

1. Turn the ignition switch to the ON position, activate the 25
quick attach switch to switch the auxiliary position or
the quick attach position. 24
2. If further troubleshooting is required, refer to 25 MY8680
“Electrical System Schematics”, for details. 7. Label or otherwise mark the hydraulic hoses in relation
to the variable speed fan valve (24). Disconnect and cap
8.11.11 Variable Speed Fan Valve all hoses, fittings, solenoid wire terminal leads, etc.
8. Remove the variable speed fan valve from the machine.
The variable speed fan valve is located on the bottom side of
Wipe up any hydraulic fluid spillage in, on, near and
the Radiator assembly.
around the machine.
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. b. Variable Speed Fan Valve Disassembly, Cleaning,
The housing of the variable fan valve is not serviceable and Inspection and Assembly
must be replaced if defective. 1. Place the variable speed fan valve assembly on a
suitable work surface.
a. Variable Speed Fan Valve Removal
2. Remove the solenoid valve and cartridge (25) from the
1. Park the machine on a firm, level surface, fully retract variable speed fan valve housing.
the boom, raise the boom, place the transmission in
inspection.
engine OFF.
4. Inspect the solenoid cartridge for proper operation.
2. Properly support the boom.
3. Place a Do Not Operate Tag on both the ignition key functioning properly. Check that the spring is intact.
switch and the steering wheel, stating that the machine Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the variable speed fan
4. Open the battery and engine covers. Allow the system valve for wear, damage, etc. If inner surfaces of the
fluids to cool. manifold DO NOT display an ultra-smooth, polished
G5-18A, 2505H, 25.5 31200926 8-31
Hydraulic System
finish, or components are damaged in any way, replace 8.12 HYDRAULIC CYLINDERS
the manifold or appropriate part. Often, dirty hydraulic
fluid causes failure of internal seals and damage to the
polished surfaces within the unit. 8.12.1 General Cylinder Removal Instructions
engine OFF.
6. Install the solenoid valve and cartridge in the variable 2. Chock the wheels.
speed fan valve housing.
c. Variable Speed Fan Valve Installation switch and the steering wheel, stating that the machine
1. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the variable fan valve.
fluids to cool.
2. Refer to Section 7.2.2, “Radiator/Oil Cooler
Replacement”, for detailed installation instructions.
6. Label, disconnect and cap hydraulic hoses in relation to
the cylinder.
7. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can
actually support the cylinder.
8. Remove the lock bolt and/or any retaining clips
securing the cylinder pins. Remove the cylinder pins.
Note: Check for leaks and repair as required before continuing. 9. Remove the cylinder.
10. Wipe up any hydraulic fluid spillage in, on, near or
6. Wipe up any hydraulic fluid spillage in, on, near and around the machine.
7. Close and secure the battery and engine covers. 8.12.2 General Cylinder Disassembly
8. Remove the Do Not Operate Tags from both the ignition 1. Clean the cylinder with a suitable cleaner before
key and the steering wheel. disassembly. Remove all dirt, debris and grease from the
cylinder.
d. Variable Speed Fan Valve Test 2. Clamp the barrel end of the cylinder in a soft-jawed vise
1. Turn the ignition switch to the ON position, activate the or other acceptable holding equipment if possible.
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
NOTICE
right direction. Avoid using excessive force when clamping the cylinder
3. If further troubleshooting is required, refer to Section in a vise. Apply only enough force to hold the cylinder
8.7, “Hydraulic Schematic” or Section 9.4, “Electrical securely. Excessive force can damage the cylinder tube.
System Schematics”, for details.
3. If applicable, remove the counterbalance valve from the
side of the cylinder barrel.
8-32 31200926 G5-18A, 2505H, 25.5

Hydraulic System
1
2
3
NOTICE
When sliding the rod and piston assembly out of the tube,
4 prevent the threaded end of the tube from damaging the
piston. Keep the rod centered within the tube to help
prevent binding.
6. Carefully pull the rod assembly along with the head

