Home

Service Manual

Contents

1. 4 9 e V mm T i men AYYY vic im d i oH Imm di fpe a g 5 HH B Bor P HN o s RB EP DH 8 i 221881 ra rE We ie p Ba E mno p Ho m oH p ilii lj m m i o x M oue r2 7 8 RR mm i m 9 GNO 010000918 bama wewn lt pi im Bue mim in a sH mamae eee mus 52 oy R 8 9900018 2 snare 1 Boss en E pg 7 H 8 d Ba Lia BH BB O Hom BH Hh EU iG exc ss iP S ante ed Ku EE Re oeque DEO ia Real Wes mmi LL sf a HARA DENTO Bend i yH 23 M 4 i p i y a H 11915121919 ES P
2. a Y m 5 ze g 5 5 ii i E EEEE i l fost m uD ue Whee T lt acm EE c ey A A H 9 0007187 Kie P 4 5 CAB Rm was s CAB Crs 5 Lb Be CAB ved CAS 24 INNEN TERRE mem i LS FTN ad ee HE E 1 E canes BOLA s EC E dcc i bang Ee A Re kk ERIN 3 i epee nare Tei i 45 E i HRT FTO CS dirgama EH seres fK 2i o 4 BE i loq Stet uen 4 i d i pee Ae e i
3. m mm 5 A STE ee eer li e 295 gt fis i Ead ES EL JE EE ion H HH 5 i i Bg diu d oH do Wu os uo 1 d l i A d d i 5 i i fay 08 E E i iP od vero 3 aw roramons EE i i Uu i j 88 3 e ii i EE 4 r a e CERE TET lt PHS Moreno WENOGM TMS 1736 1 901 IHM pue nem eee 1 n E sese cover d siii i mE F M mmm TOT ee TEW LH i M i lt amv ROOM sven OMVSI 1 SIVLS We 1 190 LHM lt am aaaea YS aus Sars Me Ei RIA T maar ees C gt amp cial rion E 3 mem 1 ma so 29 ZMGINSSVIDLIHM i eae es 2 i d ise i GG EE 5 an j TB LM 8
4. Install extend retract cylinder mounting pin 11 Install lock bolt and nut 10 at rear of extend retract cylinder Install wear pads shims and bolts previously removed from rear of second boom section DO NOT tighten the wear pads at this time Uncap and reconnect extend retract cylinder fittings and plugs from extend retract cylinder tubes and tighten until wrench tight Mark fitting then torque to specification Refer to Section 2 3 3 Hydraulic Hose Torque Chart Uncap and reconnect tilt hoses and if equipped auxiliary hoses Attach both sets to their appropriate fittings until wrench tight Mark fitting then torque to specification Refer to Section 2 3 3 Hydraulic Hose Torque Chart Adjust and shim each wear pad as needed Properly connect battery G5 18A 2505H 25 5 i M P is 12 Start engine and operate all boom functions several times to bleed any air out of hydraulic system Check for fluid leaks Check hydraulic fluid level in tank and add fluid as required MY2000 13 16 17 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 If adj
5. SEN Deutz Description Codes Codes Codes 609 1328 12 Too many recognized misfires in cylinder 6 in firing order 610 1322 12 Too many recognized misfires in more than one cylinder 612 523612 12 Internal ECU monitoring detection reported error 613 523612 12 Internal ECU monitoring detection reported error 614 523612 12 Internal ECU monitoring detection reported error 615 523612 12 Internal ECU monitoring detection reported error 616 523612 12 Internal ECU monitoring detection reported error 617 523612 12 Internal ECU monitoring detection reported error 618 523612 12 Internal ECU monitoring detection reported error 619 523612 12 Internal ECU monitoring detection reported error 620 523612 12 Internal ECU monitoring detection reported error 621 523612 12 Internal ECU monitoring detection reported error 623 523612 12 Internal ECU monitoring detection reported error 624 523612 12 Internal ECU monitoring detection reported error 625 523612 12 Internal ECU monitoring detection reported error 627 523612 12 Internal ECU monitoring detection reported error 628 523612 12 Internal ECU monitoring detection reported error 637 523612 12 Internal ECU monitoring detection reported error 648 523008 1 Manipulation control was triggered 649 523008 2 Time out error in Manipulation control 732 100 3 Sensor error oil pressure signal range check high 733 100 4 Sensor error oil pressure sensor
6. 6 3 6 5 2 Transmission 6 4 6 5 3 Transmission 1 5 6 4 G5 18A 2505H 25 5 6 1 6 Transmission 6 1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the transmission The following illustration identifies the components that are referred to throughout this section TOP FILL PORT HYDROSTATIC TRANSMISSION FORWARD RELIEF VALVE SHUTTLE VALVE 5 9 7 REVERSE RELIEF VALVE DIRECTIONAL CONTROL VALVE L Cm a VIEW FROM BOTTOM WITH MY8920 PLATE REMOVED 6 2 G5 18A 2505H 25 5 Transmission 6 2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the Safety Practices section of this manual 6 3 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications towing maintenance information and transmission removal and installation procedures For internal transmission service instruct
7. LNOYA GNOOAS DINLOATA HLIM XNV TWNOILdO j wS pp mo i IWNOILdO ANS d Xn LNOUS uva MAL2720B G5 18A 2505H 25 5 83 Hydraulic System 2505H amp 25 5 b s 9 LNOM4 GNOO3S TVNOLLdO ve ge Wave TWNOILdO ONIHJa3IS 8 P 4 SWAIN aot LNOU4 D x eB TVNOLLdO IIVAA WOU EM 5992777 i ve ge ge NOLLOSNNOO i E oN A SN LY H pane Xnv 1NON4 Xnv ist SNOILdO AYVITIIXNV NN INCA MAL2730B G5 18A 2505H 25 5 Hydraulic System n 8 8 HYDRAULIC RESERVOIR The hydraulic reservoir and fuel tank are part of the fra
8. MAL2710B hand NLIS Feet ee _ T v T a BANAONHONI A i 1 UALS G5 18A 2505 25 5 ga Hydraulic System G5 18A SNOI LdO AYVITIXNV TCOIHLOGI3 LNOYS GQNOO3S TWNOILdO ve Zi rm
9. 8 26 8 12 2 General Cylinder Disassembly 8 26 8 12 3 Cylinder Cleaning Instructions 8 27 8 124 Cylinder 8 27 8 12 5 General Cylinder 8 27 8 12 6 General Cylinder 8 28 8 12 7 Steering 8 28 8 12 8 Hydraulic Cylinder Torque Specifications 8 29 G5 18A 2505H 25 5 alls Hydraulic System 81 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 illustration identifies the components that are referred to throughout this section COMPENSATING CYLINDER HYDRAULIC RESERVOIR AND LIFT LOWER CYLINDER UNDER EXTEND RETRACT CYLINDER gt E Dc HYDRAULIC FILTER HYDROSTATIC DRIVE PUMP IMPLEMENT PUMP FRONT AXLE DRIVE MOTOR STEERING CYLINDER MY8690 G5 18A 2505H 25 5 8 3 Hydraulic System 8 2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety pre
10. 2 15 2 5 Fluids Lubricants 2 16 2 5 1 FIUS OU 2 16 2 5 2 Capacities vae eed eye Woe aan 2 18 2 6 Maintenance 2 19 2 6 1 10 151 50 amp 50 Hour Maintenance 2 19 2 6 2 1st 250 250 amp 500 Hour Maintenance Schedule 2 20 2 6 3 1000 amp 1500 Hour Maintenance 2 21 2 7 Lubrication 2 22 2 7 1 250 Hour Lubrication 2 22 G5 18A 2505H 25 5 2 1 General Information and Specifications 2 1 REPLACEMENT PARTS AND WARRANTY INFORMATION 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 De
11. 9 10 2 Dash Switches 9 10 3 Fuel Level Indicator and Fuel Level 9 10 4 9 10 5 Coolant Temperature 9 10 6 Oil Pressure 911 Load Stability Indicator System 2505H amp 25 5 9 11 1 ESIAXIGE S NSOF Dea KIE dol Re oe arate 9 11 2 ESI Boom Sensors eee A A 9 11 3 ESI Modules v4 ee OR Ro ee 9 11 4 LSI System 9 11 5 9 11 6 500 Hour LSI UGM Calibration G5 18A 2505H 25 5 PAGE 9 3 9 4 9 4 9 7 9 15 9 15 9 17 9 17 9 18 9 18 9 18 9 19 9 19 9 20 9 20 9 21 9 21 9 22 9 22 9 23 9 23 9 24 9 24 9 25 9 26 9 26 9 27 9 28 9 29 9 31 9 32 9 1 Electrical System 9 12 9 13 9 14 Hand Held Analyzer 2505H amp 25 5 9 32 9 12 1 Analyzer 9 32 9 12 2 Analyzer Software Version 1 0 9 33 Diagnostic Trouble Codes DTC on Ground Mod
12. 24 9 3 1 Engine Compartment Relays and Fuses 9 3 2 Cab Compartment Fuses 9 3 3 Power Distribution Module 9 3 4 Cab Fuses 9 4 Electrical System 9 5 Engine Start 9 5 1 SIAO MM 9 6 Charging Circuit 222 200 gerer rs 9 6 1 Alternator pera ep e OR Ra mE A 9 7 Electrical System 9 7 1 Back Up chu dat acerca dud Ede dt ee 9 7 2 Gauge 9 8 Window 9 8 1 Windshield Wiper 9 8 2 Rear Window or Roof Wiper Motor if equipped 9 8 3 Windshield Washer Reservoir and 9 9 Cab Heater AC and Fan 9 9 1 Cab Heater AC 9 10 Switches Solenoids and 9 10 1 Ignition Key
13. 3 5 3 4 4 Second Boom Section Installation 3 6 3 4 5 Extend Retract Cylinder 3 7 3 4 6 Extend Retract Cylinder Installation 3 9 3 5 Boom Wear 3 9 3 5 1 Wear Pad 3 9 3 5 2 Wear Pad Installation and Lubrication 3 9 3 5 3 Boom Wear Pad 3 10 3 6 Quick Attach Assembly 3 10 3 6 1 Quick Attach Assembly 3 10 3 6 2 Quick Attach Assembly 3 11 3 7 Em 3 11 3 8 Boom Prop If Equipped 3 12 3 8 1 Prop Installation n ee xut Pedy eae 3 12 3 8 2 Prop Removal ss 3 12 3 9 Emergency Boom Lowering Procedure 3 13 3 9 1 Equipment and Supplies Required 3 13 3 9 2 Lowering Procedure 3 14 3 10 Troubleshooting 2 2 5 4 3 15 G5 18A 2505H 25 5 3 1 Er Boom 3 1 BOOM SYSTEM COMPONENT TERMINOLOGY To understand the safety operation an
14. 8 4 8 4 Specifications 8 4 8 5 Hoses Tube Lines Fittings 8 4 8 5 1 Replacement Considerations 8 4 8 5 2 Hose Tube Line and Fitting 8 4 8 6 Hydraulic Pressure 8 5 8 6 1 Pressure Checks and 8 5 8 6 2 Main Control Valve Pressure 0 8 5 8 6 3 Charge Pressure 0 8 6 8 6 4 Boom Function Pressure 0 8 6 8 6 5 Steering Pressure 0 8 6 8 6 6 Fan Speed Pressure and Direction 0 8 6 8 7 1 1 8 7 8 8 Hydraulic Reservoir 8 10 8 8 1 Pressurized Hydraulic Oil Fill 8 10 8 8 2 Hydraulic Oil Reservoir 0 8 10 8 8 3 Hydraulic Oil Reservoir 0 8 10 8 9 Hydraulic System 8 11 8 9 1 Implement Pump
15. 2 22 2 2 9 4 9 3 Puses and Helays oi ni hee Xe ER Pu DER oe rea gaa eae 9 4 9 4 Electrical System Schematics 9 7 9 5 Engine Start Circuit 1 9 15 9 6 Charging 9 17 9 7 Electrical System Components 2 9 18 9 8 Window 4 9 19 9 9 Cab Heater AC and Fan 1 9 21 9 10 Switches Solenoids and 9 22 9 11 Load Stability Indicator System 2505H amp 25 5 9 26 9 12 Hand Held Analyzer 2505H amp 25 5 9 32 9 13 Diagnostic Trouble Codes DTC on Ground Module 9 34 9 14 Engine Diagnostic Trouble Code EMR4 9 39 G5 18A 2505H 25 5 Section Subject Page iv G5 18A 2505H 25 5 Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1 1 Introduction isos ace 1 ex mmm Re 1 2 1 2 DISCIAIMGN 4 222 EEUU 1 2 1 3 Operation amp Safety 1 2 1 4 Do Not Operate
16. The number of shims can vary at each shim point The bottom wear pads must be shimmed equally on each side Maintain a total boom section clearance of 0 070 0 130 in 1 78 3 30 mm both the horizontal and vertical directions gt j m MY3620 The length of wear pad bolt depends on number of shims spacers and washers being used The thickness of each threaded wear pad insert is 0 312 in 7 92 mm A The bolt length should be determined by measuring distance from face of insert to face of boom B 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 Ib ft 43 50 Nm 3 8 24 Hollow Bolt 15 17 Ib ft 20 23 Nm 1 2 20 Bolt 76 86 Ib ft 103 116 Nm 1 2 20 Hollow Bolt 45 50 Ib ft 61 68 Nm Torque wear pad bolts after shimming is completed Lubricate face and pockets of each wear pad after being installed 3 5 3 Boom Wear Pad Lubrication After replacing any wear pads or after prolonged periods of inoperation Lubrication of boom wear surfaces with grease is recommended to keep boom wear surface
17. 28 BESS 38848 emme ooa oL amora no mua 1 i URED AR dO 0000 15 euumus eesoa ormona NO amam mud i 21222 47 AA eee OMNE MOTO 62990 EI Di amoran 1904 E 44 5 gt E PE 35 emine ao E E 8 1 9 7 z L Electrical System Engine Schematic f 9 12 Electrical System 9 Option Frame Schematic
18. adjustment is required adjust the main relief cartridge 2 on the main control valve Recheck pressure after any adjustment has been made Hydraulic System Charge Pressure Checking QNI 1 Attach pressure gauge to the test port 3 on the hydrostatic transmission 4 to check the system pressure The pressure should be 350 410 psi 24 1 28 2 bar with the engine at low idle 2 The charge pressure relief valve is preset at the factory and is not adjustable 8 6 4 Boom Function Pressure Checking 1 Attach 5000 psi 345 bar gauge to the test port 5 at the rear of the implement pump to check the system pressure Make sure the gauge is visible from inside the cab 2 See Section 8 6 Hydraulic Pressure Diagnosis for start up procedure Check the boom function pressure with the park brake on and the service brake off at full throttle Retract each boom circuit function until the cylinder bottoms Each circuit function pressure should be 3585 3665 psi 247 252 7 bar at full throttle Note With the machine at operating temperature the 3585 3665 psi 247 252 7 bar pressure reading at the main control valve is 125 psi 13 3 bar HIGHER than the 3450 3550 psi 237 8 244 7 bar of each individual valve section function DO NOT adjust the main control valve relief pressure below 3585 3665 psi 247 252 7 bar To check individual valve section pressures ins
19. 2 3 3 Hydraulic Hose Torque Chart O Ring Face Seal amp JIC Torque Chart Size ORFS JIC Flats Method 4 ds Nm 1 5 to 1 75 a Gi Nn Gi wot 8 c Ho ia 1 5 to 1 75 10 a m a 1 5 to 1 75 i i00 Nm 100 N SOUS w df 1654 20 20 Nm 0 75 to 1 0 a 20001 206 07510 32 356 0 75101 0 Note By definition the Flats Method will contain some variance Use the Flats Method only when accessibility with a torque wrench is not possible G5 18A 2505H 25 5 Torque Wrench 1 Identify the appropriate application and refer to the above chart for the correct torque value If equipped lubricate o ring with hydraulic oil Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected Average hand torque is 3 Ib ft 4 Nm Use the double wrench method while tightening to avoid hose twist Torque wrench must be held at the center of the grip Apply constant force until it clicks After connection has been properly tightened mark a straight line across connecting parts indicating that connection has been properly tightened Flats Method 1 If equipped lubricate o ring with hydraulic oil Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected Average hand torque is 3 Ib ft 4 Nm Mark a dot on one of swivel nut flats and another dot in line on hex of adapter it s connecti
20. 2 3 2 Metric Fastener Torque Chart Continued 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 Size Pitch Stress Dry or Loctite 26 3 242 or 271 26 ies 0 17 Vibra TITE 111 or 140 M 131 0 18 Sq mm KN N m N m N m 3 0 5 5 03 3 13 3 5 0 6 6 78 4 22 4 0 7 8 78 5 47 5 0 8 14 20 8 85 6 1 20 10 12 5 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 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 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 G5 18A 2505H 25 5 General Information and Specifications
21. AT _ L mor e ea E dg Lia Er i ii _ 4 TEA BEE TTTTTT n OO 7 m MY8720B G5 18A 2505H 25 5 2 9 S3NIHOVW SNV 39 XINO 1 rehome Eg ii 9108 H 120 LHM I PII a m KS orams honed 1 gt
22. gig i B 8 Blg E aus n n 21 7010 i4 BE HB 88 E H I SES OY i nau HB dd 88632688 Hoi OMVVI NOI POP COOSA AAAAKAKA A 95399 9 R2 1 LL AAE Hoeng 4 6 n NN CAEL c EE 4 Le Ly amicos SIHON NYOM SIHON NOOG HOLMS LOTE WS MERNO NS 1 s 1 z G5 18A 2505H 25 5 MY8730B Electrical System b Cab Schematic B Electrical System c Cab Roof AC and Miscellaneous Schematic a m e d i 54 i 1 90m 900X ous i 1 I a go Dt mm e
23. 8 11 8 9 2 Implement Pump 8 11 8 9 3 Pump bee EIE Rad AERE 8 11 8 10 Front Drive Motor 8 12 8 10 1 Front Drive Motor 8 12 8 10 2 Front Drive Motor Installation 8 12 8 11 Control ValveS 2 2 i culi is 8 13 8 11 1 Main Control 4 8 13 8 11 2 Service Brake 8 14 8 11 3 Brake Valve 05 18 8 16 8 11 4 Hand Brake Valve 2505H amp 25 5 8 17 8 11 5 Steering Orbitrol Valve 8 18 8 11 6 Pilot Select Valve 8 18 8 11 7 INCHING ValVe wens eee rd e Pent e Gur e RR ad wed 8 19 8 11 8 Priority Valve 8 21 8 11 9 Steer Select 8 22 8 11 10 Quick Attach 8 23 8 11 11 Variable Speed Fan 8 24 G5 18A 2505H 25 5 Hydraulic System 8 12 Hydraulic Cylinders 22292002 09 ee cade ee ae 8 26 8 12 1 General Cylinder Removal
24. REID Ya bee fea Te ake 7 10 7 7 Engine 7 11 Section 8 Hydraulic dece RO ROME Rada edid iare Ed d Rd ae 8 1 8 1 Hydraulic Component Terminology 8 3 8 2 Safety Information 4 8 4 8 3 General 8 4 8 4 SDeCIfICations Gd Eu d beg 8 4 8 5 Hoses Tube Lines Fittings 8 4 8 6 Hydraulic Pressure Diagnosis 8 5 8 7 Hydraulic Schematic akon eoe im dore 8 7 8 8 Hydraulic 8 10 8 9 Hydraulic System 1 8 11 8 10 Front DAVE MIOT Bee ES UD Rue we ge 8 12 8 11 Control Valves n A Rx d eR p e OA E bem 8 13 8 12 Hydraulic Cylinders 1 8 26 ii G5 18A 2505H 25 5 Section Subject Page Section 9 Electrical Systemi wa arcana msi DR D OR 9 1 9 1 Electrical Component Terminology 9 3 9 2 Safety Information
25. Brake Performance Test 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 Park Brake Valve G5 18A Park Brake Valve Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery Remove the four capscrews holding the cover below the seat The park brake valve is mounted on the backside of the cover Label disconnect and cap the hydraulic hoses on each side and bottom of the park brake valve Disconnect and cap all hoses fittings etc Remove the two capscrews and two lockwashers mounting the park brake valve to the cover 8 16 b 1 Park Brake Valve Disassembly Cleaning Inspection and Assembly Place the park brake valve on a suitable work surface MY2150 Remove the solenoid valve 1 and cartridge 2 from th
26. oa i a ni Eug 11 t EE F3 F4 gt REI S a 2 Se i 2470 Fuse Relay Function Amp Rating F21 Hazard 10 F22 LSI Over Ride 5 F23 Dome Light 10 F24 Analyzer 5 F25 Front Washer amp 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 Electrical System 9 4 ELECTRICAL SYSTEM SCHEMATICS a Cab Schematic A
27. Electrical System 9 11 LOAD STABILITY INDICATOR SYSTEM 2505H amp 25 5 4 5 ___ Y 4 4 The LSI 1 provides visual and audible indication of forward stability limitations when machine is static on firm level surface Green LED 2 will illuminate when LSI power is on When approaching forward stability limitations LEDs progressively illuminate green 3 then orange 4 and finally red 5 f the red LED iluminates the warning buzzer also sounds The LSI has two modes Active Mode CE amp AUS As the telehandler reaches forward stability limitations and the red LED 5 illuminates the automatic function cut out is activated All boom functions are disabled except boom retract CE amp AUS and boom lift CE Retract boom to fully re enable functions n some instances the LSI system may slow down or stop boom functions if operated close to forward stability limitations When LEDs begin to flash certain functions can not be operated Retract boom and or return the joystick to neutral position for a short period to allow system to reset and LEDs to stop flashing before proceeding with operation Passive Mode CE The orange LED 7 illuminates when the following occurs The park brake is not applied and transmission control lever is in the forward or reverse position When approaching forward stability limitations visual and aud
28. Note It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed Some cylinder parts are sealed with a special organic sealant 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 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 sealant often leaves a white powdery residue on threads and other parts which must be removed by brushing with a soft brass wire brush prior to reassembly 9 Remove the piston head 4 from the rod 5 and carefully slide the head gland 6 off the end of the rod 10 Remove all seals back up rings and o rings 2 from the piston head and all seals back up rings and o rings from the head gland Note The head gland bearing will need to be inspected to determine if replacement is necessary DO NOT attempt to salvage cylinder seals sealing rings or o rings ALWAYS use a new complete seal kit when rebuilding hydraulic components Consult the parts manual for ordering information 8 12 3 1 Discard all seals back up rings and o rings Replace with new items from complete seal kits to help ensure proper cylinder function
29. both ignition key switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool Remove the air cleaner assembly Remove cooling system Refer to Section 7 2 Engine Cooling System 9 Drain the hydraulic oil reservoir Refer to Section 8 8 2 Hydraulic Oil Reservoir Draining 10 Label disconnect and cap all hydraulic hoses attached to transmission and implement pump 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 6 Transmission 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 A 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 Install cooling system Refer to Section 7 2 Engine Cooling System Fill hydraulic reservoir with clean fresh oil and bleed system DO NOT overfill Properly connect battery Check hydraulic oil level and add o
30. i 1 m 5 1 E 557 e ie T emis BRI Ld 1 i af 8 1 sacas P mum Ec E erm ehana D ih soe DI esr auo 999x374 ia VID IH a A H El 1 ey ao Fe 0005718 enum i E P D erar ua 3OOW EID IR ewavemww 0 19 e GNO L PME 5 pm wwe op 4 emori i wh e sno Goes IM E is RE Hn NES 444 Ca EXizill ihi HIT HT a o T m lt G5 18A 2505H 25 5 MY8740B
31. 1 2 1 5 Safety 1 2 1 5 1 Safety Alert System and Signal 1 2 1 6 Safety Instructionis ee eee 1 3 1 6 1 Personal Hazards osse weave ac ede ie Pe vd eee 1 3 1 6 2 Equipment 1 3 1 6 3 General 1 3 1 6 4 Operational 1 4 1 7 Safety 2 5222 53 eae dee Rm Ree ees 1 4 G5 18A 2505H 25 5 1 1 Safety Practices A 11 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures Following the procedures in this manual will help assure safety and equipment reliability Read understand and follow the information in this manual and obey all locally approved safety practices procedures rules codes regulations and laws These instructions cannot cover all details or variations in the equipment procedures or processes described nor provide directions for meeting every possible contingency during operation maintenance or testing When additional information is desired consult the local JLG Dealer Many factors contribute to unsafe conditions carelessness fatigue overload inattentiveness unfamiliarity even drugs and al
32. Gauge Cluster 9 18 a Removal NOTICE Static electricity can cause damage to the operator s gauge Avoid any manner of touching hands tools etc the printed circuit boards and terminals Disconnect the battery negative cable at its battery terminal before beginning this procedure Failure to comply can result in damage and or malfunction of the gauge 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery 5 Remove the screws holding the instrument panel to the dash 6 Slide the instrument panel out of the operator console 7 Disconnect the wiring harnesses from the rear of the gauge 8 Remove the two wing nuts and bracket securing the gauge to the instrument panel b Installation 1 Position the gauge in the instrument panel and secure with the previously removed bracket and wing nuts 2 Connect the wiring harnesses to the rear of the gauge 3 Position the instrument panel in the operator console 4 Secure to the panel with four previously removed screws 5 Properly connect the battery 6
33. drain the axle and inspect internal parts for water damage and contamination Before assembling and refilling the unit with the specified lubricant s clean examine and replace damaged parts as necessary Axles Drive Shafts Wheels and Tires 5 4 5 Axle Removal A WARNING 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 parking brake mechanism and a limited slip feature the rear axle has none of these The following steps outline a typical axle removal procedure suitable for either the front or the rear axle assembly Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components If using a steam cleaner seal all openings before steam cleaning Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 1 Park machine on a hard level surface 2 Fully retract boom lower boom place transmission control lever in N NEUTRAL 3 Engage park brake and shut engine OFF 4 Place a Do Not Operate Tag on
34. 1488 523718 3 SCR main relay short circuit to battery only CV56B 1488 523718 3 SCR main relay short circuit to battery only CV56B 1489 523718 4 SCR main relay short circuit to ground onlyCV56B 1489 523718 4 SCR main relay short circuit to ground only CV56B 1490 4376 5 SCR reversing valve open load 1490 4376 5 SCR reversing valve open load 1491 4376 12 SCR reversing valve over temperature 1491 4376 12 SCR reversing valve over temperature 1493 4376 4 SCR reversing valve short circuit to ground 1493 4376 4 SCR reversing valve short circuit to ground 1494 2659 0 Physical range check high for EGR mass flow 1494 2659 0 Physical range check high for EGR mass flow 1495 2659 1 Physical range check low for EGR mass flow 1495 2659 1 Physical range check ow for EGR mass flow 1496 2659 11 Exhaust gas recirculation EGR mass flow shut off demand 1496 2659 11 Exhaust gas recirculation EGR mass flow shut off demand 1505 524057 2 Electric fuel pump fuel pressure build up error 1505 524057 2 Electric fuel pump fuel pressure build up error 1523 2659 2 Exhaust gas recirculation AGS sensor plausibility error 9 56 G5 18A 2505H 25 5 Electrical System Fault TU Deutz Description Codes Codes Codes 1523 2659 2 Exhaust gas recirculation AGS sensor p
35. 22e Eee aa eer ee 4 11 G5 18A 2505H 25 5 4 1 a ce 41 OPERATOR CAB 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 machine cab and covers The following illustration identifies the components that are referred to throughout this section LSI INDICATOR 2505H amp 25 5 ACCESSORY CONTROL LEVER IF EQUIPPED POWER OUTLET JOYSTICK FRAME LEVEL INDICATOR RIGHT HAND CONSOLE HORN BUTTON LONGITUDINAL LEVEL INDICATOR AUS STEERING WHEEL INSTRUMENT PANEL PARK BRAKE SWITCH G5 18A LSI OVERRIDE SWITCH 2505H amp 25 5 TRANSMISSION CONTROL LEVER QUICK ATTACH SWITCH IF EQUIPPED TILT STEERING COLUMN IF EQUIPPED IGNITION SWITCH ACCELERATOR PEDAL MY8850 PARK BRAKE LEVER 2505H amp 25 5 4 2 G5 18A 2505H 25 5 Cab a 4 2 SAFETY INFORMATION WARNING DO service the machine without following all safety precautions as outlined in the Safety Practices section of this manual 4 3 OPERATOR CAB 4 3 1 The welded metal cab features a modular design allowing for a relatively quick simple exchange of entire cab and or component parts Cab is bolted directly to frame Operator Cab Description The operator cab is a
36. 25 5 Hydraulic System n 4 Properly connect the battery 5 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 6 Inspect the park brake valve and connections for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF 7 Install the park brake cover with the four capscrews 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 9 Close and secure the battery and engine covers 10 Remove the Do Not Operate Tags from both the ignition key and the steering wheel d Park Brake Valve Test 1 Start the machine and engage the shift lever to the forward position Slowly depress the throttle to mid idle The parking brake will not allow the machine to move 2 If further troubleshooting is required refer to the Section 8 7 Hydraulic Schematic or Section 9 4 Electrical System Schematics 8 11 4 Brake Valve 2505H 25 5 The hand brake valve is located in the cab beside the seat a Hand Brake Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the hand brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machi
37. 4 Auxiliary 5 and Joystick 6 amp 7 9 3 2 Cab Compartment Fuses and Relays 2480 The cab fuse block 8 is located behind access panel at the right side of the dash G5 18A 2505H 25 5 Electrical System 9 3 3 Power Distribution Module LJ FIG F6 C3 hd Fro L1 RI i rur PO ENIRA i Olle SO MAP0030 Fuse Relay Function Amp Rating F1 Drive Cut Out 15 F2 Auxiliary Circuit 15 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 amp Horn 15 F14 Front Worklights 10 F15 Boom Worklights 10 F16 Rear Worklights 10 R1 Worklights 35 R2 Back Up Alarm Reverse Light 35 G5 18A 2505H 25 5 Electrical System 9 3 4 Cab Fuses Relays O 24900 wo L2 C1 1 E ei e PH e E