gland out of the cylinder barrel.
7. Fasten the rod end in a soft-jawed vise, and put a
padded support under and near the threaded end of
the rod to help prevent damage to the rod.
1
8. Remove the set screw (3) from the piston (4).
Note: It may be necessary to apply heat to break the bond of
the sealant between the piston and the rod before the piston
2 5 can be removed.
6 Some cylinder parts are sealed with a special organic sealant
MAH0160
and locking compound. Before attempting to disassemble
these parts, remove any accessible seals from the area of the
bonded parts. Wipe off any hydraulic oil, then heat the part(s)
uniformly to break the bond. A temperature of 300 - 400° F
NOTICE (149 - 204° C) will destroy the bond. Avoid overheating, or
the parts may become distorted or damaged. Apply
sufficient torque for removal while the parts are still hot. The
DO NOT tamper with or attempt to adjust the sealant often leaves a white, powdery residue on threads and
counterbalance valve cartridge. If adjustment is other parts, which must be removed by brushing with a soft
necessary, replace the counterbalance valve with a new brass wire brush prior to reassembly.
part.
9. Remove the piston head (4) from the rod (5) and
4. Extend the rod (5) to allow access to the base of the carefully slide the head gland (6) off the end of the rod.
cylinder. 10. Remove all seals, back-up rings and o-rings (2) from the
piston head and all seals, back-up rings and o-rings
NOTICE from the head gland.
Note: The head gland bearing will need to be inspected to
Protect the finish on the rod at all times. Damage to the determine if replacement is necessary.
surface of the rod can cause seal failure.
DO NOT attempt to salvage cylinder seals, sealing rings or o-
5. Using a pin spanner wrench, unscrew the head gland (6) rings. ALWAYS use a new, complete seal kit when rebuilding
from the barrel (1). A considerable amount of force will hydraulic components. Consult the parts manual for
be necessary to remove the head gland. Carefully slide ordering information.
the head gland down along the rod toward the rod eye
end, away from the cylinder barrel. 8.12.3 Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace with
new items from complete seal kits to help ensure
proper cylinder function.
2. Clean all metal parts with an approved cleaning solvent
such as trichlorethylene. Carefully clean cavities,
grooves, threads, etc.
G5-18A, 2505H, 25.5 31200926 8-33

Hydraulic System
Note: If a white powdery residue is present on threads and 3. Fasten the rod eye in a soft-jawed vise, and place a
parts, it can be removed. Clean the residue away with a soft padded support under and near the threaded end of
brass wire brush prior to reassembly, and wipe clean before the rod (5) to prevent any damage to the rod.
reinstallation.
8.12.4 Cylinder Inspection NOTICE

1. Inspect internal surfaces and all parts for wear, damage, Protect the finish on the rod at all times. Damage to the
etc. If the inner surface of the tube does not display a surface of the rod can cause seal failure.
smooth finish, or is scored or damaged in any way,
replace the tube. 4. Lubricate and slide the head gland (6) over the cylinder
rod (5). Install the piston head (4) on to the end of the
2. Remove light scratches on the piston, rod or inner
surface of the tube with a 400 - 600 grit emery cloth. Use cylinder rod. Loctite® 243TM and install the setscrew (3) in
the emery cloth in a rotary motion to polish out and the piston head. Refer to Section 8.12.8, “Hydraulic
blend the scratch(es) into the surrounding surface. Cylinder Torque Specifications”, for tightening
guidelines for the piston head and the set screw.
3. Check the piston rod assembly for run-out. If the rod is
bent, it must be replaced.
8.12.5 General Cylinder Assembly NOTICE

1. Use the proper tools for specific installation tasks. Clean
tools are required for assembly. Avoid using excessive force when clamping the cylinder
barrel in a vise. Apply only enough force to hold the
1
2 cylinder barrel securely. Excessive force can damage the
cylinder barrel.
3 5. Place the cylinder barrel (1) in a soft-jawed vise or other
acceptable holding equipment if possible.
4
NOTICE
When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.
1 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
2 5 tightening guidelines for the head gland.
6 8. If applicable, thread the new counterbalance valve into
MAH0160
the block on the cylinder barrel.
2. Install new seals, back-up rings and o-rings (2) on the

piston (4) and the head gland (6).
Note: The Crowd cylinder has a spacer that MUST be installed
over the rod AFTER the head gland and BEFORE the piston
head.
8-34 31200926 G5-18A, 2505H, 25.5

Hydraulic System
8.12.6 General Cylinder Installation

1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder into
it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Uncap and connect the hydraulic hoses in relation to
the labels or markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary, fill to full mark.
6. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
7. Inspect for leaks and check level of hydraulic fluid in
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 any air from
the cylinder and hoses.
Note: To bleed air from the tilt cylinder, operate the tilt function
along with the lift cylinder as described above. More operation
cycles may be required to clear all air from the system.
8.12.7 Steering Cylinders

The steering cylinders are attached to each axle center
housing. Detailed axle service instructions are provided in
the Axle Disassembly & Assembly Manual (PN 31200451).
G5-18A, 2505H, 25.5 31200926 8-35

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
8-36 31200926 G5-18A, 2505H, 25.5

Hydraulic System
a. Lift Lower Cylinder
Head Piston CB Valve CB Valve Lock Set Screw

(882 - 1078 Nm) (1320 - 1620 Nm) (60 - 70 Nm) (12 - 15 Nm) (18 - 22 Nm)
b. Extend/Retract Cylinder

280 - 300 lb-ft 165 - 175 lb-ft 44 - 52 lb-ft 9 - 11 lb-ft
N/A
(376 - 404 Nm) (223 - 237 Nm) (60 - 70 Nm) (12 - 15 Nm)
c. Tilt Cylinder

(810 - 990 Nm) (1055 - 1295 Nm) (60 - 70 Nm) (12 - 15 Nm) (18 - 22 Nm)
d. Compensating Cylinder

600 - 730 lb-ft 781 - 955 lb-ft 13 - 16 lb-ft
N/A N/A
(810 - 990 Nm) (1055 - 1295 Nm) (18 - 22 Nm)
Use Loctite® 262TM on all Piston Applications

Use Loctite® 242TM on all Set Screws
G5-18A, 2505H, 25.5 31200926 8-37

Hydraulic System
8-38 31200926 G5-18A, 2505H, 25.5

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3.1 Engine Compartment Relays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3.2 Cab Compartment Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3.3 Power Distribution Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.3.4 Cab Fuses / Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4.1 Prior to SN 0160073904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4.2 SN 0160073904 to SN 0160076805 excluding 0160076010, 0160076011, 01600760129-
17
9.4.3 SN 0160076806 to Present including 0160076010, 0160076011, 0160076012 9-27
9.5 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.7 Charging Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.7.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.8.1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.8.2 Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.8.3 Battery Disconnect/Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.9 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.9.1 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.9.2 Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.10 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.10.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.10.2 Rear Window or Roof Wiper Motor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.10.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.11 Cab Heater/AC and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.11.1 Cab Heater/AC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.12 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.12.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.12.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.12.3 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.12.4 Hourmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.12.5 Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
G5-18A, 2505H, 25.5 31200926 9-1

Electrical System
9.13 Load Stability Indicator (LSI) (2505H & 25.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53

9.13.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.13.2 LSI Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.13.3 LSI Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.13.4 LSI Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.13.5 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-57
9.13.7 500 Hour - LSI UGM Calibration Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.14 Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.14.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.14.2 Mobile Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-63
9.14.3 Analyzer Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-63
9.14.4 Analyzer Software - Version P1.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
9.15 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
9.15.1 Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
9.15.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
9.15.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
9.15.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
9.15.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
9.15.6 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.16 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69
9.16.1 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9.16.2 Telematics Gateway (TCU) Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9.16.3 Telematics Gateway Harness Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
9.17 Diagnostic Trouble Codes (DTC) on Ground Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
9.17.1 Gauge Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
9.17.2 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
9.18 Engine Diagnostic Trouble Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-78
9-2 31200926 G5-18A, 2505H, 25.5

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
electrical components of the machine. The following
CAB FUSE DIAGNOSTIC

BOX CONNECTION
INSTRUMENT
CLUSTER
BACK-UP
ALARM
FRAME
HARNESS
HORN
RELAYS
FRAME
HARNESS FUSE
BOX
ENGINE DIAGNOSTIC
CONNECTION
ENGINE BATTERY
HARNESS
MY8700
G5-18A, 2505H, 25.5 31200926 9-3

Electrical System

DIAGNOSTIC
CONNECTION
CAB FUSE BOX
INSTURMENT
CLUSTER
FRAME HARNESS
BACK-UP ALARM
HORN
RELAYS
FUSE BOX
ENGINE DIAGNOSTIC
CONNECTION
ENGINE
HARNESS BATTERY
MAE3080
9-4 31200926 G5-18A, 2505H, 25.5

Electrical System
9.2 SAFETY INFORMATION 9.3.2 Cab Compartment Fuses and Relays
WARNING
precautions as outlined in Section 1 “Safety Practices”, of
this manual.
9.3 FUSES AND RELAYS
9.3.1 Engine Compartment Relays and Fuses

4 5 6 7 MY2480
3 8
The cab fuse block (8) is located behind an access panel at
the right side of the dash.
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).
G5-18A, 2505H, 25.5 31200926 9-5

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
9-6 31200926 G5-18A, 2505H, 25.5

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
G5-18A, 2505H, 25.5 31200926 9-7

G5-18A, 2505H, 25.5 31200926 9-8
10011381611D
MY8720
A
B
C
D
NA MACHINES
INDICATOR, TURN, HIGH BEAM
PARK BRAKE QUICK COUPLER LMI OVERRIDE
RS-232
PWR MGT
DIAGNOSTIC
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
1A
1B
2A
2B
X159
SW08
SW09
SW01
LB325
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 000-8-13 GND
BLK 000-8-12 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
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
GAUGE
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