38. 8 n 9 9 1 z L e Base Frame Schematic B G5 18A 2505H 25 5 8 4 9 s i v t 2 L m HSWSHLO CLON SETINN VO SUV STUM TIV BATLINVIOOO Brae TE we nang G5 18A 2505H 25 5 MY8770B 2 REO INVIOOD TECHIARELIVM 2905 2 1 KI INVIOOO 90 IH REO 1 20 LM X X X Y H fag 3 E 1 E ai ei i E E E i i Oon NONE X X YYYYYYYYY E i aocuuoz x i 3 i T S SPRRAREISSUDSDDUSSEPRUSSLSSS SSRPS GND WOR E401 THM ANTO KWidO T OFOO0Td AQUOS ECOL VIRO dO ABO E i E NOW aA TOOT LAM 1 i
39. Continued Values for Magni Coating Fasteners Ref 4150701 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Torque SS TPI Bolt Dia Tensile Stress Clamp Load Loctite 242 or 271 or Loctite 262 or rea K 0 17 Vibra TITE 111 or 140 Vibra TITE 131 K 0 16 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 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 In Sq LB FT LB N m FT LB N m FT LB N m 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 238
40. Cylinder Cleaning Instructions G5 18A 2505H 25 5 2 Clean all metal parts with an approved cleaning solvent such as trichlorethylene Carefully clean cavities grooves threads etc Note If a white powdery residue is present on threads and parts it can be removed Clean the residue away with a soft brass wire brush prior to reassembly and wipe clean before reinstallation 8 12 4 1 Inspect internal surfaces and all parts for wear damage etc If the inner surface of the tube does not display a smooth finish or is scored or damaged in any way replace the tube Cylinder Inspection 2 Remove light scratches on the piston rod or inner surface of the tube with a 400 600 grit emery cloth Use the emery cloth in a rotary motion to polish out and blend the scratch es into the surrounding surface 3 Check the piston rod assembly for run out If the rod is bent it must be replaced 8 12 5 1 Use the proper tools for specific installation tasks Clean tools are required for assembly General Cylinder Assembly J MAH0160 1 2 Install new seals back up rings and o rings 2 the piston 4 and the head gland 6 8 27 Hydraulic System n Note The Crowd cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head 3 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod 5 to p
41. We Tee is iners zie Ora PROTA NOUNS gt HEE LIII FE rama rai noos E jii m o aana lose mare GNO 0 000 Dt D bd e900 1M Lil D mE i i 156 MEL HO 1 900 LHM SN ACELEI OMWEI QM UC 200 LHM 8 2 120 HM ex 2 GITROd VOR IH Bk i ea 238 TIN f 8 aw TU E i monis none 1 mO wes _ Sree mE i EFEEE FEE EN TEM Sy iin sess lt meres lt H AH o a lt MY8780B G5 18A 2505H 25 5 Electrical System h Cables and Boom Schematic m d BATA Isl E 4 I2 2 Q E 722 CY L da a Hii i PERE ii foe i e uv i inouezevo E _ n E LP B nemen E Se sox Ehad OMVE Bena 2100 E JE 8 2 ii m lt MY8790B 9 14 G5
42. change filters and inspect the fluid more often When servicing the system cap or plug hydraulic fittings hoses and tube assemblies Plug all cylinder ports valves and the hydraulic reservoir and pump openings until installation occurs Protect threads from contamination and damage Some hydraulic functions are actuated by interfacing with electrical system components switches solenoids and sensors When the hydraulic system is not functioning properly check the electrical aspect of the malfunctioning circuit also 8 4 SPECIFICATIONS Refer to Section 4 After connection has been properly tightened mark a straight line across the connecting parts not covering dots indicating that connection has been properly tightened for hydraulic system specifications 8 5 HOSES TUBE LINES FITTINGS ETC There are numerous hydraulic hoses tubes fittings etc used on this machine Periodically inspect all of these and carefully examine any signs of wear abrasion and or deterioration Determine whether any further use of the component would constitute a hazard If in doubt replace the component 8 5 1 Conditions including but not limited to the following are sufficient for considering component replacement Replacement Considerations 1 Any evidence of hydraulic fluid leakage at the surface of a flexible hose or its junction with the metal and couplings 2 Any blistering or abnormal deformation to the outer
43. oo Alco eo MU7740 1 With the estimated test weight on the forks start the machine and extend the boom horizontally until the machine starts to tip This point should be at an extension of Xtip 1 of the second boom section If the machine is not tipping at this extension weight needs to be added or removed from the forks 2 By confirming that the machine tips at this point the correct amount of weight is now on the forks 3 The machine control system must be powered on for at least 10 minutes before calibration 9 30 4 The machine must be on a level surface with the wheels steered straight and park brake OFF Drive the machine forward over a distance of at least 2 m 6 5 ft before entering a calibration point Place test weight on ground apply park brake and shut engine OFF Do Not move machine Field Calibration Procedure Note The following procedure must be completed within 30 minutes of starting the procedure 1 With ignition key in OFF position press and hold SYSTEM CHECK button on LSI display and turn ignition key to engine START position Release the ignition key when engine start is achieved but continue to hold SYSTEM CHECK button on LSI display until the orange LED on LSI display goes out and buzzer sounds approximately 3 seconds Release SYSTEM CHECK button The LEDs will perform a sequence When only the third green LE
44. 10W 30 9 70 22 21 SAE 15W 40 5 120 15 49 MobilFluid 424 10W 30 0 104 20 40 MobilFluid LT 75W 80 40 0 40 20 SAE 140 50 122 10 50 a a SW 122 10 50 Axle Differential and zs Wheel End API GL 4 with LS Additives SAE90 5 104 40 or 5 9015 GL5 with LS Additives 80W 90 85W 90 4 104 20 40 75W 90 40 104 20 40 75W 40 50 40 10 MobilFluid 424 10W 30 0 104 20 40 Hydraulic System Exxon Univis HVI 26 40 0 40 20 Brake System MobilFluid 424 10W 30 15 120 10 49 Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 4 104 20 40 Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 22 104 30 40 Boom Chain Lubricant Schaffer 200S Silver Streak 50 50 Mix Standard Engine Coolant Ethylene Glycol and Water 60 40 Mix Cold Weather 2 Diesel Standard B5 Biodiesel fuels Fuel Low Sulfur ME Blend of 1 diesel and 2 diesel fuels S lt 500 mg kg winterized 2 Cold Weather B5 Biodiesel with Winter Conditioner Air Conditioning Refrigerant R 134 a Tetrafluoroethane Note Friction Modifier be added to front axle differentials refer to Section 2 5 2 Capacities G5 18A 2505H 25 5 amp General Information and Specifications 2 5 2 Capacities Engine Crankcase Oil Capacity w Filter Change 9 6 qt 9 1 L Fuel Tank Capacity 24 gal 91 L Cooling System System Capacity 14 qt 13 2 L Hydraulic System System Capacity 24 gal 91 L Rese
45. 14 from rear of boom assembly Remove any miscellaneous parts such as mirror if they will interfere with removal of cylinder Label and disconnect tilt and if equipped auxiliary hydraulic hoses attached to machine on top of boom 15 Plug and cap hose ends to prevent dirt and debris from entering hydraulic system 14 15 16 17 18 8610 Loosen and remove both extend retract cylinder tubes 16 at rear of first boom section Plug tube ends to prevent dirt and debris from entering hydraulic system Loosen and remove both fittings 17 from bottom of extend retract cylinder barrel Plug openings in extend retract cylinder barrel Loosen and remove hardware 18 securing on cylinder barrel mounting pin Remove cylinder barrel mounting pin 19 Note location of spacers and washers Attach a sling or other suitable lifting device to extend retract cylinder and carefully pull cylinder free from machine through rear of boom chassis Note The tilt hoses and if equipped auxiliary hoses may need to be moved during removal of extend retract cylinder G5 18A 2505H 25 5 M P is 3 4 6 1 Carefully install the extend retract cylinder into rear of boom using a suitable sling Extend Retract Cylinder Installation 2 Line up barrel end of cylinder with pin bores on first boom section Note The tilt hoses and i
46. 15 Install the previously removed air dam 16 Install the previously removed inside firewall plate 17 Install the previously removed right front fender Do not tighten mounting bolts at this time 18 Connect the ECM connectors and secure the wire harness 19 Properly connect the battery 20 Remove any boom support 21 Run the engine to operating temperature Visually check for leaks with the engine running Check the coolant level in the surge tank and fill or drain as necessary Check the hydraulic oil level in the tank and add hydraulic oil as required Note Refer to Section 8 11 11 Variable Speed Fan Valve for detailed testing information 22 Retract and raise boom Install previously removed boom support Shut engine OFF Note previously removed install the right front tire and torque lug nuts to 220 Ib ft 300 Nm 23 Install the previously removed engine pod side skirt and belly pan Tighten all mounting bolts including the right front fender mounting bolts 24 Install the hood and secure with the previously removed mounting bolts 25 Install each gas strut and secure with the previously removed mounting nuts 26 Adjust hood as needed 27 Close and secure the engine cover G5 18A 2505H 25 5 Engine 28 Install and secure the battery cover 29 Remove previously installed boom support 30 Remove the Do Not Operate Tags from both the ignition key and the stee
47. 2165 2945 2030 2760 11 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 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 6 G5 18A 2505H 25 5 General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Magni Coating Fasteners Ref 4150701 SOCKET HEAD CAP SCREWS Torque Torque gt T Boltpia Tensile Stress Clamp Load Torque Loctite 242 or 271 or Loctite 262 or Area See Note 4 Dry K 0 17 Vibra TITE 111 or 140 or Vibra TITE 131 Precoat 85 K 0 16 K 0 15 In Sq 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 10 24 0 1900 0 01750 32 0 1900 0 02000 1 4 20 0 2500 0 0318 2860 122 14 114 13 28 0 2500 0 0364 3280 139 16 131 15 In Sq LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 25 35 20 25 20 25 3 8 16 0 3750 0 0775 7000 35 50 35 50 35 50 24 0 3750 0 0878 7900 40 55 40 55 35 50 7 16 14 0 4375 0 1063 9550 60 80 55 75 50 7
48. 25 5 9 45 Electrical System Fault EUN Deutz Description Codes Codes Codes Physical ran heck high for exhaust k pr n rner sh 765 523920 0 2 high for exhaust gas back pressure burner shut Physical ran heck low for exhaust k pr n rner shut 768 523920 1 2 eck low for exhaust gas back pressure burner shu 770 523920 3 Sensor error exhaust gas back pressure burner signal range check high 771 523920 4 Sensor error exhaust gas back pressure burner signal range check low 776 102 3 Sensor error charged air pressure signal range check high 777 102 4 Sensor error charged air pressure signal range check low 791 411 0 Physical range check high for differential pressure Venturi unit EGR 792 411 1 Physical range check low for differential pressure Venturi unit EGR 793 411 11 Sensor differential pressure Venturi unit EGR plausibility error 794 411 2 Sensor differential pressure Venturi unit EGR CAN signal invalid 795 411 3 Sensor error differential pressure Venturi unit EGR signal range check high 796 411 4 Sensor error differential pressure Venturi unit EGR signal range check low 805 524025 14 Particulate filter regeneration not successful 807 3253 2 Sensor differential pressure DPF plausibility error regarding signal offset Physical range check high for differential pressure
49. 3 5 5 D b sU 5 9 5 6 Wheels 5 10 5 7 Steering Angle 5 11 5 8 Brakes oer el Does te p p a edd owe HATTE Re ee UR 5 11 5 9 Towing a Disabled 1 5 12 Section 6 TRANSMISSION cr ex a iR Vnde a xD REA MET MEET 6 1 6 1 Transmission Assembly Component 6 2 6 2 Safety Information 6 3 6 3 Transmission 6 3 6 4 Transmission 6 3 6 5 Transmission 6 3 Section 7 7 1 7 1 Introduction 23 3 Eh 7 2 7 2 Engine Cooling System 7 4 7 8 Engine Electrical 7 7 7 4 Systemi waste dt Medaka D ESUA Abe wih sedans MULIERE 7 7 7 5 Engine Exhaust 1 7 8 7 6 Air Cleaner Assembly 3 visa
50. 30 minutes after starting procedure Calibration Procedure 1 Start and position the machine to perform the calibration procedure 2 Remove the standard carriage and weight assembly 3 Fully retract the boom and if equipped lower the outriggers Shut the machine OFF 4 With ignition key in OFF position press and hold SYSTEM CHECK button on LSI display and turn ignition key to engine START position Release the ignition key when engine start is achieved but continue to hold SYSTEM CHECK button on LSI display until the orange LED on LSI display goes out and buzzer sounds approximately 3 seconds Release SYSTEM CHECK button 5 The LEDs will perform a rolling sequence When only the third green LED illuminates press the SYSTEM CHECK button 6 The first green LED then illuminates With no attachment outriggers down if equipped and boom fully retracted lift boom to maximum boom angle G5 18A 2505H 25 5 Press the SYSTEM CHECK button on the LSI display and release The first 3 green LEDs will illuminate The third then second green LEDs will go out as the calibration point is recorded 8 The first green LED goes out and buzzer sounds 10 11 then the red LED illuminates Lower boom until level Pressing the LSI Override button may be required to lower the boom Attach the previously removed standard carriage forks and weight Slowly extend the boom until the rear axle weight in the follow
51. 9 Passive Time out Error of CAN Receive Frame TSC1TR 299 523788 12 Time out Error of CAN Transmit Frame TrbCH Status Wastegate 300 523605 9 Time out Error of CAN Receive Frame TSC1AE Traction Control 301 523606 9 Time out Error of CAN Receive Frame TSC1AR Retarder 305 898 9 Time out Error of CAN Receive Frame TSC1TE Set point 306 520 9 Time out Error of CAN Receive Frame TSC1TR Set point 322 523867 12 2 of CAN Transmit Frame UAA1 CAN 2 Burner Air 360 523982 0 Powerstage diagnosis disabled high battery voltage 361 523982 1 Powerstage diagnosis disabled low battery voltage 376 630 12 Access error EEPROM memory delete 377 630 12 Access error EEPROM memory read 378 630 12 Access error EEPROM memory write 381 411 4 Physical range check low for EGR differential pressure 383 2791 5 Actuator EGR Valve open load 384 2791 12 Actuator EGR Valve powerstage over temperature 385 2791 3 Actuator EGR Valve short circuit to battery 386 2791 4 Actuator EGR Valve short circuit to ground 387 523612 12 Internal software error ECU injection cut off 388 190 0 Overspeed detection in component engine protection 389 190 0 Engine speed above warning threshold FOC Level 1 390 190 11 Engine speed above warning threshold FOC Level 2 391 190 14 Engine speed above warning threshold Overrun Mode 412 108 3 Sensor error ambient air pressure signal range check high 413 108 4 Sensor error ambient air pressure signal range check low 417 171 3 Sensor error
52. Close and secure the battery and engine covers 7 Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 Electrical System 98 WINDOW WIPER WASHER 9 8 1 Windshield Wiper Motor MY2220 a Removal Note It may be necessary to remove several hydraulic hoses from under the dash in order to remove and install the wiper motor housing 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery 5 Remove the lower access panel below the instrument panel 6 Disconnect the right side defroster hose from dash panel hose connector 7 Disconnect the cab harness connectors from the wiper motor 8 Remove the linkage attached to the wiper motor 9 Loosen and remove the four bolts holding the wiper motor to the mounting bracket Note Reiain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing 10 Remove the motor from the inside of the cab G5 18A 2505H 25 5 b Disassembly DO NOT disassemble the motor The motor is not
53. 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 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 18 28 0 2500 0 0364 3280 139 16 181 15 In Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 25 35 20 25 20 25 3 8 16 0 3750 0 0775 7000 35 50 35 50 35 50 24 0 3750 0 0878 7900 40 55 40 55 35 50 7 16 14 0 4375 0 1063 9550 60 80 55 75 50 70 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 13 0 5000 0 1419 12750 90 120 85 115 80 110 20 0 5000 0 1599 14400 100 135 95 130 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 410 280 380 16 0 7500 0 3730 33600 355 485 335 455 315 430 7 8 9 0 8750 0 4620 41600 515 700 485 660 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 12 1 0000 0 6630 59700 845 1150 795 1080 745 1015 11 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 11 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 13 8 6 1 3750 1 1550 104000 2025 2755 1905 2590 1785 2430 12 1 3750 1 3150 118100 2300 3130
54. OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery Label or otherwise mark the hydraulic hoses in relation to the inching valve Disconnect and cap all hoses fittings etc Remove the capscrews that attach the valve to the frame Remove the inching valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine Inching Valve Disassembly Cleaning Inspection and Assembly Place the inching valve assembly on a suitable work surface Remove the cartridge 1 from the inching valve housing Clean all components with a suitable cleaner before inspection 8 19 n Hydraulic System 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 Inspect internal passageways of the inching valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS rep
55. Operation amp Safety 1 2 1 4 Do Not Operate iae viet bees 1 2 1 5 Safety Information 1 2 1 6 Safety 1 3 1 7 Safety Decals ict 1 4 Section 2 General Information and Specifications 2 1 2 1 Replacement Parts and Warranty 2 2 2 2 Thread Locking 2 2 2 3 Torque Charts eee A 2 3 2 4 Specifications REED RR a ER eee ee ee ete eee 2 14 2 5 Fluids Lubricants and Capacities 2 16 2 6 Maintenance Schedule 2 19 2 7 Lubrication Schedule evista aden sada ae 2 22 Section 3 BOOM etis wa henna ea teres 3 1 3 1 Boom System Component 3 2 3 2 Safety Information 1 3 3 3 3 Two Section Boom System 3 3 3 4 Boom Assembly 3 3 3 5 Boom Wear Pads csse e past
56. Switch engine speed control parameter short circuit to battery 842 523451 4 Eit Switch engine speed control parameter short circuit 843 523451 2 Multiple Stage Switch engine speed control parameter plausibility error 844 523452 3 Multiple Stage Switch engine torque limitation curve short circuit to battery 845 523452 4 Multiple Stage Switch engine torque limitation curve short circuit to ground 9 46 G5 18A 2505H 25 5 Electrical System Fault N Deutz Description Codes Codes Codes 846 523452 2 Multiple Stage Switch engine torque limitation curve plausibility error 849 1176 3 Sensor error pressure sensor upstream turbine signal range check high 850 1176 4 Sensor error pressure sensor downstream turbine signal range check high 856 523613 0 Maximum positive deviation of rail pressure exceeded RailMeUnO Maximum positive deviation of rail pressure in metering unit 857 269013 9 exceeded i 858 523613 0 Rail system leakage detected RailMeUnlO Maximum negative deviation of rail pressure in metering unit ii 9 RailMeUn2 P j 860 523613 0 Negative deviation of rail pressure second stage RailMeUn22 861 523613 1 Minimum rail pressure exceeded RailMeUn3 862 523613 0 Maximum rail pressure exceeded RailMeUn4 864 523613 2 Set point of metering unit in overrun mode
57. both ignition key switch and steering wheel 5 Properly disconnect battery 6 Open engine cover Allow system fluids to cool 7 If the axle will be disassembled after removal the oil will have to be drained Loosen the breather to release possible internal pressure then tighten breather with a torque wrench to 9 Ib ft 12 Nm 2091 A 5 4 8 If axle will be disassembled after removal place a suitable receptacle under axle 1 drop box 2 and wheel hubs 3 drain plugs 4 Remove drain plugs and allow axle oil to drain into receptacle Transfer used axle oil into a suitable covered container and label container as Used Oil Dispose of used oil at an approved recycling facility 9 Label disconnect and cap steering and brake lines at axle Wipe up any spilled oil 10 Block front and rear of both tires on axle that is not being removed Ensure that machine will remain in place during axle removal before proceeding 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 remain in place during axle removal 12 Support axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise axle or machine 13 Mark and remove both wheel and tire
58. cab have the assistant turn the ignition key switch to the RUN position DO NOT start the engine Observe the fuel level indicator needle on the operator s instrument cluster Turn the ignition key switch to the OFF position The fuel level indicator needle should return to the EMPTY position Fuel Level Circuit Tests If the fuel level indicator is suspected of giving a false reading perform the following checks 1 If the fuel level indicator needle does not move check the fuel tank for fuel Check for loose or defective wiring faulty ground connections or corrosion on the fuel tank sender and wiring lead If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN position use a test lamp to determine whether current is flowing from the ignition switch to the fuel level sender If the fuel level indicator does not move and a faulty or defective fuel level sender in the fuel tank has been ruled out and in addition wiring and connectors have been checked and ruled out the fuel level indicator is defective and the instrument cluster must be replaced 9 23 Electrical System 5 Check that the ignition terminal has current and that the fuse in the fuse panel is not blown 6 Check for broken shorted frayed disconnected or damaged wiring between the fuel level indicator wiring at the cab fuse and relay panel ignition key switch and from
59. check low Actuator position for EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 1016 51 7 not plausible 1017 51 5 Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 open load Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 power stage 1018 51 12 over temperature 1019 51 3 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to battery 1020 51 4 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground 1021 51 12 Mechanical actuator defect EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check 1022 51 6 high 1023 51 5 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check low Position sensor error of actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 1024 51 3 signal range check high Position sensor error actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal 1025 51 4 range check low 1026 4769 2 Sensor exhaust gas temperature downstream DOC plausibility error 1029 4766 0 Physical range check high for exhaust gas temperature downstream DOC 1032 4766 1 Physical range check low for exhaust gas temperature downstream DOC 1034 4769 3 Sensor error exhaust gas temperature downstream DOC signal range check high 1035 4769 4 Sensor error exhaust gas temperature downstream DOC signal range check low 1036 4768 2 Sensor exhaust gas temperature upstream DOC plausibility error 103
60. circuit Enable Output Circuit Module Telescope Enable 1 Latched Check wiring to Valve Short to 33440 The module is detecting Deactivate Telescope Pin J1 10 on the Ground short to B Enable Output Battery Module Passive Mode The module is detecting a Latched Check wiring to Indicator Short to 33441 9 Deactivate Indicator Output Pin J1 12 on the Ground short to ground Ground Module This fault can only be Passive Mode detected if the machine is Latched Check wiring to Indicator Short to 33442 configured for the CE Deactivate Indicator Output Pin J1 12 on the Ground Battery market The module is Module detecting short to B Not Latched Battery Voltage Battery voltage is less than Revert to normal ow D 441 9V for at least 250ms and Deactivate all Module operation when battery y engine is not in a cranking Outputs voltage greater than or Shutdown state equal to 11V for at least 1000mS Battery voltage greater than Deactivate all Module Latched 100 High Syster Tu 16V for at least 250mS Outputs Fix supply voltage Shutdown p pply g Sensor r E Limit all lift down speed to Latched Check wiring to 4578 p Creep mode without Pins J2 1 J2 2 on the activating LSI Cutout Ground Module G5 18A 2505H 25 5 9 35 Electrical System Out of Range and OMD reading is 100 Trigger Possible Latch Reset Help Message DTC Symptom Action
61. covering of a hydraulic hose 3 Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by normal tightening or other recommended procedures 4 Evidence of excessive abrasion or scrubbing on the outer surface of a hose rigid tube or hydraulic fitting Modification must be made to eliminate the interference of the elements in contact with one another or to otherwise protect the components from contact with one another Slightly moving a hose or adjusting a plastic tie wrap may often be all that is necessary to eliminate interference evaluate each situation and proceed as required by the individual circumstances 8 5 2 Hose Tube Line and Fitting Replacement Before removing a hydraulic hose or component always mark or otherwise label the related parts and the exact location of the hose or component to aid in proper reinstallation Hydraulic fluid is a good cleaner and can remove most liquid ink type markings so make sure the mark or label will remain intact Alternative methods to using markers include color coded tie wraps number tag sets alpha numeric stampings or markings and suitably labeled pieces of tape Select an appropriate marking method for the conditions and proceed accordingly G5 18A 2505H 25 5 833 Hydraulic System NEVER replace hydraulic hose or other component with a part not specifically designed for this machine Use only factory approved parts for best p
62. drive belt Check for proper fan belt deflection Reattach the previously labeled electrical wires to the alternator Properly connect the battery Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel 9 17 Electrical System 97 ELECTRICAL SYSTEM COMPONENTS 9 7 1 The back up alarm is located at the rear of the machine Back up Alarm When the park brake is released and the transmission shift control switch transmission control lever is shifted to the R REVERSE position the back up alarm will automatically sound CE Only Place the transmission control lever in R REVERSE to test the back up alarm The back up alarm must not sound when the transmission control lever is in N NEUTRAL or F FORWARD Also with the ignition key switch in the RUN position the back up alarm will sound when the transmission control lever is shifted into the R REVERSE position a Disassembly DO NOT disassemble the back up alarm Replace a defective or faulty alarm with a new part b Inspection and Replacement Inspect the wiring harness connector and alarm terminals for continuity and shorting Test the alarm by turning the ignition key switch to the RUN position and shifting the transmission control lever into the REVERSE position The alarm should sound Replace a defective or faulty alarm with a new part 9 7 2