Sheet3-[8,B] WHT 077-3 RH STOP 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
3
M LB326
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
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
IGNITION SWITCH
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
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
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
2
DESCRIPTION
WHT 058-8-1 APS GND

WHT 058-8 APS GND
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
FUSE, RIGHT HIGH BEAM
4
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"
Prior to SN 0160073904 9.4.1
ELECTRICAL SYSTEM SCHEMATICS 9.4
Electrical System
G5-18A, 2505H, 25.5
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
b. Cab Schematic “B”
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
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 073-9 AC PRES SW
WHT 065-1-2 STR SEL

S186
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
31200926
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,C] 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 073-3 FAN L 14AWG

WHT 071-6-1 RH TRN
WHT 071-5 L TRN
WHT 073-1 FAN H 14AWG

RED 061-8-3 FLASHER

WHT 071-6 R TRN
WHT 073-2 FAN M 14AWG
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 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
3
2
1
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
10011381611D
MY8730
Electrical System
9-9
G5-18A, 2505H, 25.5 31200926 9-10
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 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
RED LSI CABLE 1
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+
BLK 058-1 SPEAKER-
3
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
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
Cab Roof, AC and Miscellaneous Schematic c.
Electrical System
1 2 3 4 5 6 7 8
G5-18A, 2505H, 25.5

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
d. Base Frame Schematic "A"
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
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
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
27
BLU 008-2-2 BU LPS
31200926
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
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
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 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
Electrical System
9-11
G5-18A, 2505H, 25.5 31200926 9-12
1001138161D
MY8760
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
+12V 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

NC Sheet5-[1,B] 5
CO299-J2 6
7
8
BLK 000-4-2 GND
2
1
5
5
HV157
VARIABLE SPEED CONTROL

SN207
BLK 102-9 VEH SPD GND 18AWG
GND 3
Vout 2
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
TO
D B MS295-1
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.
1 2 3 4 5 6 7 8
G5-18A, 2505H, 25.5

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
Engine Schematic
RL60
X111
X37 X39
FC61
RL60-2
RL60-1
MS302
WHT TWISTED PAIR 3 INJ 1 1.5mm²
33 62
BLK TWISTED PAIR 3 INJ 1 1.5mm²
16 35 RL148-1
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
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
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

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
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
31200926
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
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 103-1 WATER/FUEL 0.75mm²
WHT 105-2 COOLANT LVL 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
Electrical System
9-13
G5-18A, 2505H, 25.5 31200926 9-14
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

1

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
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
DRIVE REVERSE 4
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
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
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
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
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
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
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

6 6
BLK 000-9 GND 10AWG


BLK 000-9-11 GND
WHT 083-2 TELE MODE 18AWG
BLK 000-9-9 GND
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
1 2 3 4 5 6 7 8
G5-18A, 2505H, 25.5

D D
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+
31200926
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
Electrical System
9-15
i.
9-16
1 2 3 4 5 6 7 8
ClearSky Schematic
D D
Electrical System
CLEARSKY
RED 061-1 BATT

23
22
21
20
19
18
17 X282
BLK 000-1 GND BLK 000-1 GND
C 16 A C
YEL 062-2 IGN RED 061-1 BATT
15 B
14 C
13 D
12 E
11 F
10 G
YEL 062-2 IGN
9 H
8 J
TO FRAME X185
TO CLEARSKY MODULE
7
6
5
4
3
2
1
X277
31200926
B B
PRECO REVERSE WARNING SYSTEM

CONNECTS TO AH99, SHEET 5 PRECO PROXIMITY SENSOR
A
B
1
2
3
4
5
6
7
8
X02
X03
BLK 2 GND
BLK GND RSS
X05
BLK GND3 GND

BLK GND RSS
RED 3 REVERSE
1
RED 2 REVERSE
S11
X04
ORN/YEL RSS SIG
1
S12
CONNECTS TO CAB BUZZER
A A
BLK 1 GND
RED 1 REVERSE
HARNESS # 1001190914
X01
A
B
CONNECTS TO REVERSE/BACK-UP ALARM
1 2 3 4 5 6 7 8
1001138161D
MY9700
G5-18A, 2505H, 25.5