63. hydraulic hoses fittings solenoid wire terminal leads etc to the steer select valve and manifold 3 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 4 Properly connect the battery 5 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions 6 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 7 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools G5 18A 2505H 25 5 Hydraulic System 8 Close and secure the battery and engine covers 9 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 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 3 Select the 2 wheel steer mode and turn the steering wheel until the left front wheel is aligned with the frame 4 With the wheel now aligned select the desired steer mode 5 If further troubleshooting is required refer to Section 8 6 5 Stee
64. i Torque Loctite 262 or i TM Sizo Pitch pe Note4 Dry or TUM 263 Torque Lub 271 De Vibra TITE 131 111 141 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 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 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 G5 18A 2505H 25 5 General Information and Specifications 2 3 2 Metric Fastener Torque Chart Continued Values for Zinc
65. if LSI Out of CAN CHECK PT or is not s 8519 AR being completed suppress LSI is calibrated or LSI Calibration within tolerance during a LSI Cutout during the CAN System Check i SFERAT OM TROLS aLa subsequent 1 2 CAN SYSTEM CHECK p procedure Permit LSI CAN Display to control its internal alarm The LSI System has Default machine to LSI Cutout if not in passive detected a checksum error Lol Faulty with its system flash and is mode or notin ES Latched Possibl System Flash CRC 99152 y calibration mode with reporting the issue replace LSI gauge Error operation only available via bus message to the Ground LSI Cancel switch Creep Module Mode operation Default hi The LSI System has ESI Cutout if not in passive detected a checksum error mode or not in LSI LSI Faulty Data with its system flash and is SM Latched Possibly 99153 calibration mode with Flash CRC Error reporting the issue on a CAN replace LSI gauge operation only available via bus message to the Ground LSI Override switch Creep Module Mode operation The ESL Systeam has Default machine to LSI detected a unacceptable Cutout if not in passive LSI Faulty Load Vallance Im ne readings mode or not in LSI y between Load Cell A and ae Latched Possibly Cells A and B 99154 calibration mode with Load Cell and is reporting f replace LSI gauge Dis
66. intake air sensor signal range check low 983 172 2 Intake air sensor plausibility error 984 523921 11 Sensor burner temperature plausibility error 986 523921 0 Physical range check high for burner temperature 989 523921 1 Physical range check low for burner temperature 994 105 3 Sensor error charged air temperature signal range check high 9 48 G5 18A 2505H 25 5 Electrical System Eu Deutz Description Codes Codes Codes P 995 105 4 Sensor error charged air temperature signal range check low 996 105 0 High charged air cooler temperature warning threshold exceeded 997 105 0 High charged air cooler temperature shut off threshold exceeded 1007 412 3 Sensor error EGR cooler downstream temperature signal range check high 1008 412 4 Sensor error EGR cooler downstream temperature signal range check low 1009 412 2 Sensor exhaust gas temperature Venturi unit EGR plausibility error 1011 523960 0 Physical range check high for EGR cooler downstream temperature 1012 523960 1 Physical range check low for EGR cooler downstream temperature 1013 523960 11 Sensor exhaust gas temperature Venturi unit EGR plausibility error Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check 1014 51 6 high 1015 51 5 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range
67. mounting plate Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 2 Use new oiled o rings as required Uncap reattach and secure the three hoses 3 Check the routing of all hoses for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required 4 Properly connect the battery 5 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 8 17 Hydraulic System 4 Inspect the hand brake valve and connections for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF 7 Install the hand brake cover with the two capscrews 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 9 Close and secure the battery and engine covers 10 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 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 the Section 8 7 Hydraulic Schematic or Section 9 4 Electrical System Schematics 8 11 5
68. secure lower dash cover Properly connect battery Close and secure engine cover Remove a Do Not Operate Tag on both ignition key switch and steering wheel aj ce 4 4 4 Accelerator Pedal Replacement b Accelerator Pedal Installation a Accelerator Pedal Removal 1 Reconnect sensor 13 to pedal assembly 2 Align pedal assembly with its mount holes under 1 Park machine on a hard level surface cab dash 2 Fully retract boom lower boom place transmission 3 Install hardware 12 securing pedal assembly control lever in NEUTRAL to mount 3 Engage park brake and shut engine OFF 4 Properly connect the battery 4 Place a Do Not Operate Tag on both ignition key 5 Close and secure engine cover switch and steering wheel 3 6 Remove a Do Not Operate Tag on both ignition key 5 Properly disconnect battery switch and steering wheel 6 Open engine cover Allow system fluids to cool MY8870 7 Remove hardware 12 securing pedal assembly to cab frame 8 Disconnect sensor 13 from pedal assembly 9 Remove accelerator pedal assembly from cab 4 6 G5 18A 2505H 25 5 cab as 4 4 5 Joystick Replacement a Joystick Removal 1 Park machine on a hard level surface KR OD Fully retract boom lower boom place transmission control lever in NEUTRAL Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignitio
69. serviceable Replace motor if found to be defective c Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found d Installation and Testing 1 Install all required hardware to the motor assembly 2 Align motor with the mounting holes and bolt the motor to the mounting bracket 3 Connect the wiper linkage to the wiper motor shaft Note Align the wiper linkage arm with the flat on the motor shaft to ensure wiper stroke covers window area and it does not swipe past the glass area 4 Connect the cab harness connectors to windshield wiper motor connectors 5 Properly connect the battery 6 Turn ignition key switch to the RUN position and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved 7 Install right side defroster hose to the dash panel hose connector 8 If previously removed install hydraulic hoses under the dash 9 Install the lower dash panel 10 Close and secure the battery and engine covers 11 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 9 19 Electrical System 9 8 2 Rear Window or Roof Wiper Motor if eq MY2520 a Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage th
70. that are referred to throughout this section FUEL PUMP FUEL FILTER OIL FILTER ALTERNATOR TURBOCHARGER STARTER MY8930 G5 18A 2505H 25 5 7 3 Engine 7 2 ENGINE COOLING SYSTEM 7 2 1 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 Surge Tank Cap 7 2 2 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 Radiator Oil Cooler Replacement f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position f 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 a Radiator Oil Cooler Removal 1 Park the machine on a firm level surface fully retract the boom raise and support the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated MY8970 3 Open the engine cover A
71. the Safety Practices section of this manual 5 3 GENERAL INFORMATION Before performing any inspection maintenance or service operation thoroughly clean the unit The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts Carefully inspect the integrity of all moving parts bearings yokes tubes gears shafts etc and fasteners nuts bolts washers etc as they are subject to major stress and wear 5 4 AXLE ASSEMBLIES 5 4 1 The front and rear axle serial number plate is located on the inside of each axle on the right side of the center section Information on the serial number plate is required in correspondence regarding the axle Axle Serial Number Plate Supply information from the axle serial number plate when communicating about an axle assembly or axle componenis 5 4 2 General axle specifications are found in Section 2 General Information and Specifications Axle Specifications 5 4 3 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 Ax
72. the pump cap all fittings and plug hoses to keep dirt amp debris from entering hydraulic system Disconnect the electrical connector 3 on the proportional valve MY8660 Support the motor and remove the four bolts 4 securing the motor to the front axle 8 12 8 10 2 1 Front Drive Motor Installation Install the motor onto the front axle and secure with the four previously removed bolts 4 Torque to 72 lb ft 97 Nm Use only new seals Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations Fill the motor with hydraulic fluid through the fill plug 5 before starting the machine Refill the hydraulic reservoir and inspect for leaks around the machine Properly connect the battery 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 Inspect for leaks and check all fluid levels Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 Hydraulic System n 8 11 CONTROL VALVES 8 11 1 The main control valve is mounted on the rear of the machine behind the rear access panel Main Control Valve FRONT OF MACHINE 2 3 4 5 The main control valve assembly consists of various working sections with their own valve assemblies each pr
73. the tie rods out through the sections 2 Disassemble each section assembly as required Some sections include a pre adjusted relief valve that regulates pressure in a specific circuit DO NOT adjust any of the relief valve assemblies Tampering with a relief valve will irrevocably alter pressure in the affected circuit requiring re calibration or a new relief valve Disassemble each Valve Section 1 Carefully separate the end cover section from the lift lower section 2 Remove the o rings from between the two sections 3 Carefully separate each remaining section and remove all o rings and seals 4 Remove any plugs check valves compensator valves anti cavitation valves shock valves or the rectangular hydraulic remote positioners from each individual valve section if equipped 5 Keep all parts being removed from individual valve sections tagged and kept together c Main Control Valve Parts Cleaning Clean all components with a suitable cleaner such as trichlorethylene before continuing Blow dry d Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear damage etc If inner surfaces of any component DO NOT display an ultra smooth polished finish or are damaged in any way replace the damaged part Often dirty hydraulic fluid causes failure of internal seals damage to the polished surfaces within the component and wear of and or harm to other parts 8 13 H
74. tipping turning or falling while positioning it beneath the machine DO NOT raise or otherwise disturb the machine while installing the axle Keep the axle supported and balanced on the jack hoist or overhead crane and sling throughout the installation procedure Position the axle under the frame and align with the holes in the frame Install the axle with capscrews locknuts and the axle plates Torque the front and rear axles to 420 Ib ft 569 Nm Install the drive shaft assemblies Refer to Section 5 5 5 Drive Shaft Installation 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 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 5 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 5 Fluids Lubricants and Capacities for proper oil and capacities Install the wheel and tire assemblies Refer to Sec
75. voltage signal range check low 76 523914 5 Glow plug control open load 77 523914 12 Glow plug control powerstage over temperature 78 523914 3 Glow plug control short circuit to battery 79 523914 4 Glow plug control short circuit to ground 82 1235 14 CAN Bus error passive warning CAN C 84 639 14 CAN Bus 0 BusOff Status 85 1231 14 CAN Bus 1 BusOff Status 86 1235 14 CAN Bus 2 BusOff Status 88 102 2 Charged air pressure above warning threshold 89 102 2 Charged air pressure above shut off threshold 96 110 3 Sensor error coolant temperature signal range check high 97 110 4 Sensor error coolant temperature signal range check low 98 110 0 High coolant temperature warning threshold exceeded 99 110 0 High coolant temperature shut off threshold exceeded 101 111 1 Coolant level too low 109 523929 0 Fuel Balance Control integrator injector 1 in firing order maximum value exceeded 110 523930 0 Fuel Balance Control integrator injector 2 in firing order maximum value exceeded 111 523931 0 Fuel Balance Control integrator injector 3 in firing order maximum value exceeded 112 523932 0 Fuel Balance Control integrator injector 4 in firing order maximum value exceeded 113 523933 0 Fuel Balance Control integrator injector 5 in firing order maximum value exceeded 114 523934 0 Fuel Balance Control integrator injector 6 in firing order maximum value exceeded 115 523929 1 Fuel Balance Control integrator injector 1 in firing order minimu
76. wheel being removed Raise the machine and position a suitable support beneath the axle Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly 5 Lower the machine onto the support 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 Axles Drive Shafts Wheels and Tires hs 5 6 2 Installing Wheel and Tire Assembly onto Machine Note The wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel TREAD ARROWS MUST POINT FORWARD INSTALL TIRES ONTO WHEELS TO ROTATE IN PROPER DIRECTION 460 1 Position wheel onto studs wheel 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 4 Tighten lug nuts in an alternating pattern as indicated in figure Torque to 221 Ib ft 300 Nm 5 Remove machine from supports 6 Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 5 7 STEERING ANGLE ADJUSTMENT Detailed axle service instructions are provided in the Axle Disassembly amp Assembly Manual P N 31200451 5 8 BRAKES 5 8 1 Brake Disc Inspection Detailed axle service instructions are provided in the Front Ax