9-17 31200926 G5-18A, 2505H, 25.5
1001138161G
MY9710
A
B
C
D
NA MACHINES
INDICATOR, TURN, HIGH BEAM
PARK BRAKE QUICK COUPLER LMI OVERRIDE
X1
NAME
F40
F39
F38
F37
F36
F35
F34
F33
F32
F31
F30
F29
F28
F27
F26
F25
F24
F23
F22
F21
F42
F41
R11
R12
R14
R13
RS-232
PWR MGT
DIAGNOSTIC
EMPTY
EMPTY
EMPTY
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
1A
1B
2A
2B
FUSE, AC
FUSE, LSI
X159
SW08
SW09
SW01
FUSE, HVAC
LB325
FUSE, RADIO
1
1
FUSE, HAZARDS
FUSE,ANALYZER
RELAY, FLASHER
FUSE, DOME LIGHT
DESCRIPTION
FUSE, LIGHT POWER

FUSE, LEFT MARKER
FUSE, FRONT WIPER
FUSE, RIGHT MARKER
RELAY, START ENABLE

FUSE, LEFT HIGH BEAM
FUSE, FLASHER POWER

FUSE, LEFT HEAD LIGHT
FUSE, REAR WIPE WASH
RELAY, HEAD LT HI BEAM

FUSE, RIGHT HIGH BEAM
RELAY, PRK BRK IND (CE)

FUSE, RIGHT HEAD LIGHT
FUSE, FRONT WASH & FAN
FUSE, HEAD LIGHT POWER
RELAY, HEAD LT LOW BEAM

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 000-8-13 GND
BLK 000-8-14 GND
BLK 000-8-12 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
BLK CAN LO
5A
5A
10A
B
35A
35A
10A
15A
15A
30A
20A
20A
15A
10A
10A
35A
35A
15A

7.5A
7.5A
7.5A
7.5A
7.5A
7.5A
7.5A
RATING
WHT 077-2-1 ST ENABLE
WHT 077-1 VALVE PK BRK
C
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-[1,A]
Sheet3-[1,B]
Sheet3-[8,B]
Sheet3-[8,B]
Sheet3-[8,A]
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
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
GAUGE
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

Sheet3-[8,B] WHT 077-3 RH STOP 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
3
M LB326
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
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
IGNITION SWITCH
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

C
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
Sheet3-[8,D] F26_A
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
RED 061-8-3 FLASHER WHT 071-2-1 HDLP LO
Sheet3-[2,A] F30_B
Sheet3-[8,B] F31_A
WHT 071-7 HDLP HI
F31_B
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 071-9 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
BLU LSI PWR WHT 071-11 RH SD LP
BLK LSI 2 S213 WHT 071-1-3 LIGHTING
RED LSI 1 WHT 071-12 LH SD LP
SHIELD LSI S WHT 071-1-4 LIGHTING
TO CAB ROOF
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 061-8 B+ 12AWG
CAB FUSE/RELAY MODULE
1 F38_B
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
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
RED 061-6-2 B+ 14AWG
F41_A
F41_B
X65 F42_A
S212
1
062-2-2 YEL 16AWG F42_B
Sheet3-[8,B]
Sheet3-[8,B]
Sheet3-[8,B]
2 BLK 000-15 GND
R13_85
TO X17
TO X66.
3 WHT 071-2 HDLP LO
S220
TO X65.
S288
RED 061-8 B+ 12AWG
R13_86
S221
4 WHT 071-9 HDLP LO
R13_87
RED 061-6-2-1 B+
R13_30
S340
S345
RED 061-6 10AWG
R13_87a
BLK 000-16 GND
8
R14_85
S344
WHT 071-3 HDLP HI
R14_86
X66 WHT 071-7 HDLP HI
3. FOR EUROPEAN CABS

R14_87
1 RED 061-6-2-2 B+
NO CONNECTOR REQUIRED
062-2-2 YEL 16AWG R14_30
BLK 000-6-8 GND

BLK 000-6 GND 10AWG

BLK 000-7 GND 10AWG
2
WHT 058-8-1 APS GND

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

R14_87a
NO HEADLIGHTS CONNECT X17
2. FOR NORTH AMERICAN CABS

3
WITH HEADLIGHTS CONNECT X17

062-4-4 YEL 16AWG
WHT 048-22 APS SIG
WHT 057-1 APS 5V
WHT 048-23 IVS2

4 FC343
FUSE LINK 16AWG
1. FOR NORTH AMERICAN CABS WITH

FUSE LINK 14AWG
8
X206
X342
X341
F
E
A
D
C
B TO
TPS
Sheet3-[8,B]
Sheet3-[2,A]
Sheet3-[5,A]
Sheet3-[1,C]
Sheet3-[1,C]
Sheet3-[8,C]
X216 RL72-R
1 SHEET 5
TO CAB
1 GND STUD
1 TO FRAME
A
B
C
D
a. Cab Schematic “A”
SN 0160073904 to SN 0160076805 excluding 0160076010, 0160076011, 0160076012 9.4.2
Electrical System
9-18
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
Sheet2-[7,B] 3
1
2
3
4
5
6
7
8
4
SW26
SW145
MS18
SW23
SW29
SW30
b. Cab Schematic “B”
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
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 070-1-13 LIGHTING SW21
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