77. 0 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 11 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 11 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 13 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 11 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 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 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 G5 18A 250
78. 0 Fuel Balance Control integrator injector 8 in firing order maximum value exceeded 1269 523989 1 Fuel Balance Control integrator injector 7 firing order minimum value exceeded 1270 523990 1 Fuel Balance Control integrator injector 8 firing order minimum value exceeded 1279 523992 9 Time out Error of CAN Receive Frame DM19Voll NOX sensor upstream 1283 523993 9 Time out Error of CAN Receive Frame DM19Vol2 NOX sensor downstream 1285 524038 9 Time out error of CAN Receive Frame ComMS SysITO error memory Slave Master Slave internal CAN message 1286 524039 9 Time out error of CAN Receive Frame ComMS_Sys2TO error memory Slave Master Slave internal CAN message 1287 524040 9 Time out error of CAN Receive Frame ComMS_Sys3TO error memory Slave Master Slave internal CAN message 1288 524041 9 Time out error of CAN Receive Frame ComMS_Sys4TO error memory Slave Master Slave internal CAN message 1289 524042 9 Time out error of CAN Receive Frame ComMS_Sys5TO error memory Slave Master Slave internal CAN message 1290 524043 9 Time out error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message Master Slave CAN Message Counter Error of CAN Receive Frame 1291 524045 9 ComMSMoFOvR 1292 524046 9 Master Slave CAN Checksum Error of CAN Receive Frame ComMSMoFOvR Master Slave CAN Messsage Length Error of CAN Receive Frame 1293 524047 9 ComMSMoFOvR 1294 524048 9 Time out error CAN message C
79. 00 255 345 238 324 225 306 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 11 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 11 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 13 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 11 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 NOTES 1 THESE TORQUE VALUES DO 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 G5 18A 2505H 25 5 2 5 General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Magni Coating Fasteners Ref 4150701 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque SES TPI Bolt Dia fons Stress Clamp Load Dry PEU nga 263 Loctite amp 242 or 271 or Loctite 2627 or rea K 0 17 Vibra TITE 1110r140 Vibra TITE 131 K 0 16 K 0 15 In Sq In LB IN LB N m IN LB N m IN
80. 18A 2505H 25 5 Electrical System 9 5 ENGINE START CIRCUIT 9 5 1 Starter MY8810 The starter 1 is located on the right side of the engine attached to the bell housing a Testing the Starter on the Engine Note The operator must be sitting on the seat to enable the starting circuit the starter does not engage when the ignition key switch is turned check the following 1 The transmission control lever is in N NEUTRAL and the park brake switch is set 2 The main fuse may be blown requiring replacement Check for the cause of the blown fuse 3 There may be a defect in the ignition key switch ignition wiring or starter solenoid 4 Check battery condition Clean the battery posts and the connectors at each end of the battery cables 5 Check for broken wiring and damaged insulation on the wiring Replace all broken or damaged wiring 6 Check all connections at the starter solenoid key switch and wiring harness plugs Clean and tighten all connections 7 Ifthe starter still does not operate after these checks have been performed check the starting circuit b Starter Circuit Checks 1 Check wires and connections for looseness corrosion damage etc 2 whirring noise is heard but the engine does not turn over the starter is spinning but not engaging the flywheel The starter drive or solenoid that pushes G5 18A 2505H 25 5 the drive forward to engage t
81. 2 1 3750 1 3150 73000 1680 2278 1260 1708 1750 2380 1506 2042 11 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 CADMIUM PLATED FASTENERS 5000059K 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER G5 18A 2505H 25 5 General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque Size Bolt Dia Stress Clamp Load Dry 242 or 271 or 262 K 0 20 Vibra TITE 111 0r140 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 37
82. 2 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 4622 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 11 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 11 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 13 8 6 1 3750 1 1550 64100 1460 1979 1100 1491 1525 2074 1322 1792 1
83. 2336 depressed at Startup or for librati d d Modul d integrity of Invalid Signal longer than 40seconds Sa ration modaj an SAUS ane disregard LSI Cancel mechanical switch Switch Input override Deactivate Lift Down Valve Lift Down Valve The module is detecting Output Also deactivate Lift Cneck wining to 335 App up Pin J1 8 on the Ground Short to Battery short to B Enable if machine is in Module LSI Cutout Latched Check wiring to Lift Down Valve 336 The module is detecting an Deactivate Lift Down Pin 21 8 on the Ground Open Circuit open circuit Output Module Telescope Out The desired current is DIA Deactivate Telescope Out Latched Check wiring to and the digital output driver s Output Also deactivate Valve Short to 33123 Pin J1 9 on the Ground Battery diagnostic feedback is low Telescope Enable if Module for a period of 250ms machine is in LSI Cutout Lift Enable Valve The module is detecting a Deactivate Lift Enable parched Cheek winna to 33159 Pin J1 7 on the Ground Short to Ground short to ground Output Module Latched Check wiring to Lift Enable Valve 33160 The module is detecting an Deactivate Lift Enable Pin 24 7 on the Ground Open Circuit open circuit Output Module 9 34 G5 18A 2505H 25 5 Electrical System Voltage Out of Range sensor voltage is less than 0 2
84. 3 523602 0 High fan speed shut off threshold exceeded 464 97 3 Sensor error water in fuel signal range check high 465 97 4 Sensor error water in fuel signal range check low 472 94 3 Sensor error low fuel pressure signal range check high 473 94 4 Sensor error low fuel pressure signal range check low 474 94 1 Low fuel pressure warning threshold exceeded 475 94 1 Low fuel pressure shut off threshold exceeded 481 174 0 High low fuel temperature warning threshold exceeded 482 174 0 High Low fuel temperature shut off threshold exceeded 488 523619 2 Physical range check high for exhaust gas temperature up stream SCR CAT 500 523915 0 HCI dosing valve DV1 over current at the end of the injection phase 501 523915 12 HCI dosing valve DV1 powerstage over temperature 502 523915 3 HCI dosing valve DV1 short circuit to battery 503 523915 3 HCI dosing valve DV1 short circuit to battery high side 504 523915 4 HCI dosing valve DV1 short circuit to ground 505 523915 11 HCI dosing valve DV1 short circuit high side powerstage 506 523916 2 Sensor HCI dosing valve DV1 downstream pressure plausibility error Physical ran heck high for ing valve DV1 wnstream pr re 508 523916 eck high for HCI dosing valve downstream pressure shut 511 523916 1 4 check low for dosing valve DV1 downstream pressure shut off 514 523916 3 Sensor error HCI dosing valve DV1 downstream pressure signal range check high 515 523916 4 Sensor error
85. 4 2 Fuel Hydraulic Oil 7 7 7 4 3 After Fuel System 7 8 7 5 Engine Exhaust 7 8 7 5 1 Exhaust System 7 8 7 5 2 Exhaust System Installation 7 9 7 6 Air Cleaner lt 7 10 7 6 1 Air Cleaner Assembly Removal 7 10 7 6 2 Air Cleaner Assembly 7 10 7 7 Engine Replacement osc scene Re a RR 7 11 7 7 1 Engine Removal s hee bd eee Ue RH 7 11 7 7 2 Engine Disassembly Inspection and 7 12 7 7 3 Engine 7 12 G5 18A 2505H 25 5 Engine 7 1 INTRODUCTION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual A WARNING Engine fuel lines are pressurized DO NOT attempt repairs unless specific training has been completed 7 1 1 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 dime
86. 40 MobilFluid LT 75W 80 40 0 40 20 SAE 140 50 122 10 50 80W 140 14 122 10 50 Axle Differential an Wheel End API GL 4 with LS Additives SAE90 164 0 40 or SAE90LS API GL5 with LS Additives 80W 90 85W 90 4 104 20 40 75W 90 40 104 20 40 75W 40 50 40 10 MobilFluid 424 10W 30 0 104 20 40 Hydraulic System Exxon Univis 26 40 0 40 20 Brake System MobilFluid 424 10W 30 15 120 10 49 Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 4 104 20 40 Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 22 104 30 40 Boom Chain Lubricant Schaffer 200S Silver Streak Ethylene Glycol 50 50 Mix Standard Engine Coolant and Water 60 40 Mix Cold Weather 2 Diesel Standard B5 Biodiesel fuels Ultra Low Sulfur Fuel Blend of 1 diesel and 2 diesel fuels 5 lt 15 mg winterized 2 kg Cold Weather B5 Biodiesel with Winter Conditioner Air Conditioning Refrigerant R 134 a Tetrafluoroethane Note Friction Modifier may be added to front axle differentials refer to Section 2 5 2 Capacities 2 16 G5 18A 2505H 25 5 General Information and Specifications b If Equipped for LS Ambient Temperature Range Type and Classification Viscosities F System Min Max Min Max SAE OW 30 20 0 29 18 SAE 5W 30 15 70 26 21 Engine Crankcase API Cl 4 Plus SAE
87. 50 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 11 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 11 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 13 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 11 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 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 G5 18A 2505H 25 5 General Information and Specifications 2 3 1 SAE Fastener Torque Chart
88. 50 psi 17 bar Fittings One 9 16 18 UNF 6 ORFS Cap One 9 16 18 UNF 6 ORFS Plug Note Machine axle fittings are 9 16 18 UNF 6 ORFS The adaptor size may vary depending on the hose end of the auxiliary hydraulic power supply G5 18A 2505H 25 5 Axles Drive Shafts Wheels and Tires hs 5 9 2 1 Securely block all four wheels Towing Procedure Ne y MYesto 2 Loosen shuttle valve 1 on hydrostatic transmission until it hits against stop 2 Note This procedure does not alter any relief settings 4 Not Shown oQ MY2050 Y 3 4 3 Connect an auxiliary hydraulic power supply to P1 port 3 on front axle and apply 220 435 psi 15 30 bar to release the park brake Note DO NOT apply more than 450 psi 31 bar to release the park brake Excessive pressure could damage the axle brake system 4 Loosen unlocking bolts 4 located at front and back side of axle housing and remove stop washers 5 Tighten unlocking bolts against axle housing 6 Release pressure from auxiliary hydraulic power supply and remove auxiliary hydraulic power supply 7 Carefully remove blocking from each tire and tow machine to a secure location 8 After machine has been towed to a secure location block all four wheels G5 18A 2505H 25 5 9 Tighten relief valve 1 on hydrostati
89. 5H 25 5 2 7 General Information and Specifications 2 3 1 SAE Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Ref 4150707 SOCKET HEAD CAP SCREWS Torque Torque Ste Bolt Dia__ Tensile Stress Clamp Load Torque Loctite 242 or 271 or Loctite 262 or Area See Note 4 Dry K 0 17 Vibra TITE 111 or 140 or Vibra TITE 131 Precoat 85 K 0 16 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 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 Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 25 35 20 25 20 25 3 8 16 0 3750 0 0775 7000 35 50 35 50 35 50 24 0 3750 0 0878 7900 40 55 40 55 35 50 7 16 14 0 4375 0 1063 9550 60 80 55 75 50 70 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 13 0 5000 0 1419 12750 90 120 85 115 80 110 20 0 5000 0 1599 14400 100 135 95 130 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0
90. 5V or greater than 4 75V Trigger Possible 2 Latch Reset Help Message DTC Symptom Actions Condition Lift Enable Valve The module is detecting Deactivate Lift Enable 869 Check wiring to 33161 Pin J1 7 on the Ground Short to Battery short to B Output Module The module is detecting Deactivate Telescope cheer waning Valve Open 33186 died Pin J1 9 on the Ground AA open circuit Out Output Circuit Module Telescope Out Latched Check wiring to Valve Short to 33188 The module is detecting a Deactivate Telescope Pin J1 9 on the Ground short to ground Out Output Ground Module Lift Down Valve The module is detecting a Deactivate Lift Down Latghed Sheck wing 33407 Pin J1 8 on the Ground Short to Ground short to ground Output Module Function Enable The module is detectin Latched Check wiring to Output Short to 33438 9 Deactivate Function Enable Pin J1 11 on the Ground short to B Battery Module Function Enable The mod le isdetecti ga Latched Check wiring to Output Short to 33443 9 Deactivate Function Enable Pin J1 11 on the Ground short to ground Ground Module Telescope Enable Latched Check wiring to Valve Short to 33444 The module is detecting a Deactivate Telescope Pin J1 10 on the Ground short to ground Enable Output Ground Module Telescope Enable Latched Check wiring to Valve Open 33439 The module is detecting Deactivate Telescope Pin 21 10 on the Ground aM open