CAB

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

WHT 074-2 WPR L 14AWG

WHT 074-3 WPR H 14AWG

30
WHT 065-1 LOCK OUT

WHT 065-1-2 STR SEL

S186

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
31200926
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,C] 10
YEL 062-11 IGN WHT 071-7 RH HDLP HI
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
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-[6,A]
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 071-5 L TRN

RED 061-8-3 FLASHER

WHT 071-6 R TRN
WHT 073-5 AC
WHT 073-6 AC
WHT 073-6 AC
YEL 062-9 BEACON
WHT 073-4 AC
WHT 076-3 F/R AUX
WHT 072-1 BEACON LP

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
3
2
1
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
1001138161G
MY9730
G5-18A, 2505H, 25.5

9-19 31200926 G5-18A, 2505H, 25.5
MAE3410D
A
B
C
D
X16
X15
TO CAB
TO CAB
SHEET 2
SHEET 2
HARNESS
HARNESS
1
1
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
PRESSURE SW
SHIELD LSI S
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
RED LSI CABLE 1
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
1
FRAME
S245
SHEET 5
X268
HARNESS
RL267
WHT 073-8-3 AC COMP
2
2
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
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
3
3
LB239
1
YEL 062-13-2 IGN
2
LIGHT, DOME
BLK 000-7-8 GND

1
WHT 052-3 SPEAKER+
1 LB239-G
MS243+
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
MS244+ 1
BLK 058-2 SPEAKER- S249 WH240-G
1
WIPER, ROOF MOTOR
MS244-
4
4
CUSTOMER SUPPLIED
SPEARKERS(EUROPE)
WHT 074-8-1 REAR WPR 14AWG W

1
WH241-W M
WHT 074-9 R WPR 14AWG P
1
WH241-P
1
WH241-G
WIPER, REAR MOTOR
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
5
5
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
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
6
6
SWITCH, AUX DECOMP
SW145
072-1 BLU
1 1
000-8-1 BLK
2 2
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
7
7
WORKLIGHT
REAR RIGHT
051-6-2 BLU BLUE

1 1 1
000-8-28 BLK BLACK
2 2 2
X106 X106 LB106
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
6
5
4
3
2
1
8
8
X22
TO CAB
SHEET 3
HARNESS
FOR REFERENCE ONLY
A
B
C
D
Cab Roof, AC and Miscellaneous Schematic c.
Electrical System
9-20
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 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
1
2
1
2
F5 FUSE, SYSTEM MODULE 15A
PWR
OUT
GND
F6 FUSE, CLEARSKY 5A
HV334
HV335
87
30
87a
85
86
F7 FUSE, REVERSE CIRCUIT 15A
TO RL71-R
VALVE, DIVERTER, AUX
TO RL71-B+
VALVE, QUICK COUPLER
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
F9 FUSE, LSI SYSTEM 10A
F10 FUSE, ECM 15A
JS76
X120
X279
RL71
RL72
RL75
FC73
AH74
SN77
HV78
HV79
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
BLK 000-3-25 GND

BLK 000-3-26 GND
BUSS BAR 1
BUSS BAR 1
BUSS BAR 1
BUSS BAR 2
BUSS BAR 2
GRN 079-2 FT
GRN 079-3 FT
WHT 076-3-2 AUX QC
Electrical System
F16 FUSE, REAR WL 10A

d. Base Frame Schematic “A”
GRN 025-1 AUX
YEL 062-6 IGN

YEL 062-7 IGN
RED 061-5 KEY
YEL 062-8 BK UP
YEL 062-8 BK UP
WHT 52-3 HORN
WHT 52-2 HORN
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
BLK 000-3-20 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
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
WHT 076-3-1 AUX DIVERTER
YEL 051-4 RR WK LP
YEL 062-3-2 F/R AUX

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

RED 061-2-3 RR PWR
RED 061-1 B+ 10AWG
RED 061-1 B+ 10AWG
061 FUSIBLE LINK 16 GA

WHT 048-9 FUEL SENS
RED 001-2 BATT 6AWG

WHT 065-2-1 CRB STR
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
WHT 065-3-1 4W STR

YEL 051-1 WK LP 12AWG
Sheet6-[6,B]
Sheet6-[3,B]