91. 6 Ib ft 35 Nm and finally to 52 59 Ib ft 70 80 Nm 6 Permanently mark position of bolt head and sensor body 7 Leave the machine undisturbed for a minimum of 6 hours before moving 8 Plug the electrical connector into the sensor assembly 9 Properly connect the battery G5 18A 2505H 25 5 10 Close and secure the battery and engine covers 11 Remove the Do Not Operate Tag from the ignition key switch and the steering wheel 12 Calibrate the LSI system refer to Section 9 11 4 LSI System Calibration 9 11 2 LSI Boom Sensors MAM2910 The LSI sensors 2 are bolted on the left inside of the first boom section a LSI Boom Sensor Removal 1 Remove any fork carrier or attachment from the machine 2 Park the machine on a firm level surface level the machine fully retract the boom fully raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the battery and engine covers Allow the engine to cool 5 Properly disconnect the battery 6 Disconnect the LSI electrical connectors 7 Loosen and remove the two bolts holding the LSI assembly to the side of the boom 8 Remove and discard the sensor assembly 9 27 Electrical System b LSI Sensor Boo
92. 672 524118 9 Time out error of CAN Receive Frame ComRxCMI 1673 524119 9 Time out error of CAN Receive Frame ComRxCustSCR3 1673 524119 9 Time out error of CAN Receive Frame ComRxCustSCR3 1674 524102 9 Time out error of CAN Receive Frame ComRxDPFBrnAirPmpCtl 1674 524102 9 Time out error of CAN Receive Frame ComRxDPFBrnAirPmpCtl 1675 524103 9 Time out error of CAN Receive Frame ComRxDPFBrnAirPmp 1675 524103 9 Time out error of CAN Receive Frame ComRxDPFBrnAirPmp 1676 524104 9 Time out error of CAN Receive Frame ComRxDPFCtl 1676 524104 9 Time out error of CAN Receive Frame ComRxDPFCtl 1677 524106 9 Time out error of CAN Receive Frame ComRxEGRMsFlwl 1677 524106 9 Time out error of CAN Receive Frame ComRxEGRMsFlwl 1678 524107 9 Time out error of CAN Receive Frame ComRxEGRMsFlw2 1678 524107 9 Time out error of CAN Receive Frame ComRxEGRMsFlw2 1679 524109 9 Time out error of CAN Receive Frame ComRxEGRTVActr 1679 524109 9 Time out error of CAN Receive Frame ComRxEGRTVActr 1680 524111 9 Time out error of CAN Receive Frame ComRxETVActr 1680 524111 9 Time out error of CAN Receive Frame ComRxETVActr 1681 524113 9 Time out error of CAN Receive Frame ComRxITVActr 1681 524113 9 Time out error of CAN Receive Frame ComRxITVActr 1682 524120 9 Time out error of CAN Receive Frame ComRxSCRHtDiag 1682 524120 9 Time out error of CAN Receive Frame ComRxSCRHiDiag 1683 524121 9 Time out error of CAN Receive Frame ComRxTrbChActr 1683 524121 9 Time out error of CAN Receive Frame Com
93. 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 11 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 11 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 13 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 11 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 NOTES 1 THESE TORQUE VALUES DO 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 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 8 G5 18A 2505H 25 5 General Information and Specifications 2 3 2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC HEX SOCKET HEAD BOLTS CLASS 8 METRIC NUTS Torque a Torque
94. 9 4765 0 Physical range check high for exhaust gas temperature upstream DOC 1042 4765 1 Physical range check low for exhaust gas temperature upstream DOC 1044 4768 3 Sensor error exhaust gas temperature upstream DOC signal range check high 1045 4768 4 Sensor error exhaust gas temperature upstream DOC signal range check low 1047 3248 Sensor error particle filter downstream temperature signal range check low 1066 1180 11 Sensor exhaust gas temperature upstream turbine plausibility error 1067 1180 3 Sensor error exhaust gas temperature upstream turbine signal range check high G5 18A 2505H 25 5 9 49 Electrical System ee ud Deutz Description 1068 1180 4 4 exhaust gas temperature upstream turbine signal range 1069 4360 0 Physical range check high for urea catalyst upstream temperature 1070 4360 1 Physical range low for urea catalyst upstream temperature 1072 4360 3 1 error urea catalyst exhaust gas temperature upstream signal range check 1073 4360 4 2 error urea catalyst exhaust gas temperature upstream signal range check 1074 1761 14 Urea tank level warning threshold exceeded 1077 3361 3 Urea dosing valve short circuit to battery on high side 1078 3361 3 Urea dosing valve short circuit to battery or open load on high side 1079 3361 4 Urea dosing valve sh
95. AID Immediately clean dress and report all injuries cuts abrasions burns etc no matter how minor the injury may seem Know the location of a First Aid Kit and know how to use it CLEANLINESS Wear eye protection and clean all components with a high pressure or steam cleaner before attempting service General Hazards When removing hydraulic components plug hose ends and connections to prevent excess leakage and contamination Place a suitable catch basin beneath the machine to capture fluid run off It is good practice to avoid pressure washing electrical electronic components In the event pressure washing the machine is needed ensure machine is shut down before pressure washing Should pressure washing be utilized to wash areas containing electrical electronic components it is recommended a maximum pressure of 750 psi 52 bar at a minimum distance of 12 in 30 5 away from these components If electrical electronic components are sprayed spraying must not be direct and for brief time periods to avoid heavy saturation Check and obey all Federal State and or Local regulations regarding waste storage disposal and recycling Safety Practices 1 6 4 ENGINE Stop the engine before performing any service unless specifically instructed otherwise Operational Hazards VENTILATION Avoid prolonged engine operation in enclosed areas without adequate ventilation SOFT SURFACES AND SLOPES NE
96. AN Transmit Frame SCR3 1662 524117 9 Time out error of CAN Transmit Frame SCR3 1663 524097 9 Time out error of CAN Transmit Frame DPFBrnAirPmpCtl 1663 524097 9 Time out error of CAN Transmit Frame DPFBrnAirPmpCtl 1664 524098 9 Time out error of CAN Transmit Frame ComDPFBrnPT 1664 524098 9 Time out error of CAN Transmit Frame ComDPFBrnPT 1665 524099 9 Time out error of CAN Transmit Frame ComDPFCI 1665 524099 9 Time out error of CAN Transmit Frame ComDPFCI 1666 524100 9 Time out error of CAN Transmit Frame ComDPFHisDat 1666 524100 9 Time out error of CAN Transmit Frame ComDPFHisDat 1667 524101 9 Time out error of CAN Transmit Frame ComDPFTstMon 1667 524101 9 Time out error of CAN Transmit Frame ComDPFTstMon 1668 524105 9 Time out error of CAN Transmit Frame ComEGRMsFlw 1668 524105 9 Time out error of CAN Transmit Frame ComEGRMsF Iw 1669 524108 9 Time out error of CAN Transmit Frame ComEGRTVActr 1669 524108 9 Time out error of CAN Transmit Frame ComEGRTVActr 1670 524110 9 Time out error of CAN Transmit Frame ComETVActr 1670 524110 9 Time out error of CAN Transmit Frame ComETVActr 1671 524112 9 Time out ComITVActr 1671 524112 9 Time out ComITVActr 1672 524118 9 Time out error of CAN Receive Frame ComRxCMI G5 18A 2505H 25 5 9 57 Electrical System Fault am Deutz Description Codes Codes Codes 1
97. Auxiliary Hydraulic Power Supply Equipment and Supplies Required Portable hydraulic unit or another machine with an auxiliary hydraulic power supply with a capac ity to hold up to 3 gal 11 4 L of hydraulic oil from the machine during lowering process EQUIPMENT DAMAGE Auxiliary Hydraulic Power Supply hydraulic oil must be compatible with hydraulic oil shown in Section 2 5 Fluids Lubricants and Capacities Hoses Two Hydraulic Hoses Approximately 10 ft 3 0 m each with a minimum I D of 0 375 in 9 5 mm and a minimum rating of 4000 psi 275 8 bar Fittings Two 1 in 25 4 mm 14 ORFS Caps Two 1 in 25 4 mm 14 ORFS Plugs Note Machine extend retract and lift lower hoses are 14 ORFS The adaptor size may vary depending on the hose ends of the auxiliary hydraulic power supply 3 13 Er Boom 3 9 2 Lowering Procedure b Lower the boom as follows a boom as follows 1 Place a suitable receptacle under main control valve 1 Place a suitable receptacle under hose connections 6 0040 0 7 VIEW FROM LEFT SIDE T 2 Locate the extend retract cylinder connection 4 and 2 Label and disconnect lift lower cylinder hoses 5 along the left side of the boom where the hoses from the valve connect to the steel tube 3 Label and disconnect hoses from steel tubes along left side of boom Install plugs in hoses to prevent fluid loss Cap all f
98. CODE EMR4 9 14 1 Gauge Fault Code Display el SEN Deutz Description Codes Codes Codes 1 132 11 Air flow sensor load correction factor exceeding the maximum drift limit plausibility error 2 132 11 Air flow sensor load correction factor exceeding drift limit plausibility error 3 132 11 Air flow sensor low idle correction factor exceeding the maximum drift limit 4 132 11 Air flow sensor load correction factor exceeding the maximum drift limit 9 172 2 Sensor ambient air temperature plausibility error 34 523006 3 Controller mode switch short circuit to battery 35 523006 4 Controller mode switch short circuit to ground 36 523923 3 UB1 Short circuit to battery error of actuator relay 1 37 523924 3 UB2 Short circuit to battery error of actuator relay 2 38 523925 3 UB3 Short circuit to battery error of actuator relay 39 523926 3 UB4 Short circuit to battery error of actuator relay 4 40 523927 3 UB5 Short circuit to battery error of actuator relay 5 45 168 3 Sensor error battery voltage signal range check high 46 168 4 Sensor error battery voltage signal range check low 47 168 2 High battery voltage warning threshold exceeded 48 168 2 Low battery voltage warning threshold exceeded Break lever main switch and break lever redundancy switch status 49 597 2 not plausible 55 523910 14 Air pump doesn t achieve air mass flow set point 56 524013 7 Burner flame unintentional deleted 57 524020 14 Engine power Not enough oxyg
99. COMPONENTS Never alter remove or substitute any items such as counterweights tires batteries or other items that may reduce or affect the overall weight or stability of the machine BATTERY DO NOT charge a frozen battery Charging a frozen battery may cause it to explode Allow the battery to thaw before jump starting or connecting a battery charger 1 7 SAFETY DECALS Check that all safety decals are present and readable on the machine Refer to the Operation amp Safety Manual supplied with machine for information G5 18A 2505H 25 5 Section 2 General Information and Specifications Contents PARAGRAPH TITLE PAGE 2 1 Replacement Parts and Warranty 2 2 2 2 Thread Locking 2 2 2 3 Torque Charts Ret ee eee eee 2 3 2 3 1 SAE Fastener Torque 2 3 2 3 2 Metric Fastener Torque 2 9 2 3 3 Hydraulic Hose Torque 2 13 2 4 Specifications 2 we es Se Be ee hee 2 14 2 4 1 Travel Speed DA EEG Re n RE UR 2 14 2 4 2 Hydraulic Cylinder Performance Specifications 2 14 2 4 3 Electrical 2 14 2 4 4 Engine Performance Specifications 2 15 2 4 5
100. D illuminates press the SYSTEM CHECK button The first green LED then illuminates With no attachment and boom retracted lift boom fully Press the SYSTEM CHECK button on the LSI display and release The first 3 green LEDs will illuminate The third then second green LEDs will go out as the calibration point is recorded The first green LED goes out and buzzer sounds then the red LED illuminates Lower boom and without moving the machine pick up the proper test weight W listed in the table Pressing the LSI Override button may be required to lower the boom 2 gt 774 7 With the boom horizontal slowly extend the boom to the distance of Xcal 2 The proper calibration weight is now on the rear axle and the LSI can now be calibrated G5 18A 2505H 25 5 Electrical System 8 Press the SYSTEM CHECK button on the LSI 9 11 5 LSI CAN Check PT display and release As the calibration point is recorded buzzer sounds and the LEDs will flash and BU the LSI calibrated the UGM also needs calibrated and verified perform a sequence until all are flashing 9 Perform the LSI CAN Check PT to finalize the calibration Refer to Section 9 11 5 LSI CAN Check PT 2 Connect the analyzer cable connector to the connector at the right rear corner of the cab by the operator seat 1 The machine must be on a level surfac
101. DPF shut 809 Be off regeneration Physical ran heck low for differential pr re DPF shut 812 3251 1 eck low for differential pressure shu 814 3253 3 Sensor error differential pressure DPF signal range check high 815 3253 4 Sensor error differential pressure DPF signal range check low 825 523009 9 Pressure Relief Valve PRV reached maximum allowed opening count 826 523470 2 Pressure Relief Valve PRV forced to open performed by pressure increase 827 523470 2 Pressure Relief Valve PRV forced to open performed by pressure shock 828 523470 12 Open Pressure Relief Valve PRV shut off condition 829 523470 12 Open Pressure Relief Valve PRV warning condition 830 523470 14 Pressure Relief Valve PRV is open 831 523470 11 The PRV can not be opened at this operating point with a pressure shock 832 523470 11 Rail pressure out of tolerance range 833 523009 10 Pressure relief valve PRV reached maximum allowed open time 834 523906 5 Electrical fuel pre supply pump open load 835 523906 12 Electrical fuel pre supply pump power stage over temperature 836 523906 3 Electrical fuel pre supply pump short circuit to battery 837 523906 4 Electrical fuel pre supply pump short circuit to ground 838 523450 3 Multiple Stage Switch constant speed short circuit to battery 839 523450 4 Multiple Stage Switch constant speed short circuit to ground 840 523450 2 Multiple Stage Switch constant speed plausibility error 841 523451 3 Multiple Stage