1. BASE NORTH AMERICAN
Sheet6-[6,B]
2. LSI & OPTION EQUIPED

MACHINES HAVE X163A MACHINES X83
Sheet6-[1,B]
Sheet6-[1,B]
JUMPER PLUGS INTO X184
S118
S138
S337
S338
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 HV80 X336 3
WHT 065-2-1 CRB STR WHT 076-3 F/R AUX WHT 076-3 F/R AUX SHEET 9
X27 14 1 1 4
WHT 065-3-1 4W STR BLK 000-3-6 GND BLK 000-3-24 GND
15 2 2
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
S296
RED CABLE 4 CAN HI
20
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
RELAY AUX
26 4
27
BLU 008-2-2 BU LPS
28
31200926
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
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 000-3-8 GND

BLK 000-3-19 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
86
85
30
87
87a
Sheet6-[6,B]
Sheet6-[3,B]
ALARM, REVERSE
VALVE, FUNCTION SELECT
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 000-4 GND 12AWG
BLK 000-5 GND 12AWG

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
WHT 073-8-2 AC COMP

BLK 000-3-16 GND
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
PLUGS INTO X222
ON SHEET 8
1 2 3 4 5 6 7 8
1001138161G
MY9720
G5-18A, 2505H, 25.5

9-21 31200926 G5-18A, 2505H, 25.5
MAE3430D
A
B
C
D
1
1
31
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
2
2
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
WHT 101-4 FAN REV
A 9
HV140 8
INTO X152
PLUG X154
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
3
3
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
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
VEH SPEED SENSOR 6
NC 7
4
4
WHT 101-3 FAN SPD

FAN CONTROL 8
WHT 101-4 FAN REV
FAN REVERSE 9
VEH SPEED CONTROL 10
NC 11
WHT 52-3-1 HORN A
ALARM 12
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
+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
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
3 x 4 Buss Bar

N/C Sheet5-[1,B] 5
CO299-J2 6
7
5
5

8
BLK 000-4-2 GND
2
1
HV157
VARIABLE SPEED CONTROL

SN207
BLK 102-9 VEH SPD GND 18AWG
GND 3
Vout 2
SPEED
Vcc 1
SENSOR
SENSOR, SPEED
MS295-3
6
6
A
120 Ω
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
C A A
TO
D B MS295-1
E C
F
CLEARSKY
G
YEL 062-7 IGN
H Sheet5-[3,D]
J
X185
ATTACH
DUST CAP
7
7
8
8
A
B
C
D
e. Base Frame Schematic “B”
Electrical System
f.
9-22
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
Engine Schematic
X281
2
1
1
1
1
2
1
2
1
RL60
X111
X37 X39
FC61
RL60-2
RL60-1
MS302
33 62
16 35 RL148-1
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
Electrical System
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
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

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

001-11-1 FUSIBLE LINK 12 GA

39 15
BLK TWISTED PAIR 9 CRANKSHAFT 0.75mm²
TO 54 21
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
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
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
C RED CABLE 5 CAN HI 18AWG SHEET 5
57 7 C
58 6
59 5
60 4
3
2
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
31200926
13 A
WHT 048-23 IVS2 0.75mm² BLK 000-86 GND 16AWG
16 B
GRY 048-28 ST RLY (-) 0.75mm²
28 C
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 53
BLK CABLE 15 CAN LO
K
B
54 L
WHT 103-2 WATER/FUEL 0.75mm² RED CAN HI
57 M
61 X46
BLK 058-8 APS GND 0.75mm²
TO 62 X62
GRY 048-22 APS SIG 0.75mm² RED CAN 3 HI 120 Ω
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 120 Ω
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
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 105-2 COOLANT LVL 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
MAE3440D
G5-18A, 2505H, 25.5

9-23 31200926 G5-18A, 2505H, 25.5
MAE3450D
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
1
1
BLK 000-9-13 GND

2
85
3
87a BLK 000-3-3 GND
1
30 BLK 000-3-23 GND
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

1

WHT 071-10 LH HDLP LO

WHT 076-7 JS C/O 18AWG
X222
TO BASE
WHT 076-9 LSI O/R 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
2
2
BLK 000-9-4 GND SIDE

MS189 1
LB160
LIGHT, LEFT HEADLIGHT
TURN
ON PAGE 5
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
A LB161
X183
LIGHT, RIGHT HEADLIGHT
TURN
ON
S203
X103
X183
INTO
S201
S199
PLUGS
PAGE 5
S202
S200
S194
STOP
7
3
3
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
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
1
DIAGNOSTIC
LB162
LIGHT, TAIL LIGHT, RIGHT
IGN PWR (7-33V) 1

BLK 000-9-14 GND 18AWG TAIL
GROUND 2
BOOM TELE STATE 2 3
DRIVE REVERSE 4
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
NC 12 1
CO300-J1 LB163
LIGHT, TAIL LIGHT, LEFT
NC 1
4
4
TAIL
A
B
C
A
B
C
NC 2
NC 3
LSI REMOTE MODULE

MS114-3
MS114-2

+5V OUT 4
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
BLK 000-10-2 GND
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
TELESCOPE COMMAND 4 MS164-6
WHT 007-3 DR FWD 18AWG WHT 071-12-3 LH TAIL
DRIVE FORWARD 5 1
BOOM TELE STATE 1 6 MS164-7
TRAILER CONNECTOR
5
5
LIFT MODE VALVE 7

S195
LIFT DOWN VALVE 8

TELE OUT VALVE 9
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
LSI PASSIVE LAMP 12 LB165
LIGHT, LICENSE
CO301-J1
+5V OUT 1
PRESSURE SENSOR 2
LSI MAIN MODULE

ANALOG GROUND 3
NC 4
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
6
6
SN297
S196
BLK 000-9-7 GND
BLK 000-9-6 GND
7
7
S197
S198
X170 X160
YEL 062-23 IGN YEL 062-23
1 1
BLK 000-10-5 GND BLK 000-10-5
2 2
3 3
YEL 062-22 IGN YEL 062-22
4 4
BLK 000-10-6 GND BLK 000-10-6
5 5

6 6
BLK 000-9 GND 10AWG



BLK 000-9-11 GND
WHT 083-2 TELE MODE 18AWG
BLK 000-9-9 GND
BLK 000-9-8 GND

BLK 000-9-10 GND
X178
X179
8
8
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

G5-18a Service Manual

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Service Manual

An Oshkosh Corporation Company

DATE REVISION DESCRIPTION

G5-18A, 2505H, 25.5 31200926 i

ii 31200926 G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 31200926 iii

iv 31200926 G5-18A, 2505H, 25.5

G5-18A, 2505H, 25.5 31200926 v

vi 31200926 G5-18A, 2505H, 25.5

PARAGRAPH TITLE PAGE

G5-18A, 2505H, 25.5 31200926 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1-2 31200926 G5-18A, 2505H, 25.5

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

G5-18A, 2505H, 25.5 31200926 1-3

1-4 31200926 G5-18A, 2505H, 25.5

PARAGRAPH TITLE PAGE

G5-18A, 2505H, 25.5 31200926 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-2 31200926 G5-18A, 2505H, 25.5

2.1 REPLACEMENT PARTS AND WARRANTY

Before ordering parts or initiating service inquiries, make

G5-18A, 2505H, 25.5 31200926 2-3

2.2.1 Travel Speed

Tires Approximate Speed

2.2.2 Hydraulic Cylinder Performance Specifications

Approximate Times (sec.)

2.2.3 Electrical System

2.2.4 Steering Angle Specification

Model Angle (in Degrees)

2-4 31200926 G5-18A, 2505H, 25.5

2.2.5 Engine Performance Specifications

Duraforce Pneumatic 80 psi (5,5 bar)

G5-18A, 2505H, 25.5 31200926 2-5

2.3 FLUIDS, LUBRICANTS AND CAPACITIES

a. If Equipped for ULS

Ambient Temperature Range

MobilFluid 424 10W-30 6 115 -15 46

Ethylene Glycol 50/50 Mix Standard

2-6 31200926 G5-18A, 2505H, 25.5

Ambient Temperature Range

API GL5 with LS Additives 85W-90LS

Ethylene Glycol 50/50 Mix Standard

G5-18A, 2505H, 25.5 31200926 2-7

Engine Crankcase Oil

2-8 31200926 G5-18A, 2505H, 25.5

2.4 MAINTENANCE SCHEDULE

2.4.1 10,1st 50 & 50 Hour Maintenance Schedule

Check Fuel Check Engine Check Hydraulic Check Tire Additional

Drain Fuel/ Check Engine Check Check Check Brake

G5-18A, 2505H, 25.5 31200926 2-9

2.4.2 1st 250, 250 & 500 Hour Maintenance Schedule

Change Axle Change Wheel Change Front

Check Axle Check Wheel Check Front Check Check Boom

Check Enclosed Lubrication

2-10 31200926 G5-18A, 2505H, 25.5

2.4.3 1000 & 1500 Hour Maintenance Schedule

Change Axle Change Wheel Change Front Change Check

Change Change Fuel Filter