102. DPF wasn t regenerated power reduction phase 2 manual vee 958022 19 regeneration P 1221 524023 14 DPF wasn t regenerated warning condition manual regeneration mode 1222 190 14 Camshaft and Crankshaft speed sensor signal not available on CAN 1223 51 5 Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 open load 1224 51 6 Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 over current 1225 51 12 Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 over temperature 1226 51 3 EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 short circuit to battery 02 1227 51 3 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to battery A67 1228 51 4 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground 02 1229 51 4 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground A67 1230 51 6 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Overload by short circuit Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Power stage over al n temperature due to high current Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Voltage 1232 51 4 below threshold 1239 523984 3 UB6 Short circuit to battery error of actuator relay 7 1240 523985 3 UB7 Short circuit to battery error of actuator relay 1243 523988 5 Charging lamp open load 1244 523988 12 Charging lamp over temperature 1245 523988 3 Charging lamp short circuit to battery 1246 523988 4 Ch
103. Fuel Filter Check LSI Check Wheel Oil and Filter Air Filter if equipped for LS Calibration Lug Nut Elements CE amp AUS Torque OAH2211 2 20 G5 18A 2505H 25 5 General Information and Specifications 2 6 3 1000 amp 1500 Hour Maintenance Schedule Change Axle Change Wheel Change Front Differential Oil End Oil Axle Drop Hydraulic Box Oil Fluid amp Filters Change Change Fuel Filter Transmission if equipped for ULS Filter Change Engine Coolant G5 18A 2505H 25 5 Hydraulic Tank Cap 2220 2 21 amp General Information and Specifications 2 7 LUBRICATION SCHEDULE 2 7 1 250 Hour Lubrication Schedule OAL1980 2 22 G5 18A 2505H 25 5 m ey Section 3 Boom Contents PARAGRAPH TITLE PAGE 3 1 Boom System Component 3 2 3 2 Safety 3 3 3 3 Two Section Boom System 3 3 3 3 1 Boom System 3 3 3 4 Boom Assembly 3 3 3 4 1 Complete Boom 3 3 3 4 2 Complete Boom Installation 3 4 3 4 3 Second Boom Section
104. GA a w Tew td ee ol AU aia CORN NERO UAI TaN OON id 8 2 9 8 v 2 n Electrical System d Base Frame Schematic A G5 18A 2505H 25 5 MY8750B 9 10 8760 9 11 Electrical System 9 URN BUSAY NV a vim D o M g CON VO INV GA TV Sees gr RE Els BRE ja di i Ad iii f E T aga ii HH di i Hg 0548 is hg i p 3 ji i HT E 8 OMVZI GNO 9 000 i p 0 ARS lt Bee g 1 a a decl 2 i df zz i wd i S Hi dd co BEHIRININISINI
105. H 25 5 Section 5 Axles Drive Shafts Wheels and Tires Contents PARAGRAPH TITLE PAGE 5 1 Axle Drive Shaft and Wheel Component 5 2 5 2 Safety 5 3 5 3 General Information 5 3 5 4 Axle 4 4 5 3 5 4 1 Axle Serial Number 5 3 5 4 2 Axle Specifications 5 3 5 4 3 Axle Internal 5 3 5 4 4 Axle 5 3 5 4 5 Axle Removal 52 99 5 4 5 4 6 Axle 5 5 5 4 7 Axle Assembly and Drive Shaft Troubleshooting 5 6 5 5 Drive Shafts re 5 9 5 5 1 Drive Shaft 5 9 5 5 2 Drive Shaft 5 9 5 5 3 Drive Shaft 5 9 5 5 4 Drive Shaft Cleaning and 0 5 9 5 5 5 Drive Shaft Installation 5 9 5 6 Wheels and 2 22 22 2224 2 42 5 10 5 6 1 Removing Wheel and Tire Assembly from Mach
106. HCI dosing valve DV1 downstream pressure signal range check low 516 523917 2 Sensor DV1 amp DV2 upstream pressure plausibility error Physical ran heck high for DV1 amp DV2 tream pr re Big Beer Physical ran heck low for DV1 amp DV2 tream pr re 524 523917 3 Sensor error DV1 amp DV2 upstream pressure signal range check high 525 523917 4 Sensor error DV1 amp DV2 upstream pressure signal range check low 526 523918 2 Sensor DV1 amp DV2 upstream temperature plausibility error Physical ran heck high for DV1 amp DV2 tream temperature Physical ran heck low for DV1 amp DV2 tream temperature shut off 531 523918 1 2 check low fo amp upstream temperature shut o 534 523918 3 Sensor error DV1 amp DV2 upstream temperature signal range check high 535 523918 4 Sensor error DV1 amp DV2 upstream temperature signal range check low 543 676 11 Cold start aid relay error 544 676 11 Cold start aid relay open load 545 729 5 Cold start aid relay open load G5 18A 2505H 25 5 9 43 Electrical System Fault ah Deutz Description Codes Codes Codes 547 729 12 Cold start aid relay over temperature error Check of missing injector adjustment value programming IMA injector 1 999 23895 13 in firing order ne is heck of missing injector adjustment val rogr
107. I CANCEL SW LIFT DN OUTPUT HYD FLUID TEMP POWER MODULE LOAD MOMENT CAN 1 STATISTICS CALIBRATION DATA POWER MODULE CURRENT ENGAGED xc VOLTAGE XX XV STATUS STABLE LSICELLA SOFTWARE TRANS MTR FDBK TELE MODE 8W LIFT DN OUTPUT ENGINE COOLANT GROUND MODULE LOAD MOMENT CAN 1 STATSTICS CALIBRATION DATA GROUND MODULE mA ENGAGED CURRENT TEMP VOLTAGE OVERRIDE YES TX SEC LSICELLB SOFTWARE X F RDRIVE CUTOUT LIFT DN PILOT DN FDBK mA FAN SPEED OUTPUT REMOTE MODULE LOAD MOMENT CAN 1 sumsncs 2 ENGAGED SENSOR XV CURRENT JOMA VOLTAGE o BUSOFF XXX REMOTE INPUT MOD SOFTWARE PX X LIFT DN PILOT LIFT ENABLE FAN SPEED FDBK MOMENT CELLA RAW CAN 1 stansTics 2 LSI MODULE PRESSURE OOPS ENGAGED mA XXXmA VALUE PASSIVE SOFTWARE X X JOYSTICK LOCK TELE OUT X FAN REVERSE MOMENT CELLB RAW CAN 1 STATISTICS ENGAGED Xxx VALVE ENGAGED 00000 MBQ OVERRUN XXX ANALYZER VER 6 2 FORWARD AND PARK TEE OUT DISAGREE BRK OFF TRUE CURRENT REVERSE AND PARK TELE OUT FDBK mA MIDBOOM 1 8W BRKOFF TRUE OPEN FAN REV CYCLING TELE ENABLE MIDBOOM 2 SW SW ENGAGED ENGAGED OPEN FAN REV DEMAND FUNCTION ENABLE OPERATING MODE SW ENGAGED ENGAGED ACTIVE MENU ACCESS LEVEL SEATSW 1 ACCESS LEVEL CODE 000K ENGAGED MENU PERSONALITIES SEATSW 2 PERSONALIT
108. IES LIFT DOWN ENGAGED LFTDNZN 1 OMD 50 XX UFTDNZN 1 B0 OMDc75 XX LFTDNZN 1 OMD 76 XX UFTDNZN 2 OMD 50 XX UFTDNZN 2 50 lt OMD lt 75 XX UFTDNZN 2 OMD75 XX CREEP XX MENU MACHINE SETUP ATIS FAN CONFIG 2 amp REV TRE LARGE 278 05 CM SPEED UNIT KPH TEMP UNIT CELCIUS MENU FAN REVERSE OPERATOR TOOLS INTERVAL XXMIN FAN REVERSE PERFORM LSI XX MIN SYSTEM REMOVE WEIGHTS AND ATTACHMENTS TELESCOPE IN AND FULLY LIFT UP STOP WAIT 1 MINUTE PRESS ENTER TO STARTTEST MENU CALIBRATION TOOLS RAE SETLSI CHECK EMULATE 60 EMULATE 80 POINT YES YES NO YES NO REMOVE WEIGHTS AND ATTACHMENTS TELESCOPEINAND 2 FULLY LIFT UP STOP WAIT 1 MINUTE PRESS ENTER TO SET CHECKPOINT MY8840 G5 18A 2505H 25 5 9 33 Electrical System 9 13 DIAGNOSTIC TROUBLE CODES DTC ON GROUND MODULE 9 13 1 Gauge Fault Code Display MY9030 Fault codes will appear in the display area 7 of the gauge 8 9 13 2 Fault Codes Trigger Possible Latch Reset Help Message DTC Symptom Actions Condition System OK 1 Ground Module detects _ no problems exist Power Cycle 211 Power was cycled on Default machine to LSI Load Maman LSI Cancel Switch Cutout if not in passive Latched Check wiring to mode and not in LSI Pin J1 3 on the Ground Shutoff Input
109. Ib ft 80 Nm 2 Hose fittings loose 2 Tighten fittings 3 Axle shaft seal damaged or 3 Replace seal and or joint missing and or worn or coupling fork shaft axle shaft damaged shaft sealing surfaces 4 Input shaft multi seal ring 4 Replace multi seal ring and or damaged or missing and or input shaft Adjust ring and worn or damaged pinion input pinion alignment and bearing shaft sealing surfaces preload as described in the Axle Repair Manuals 5 Axle casing to brake housing 5 Replace o rings and seals and or brake housing to differential assembly o rings and or seals worn or damaged 6 Axle housing mounting nuts and 6 Tighten housing nuts and capscrews loose capscrews to 236 Ib ft 320 Nm 7 Differential and or axle 7 Replace housing s as needed housing s damaged 5 Oil leaking from wheel end 1 Oil level plugs loose and or 1 Replace o rings as needed and housing planet carrier o rings damaged or missing tighten plugs to 59 Ib ft BO Nm 2 O ring between hub and 2 Replace o ring housing planet carrier damaged or missing 3 Shaft seal damaged or missing 3 Replace seal and or fork joint and or worn or damaged shaft shaft sealing surfaces 4 Housing capscrews loose 4 Tighten housing capscrews to 41 Ib 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 Steeri
110. Injector 6 in firing order short circuit 586 651 4 High side to low side short circuit in the injector 1 in firing order 587 652 4 High side to low side short circuit in the injector 2 in firing order 588 653 4 High side to low side short circuit in the injector 3 in firing order 589 654 4 High side to low side short circuit in the injector 4 in firing order 590 655 4 High side to low side short circuit in the injector 5 in firing order 591 656 4 High side to low side short circuit in the injector 6 in firing order 592 523615 5 Metering unit Fuel System open load 593 523615 12 Metering unit Fuel System powerstage over temperature 594 523615 3 Metering unit Fuel System short circuit to battery high side 595 523615 4 Metering unit Fuel System short circuit to ground high side 596 523615 3 Metering unit Fuel System short circuit to battery low side 597 523615 4 Metering Unit Fuel System short circuit to ground low side 604 1323 12 Too many recognized misfires in cylinder 1 in firing order 605 1324 12 Too many recognized misfires in cylinder 2 in firing order 606 1325 12 Too many recognized misfires in cylinder 3 in firing order 607 1326 12 Too many recognized misfires in cylinder 4 in firing order 608 1327 12 Too many recognized misfires in cylinder 5 in firing order 9 44 G5 18A 2505H 25 5 Electrical System
111. JG Service Manual Models G5 18A amp 2505H Agrovector 25 5 S N 0160053000 amp After including 0160051045 0160051047 0160051049 0160051194 amp 0160051359 31200926 Revised January 8 2015 An Oshkosh Corporation Company 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 31200926 G5 18A 2505H 25 5 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 f 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 f 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 b G5 18A 2505H 25 5 31200926 SECTION CONTENTS Section Subject Page Section 1 Safety Practices i eura 1 1 1 1 Introduction SEEN REM RO EP RS 1 2 1 2 Disclaltmer 1 2 1 3
112. Refer to Section 4 4 2 Steering Column Valve Replacement for details Steering Orbitrol Valve 8 11 6 Pilot Select Valve The pilot select valve is attached to a manifold mounted on a mounting plate inside the frame in front of the comp cylinder MU7720 3 ANSI CE amp AUS Verify the correct operation of the pilot select valve solenoids boom lift lower 3 auxiliary 4 tilt 5 boom extend retract 6 and front auxiliary 7 before considering replacement of the valve The housing of the pilot select valve is not serviceable and must be replaced if defective 8 18 a Pilot Select Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery 5 Label or otherwise mark the hydraulic hoses in relation to the pilot select valve Disconnect and cap all hoses fittings solenoid wire terminal leads etc 6 Remove the capscrews that attach the valve to the frame 7 Remove the pilot select valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine b Pilot Select Valve Disass
113. Remove any fork carrier or attachment from the machine 2 Park the machine on a firm level surface level the machine fully retract the boom fully raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the battery and engine covers Allow the engine to cool 5 Properly disconnect the battery 6 Disconnect the LSI electrical connector 7 Loosen remove and discard the two bolts holding the LSI assembly to the rear axle 8 Remove and discard the sensor assembly b LSI Axle Sensor Installation 1 Ensure threads of both bolt holes are clean and free from rust water and debris 2 Clean the bare metal with a degreasing agent Loctite 7063 3 Remove any excess degreasing agent and allow to dry 4 Apply a thin film of Loctite F246 amp dhesive to the flat metal surface of the sensor ensuring the adhesive is spread evenly over the entire surface Note Follow all adhesive manufacturer s recommendations including storage life 5 Fit the sensor ensuring the lead exits in the corner direction Secure with two new bolts Socket HD Capscrew M10x35x1 5 Grade 12 9 Note It is important to prevent distortion of the sensor element therefore tighten each bolt finger tight Alternately tighten each bolt to 2
114. RxTrbChActr 1684 524122 9 Time out error of CAN Receive Frame ComRxUQSens 1684 524122 9 Time out error of CAN Receive Frame ComRxUQSens 1685 524123 9 Time out error of CAN Receive Frame ComSCRHtCtl 1685 524123 9 Time out error of CAN Receive Frame ComSCRHtCt 1686 524124 9 Time out error of CAN Receive Frame ComTxATIIMG 1686 524124 9 Time out error of CAN Receive Frame ComTxATIIMG 1687 524125 9 Time out error of CAN Receive Frame ComTxTrbChActr 1687 524125 9 Time out error of CAN Receive Frame ComTxTrbChActr 1481 524025 5 DPF system operating voltage error 1452 524044 9 message ComMS_Sys7 not received from slave 1453 523632 2 Metering control is not performed in time error 1486 523718 5 SCR main relay open load only CV56B 9 58 G5 18A 2505H 25 5 31200926 An Oshkosh Corporation Company JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 1 717 485 5161 Customer Support Toll Free 1 877 554 5438 Fax 1 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65811111 Fax 61 2 65813058 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG Latino Americana Ltda Rua Antonia Mar
115. Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations 3 Install the pin and clip 2 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 6 Properly connect the battery G5 18A 2505H 25 5 7 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 8 Inspect the service brake valve and connections for leaks and check the brake oil level Shut the engine OFF 9 Replace the necessary dash panels 10 Wipe up any hydraulic oil spillage in on near and around the machine work area and tools 11 Close and secure the battery and engine covers 12 Remove the Do Not Operate Tags from both the ignition key and the steering wheel Service Brake Bleeding Procedure re MY2050 Carefully bleed the brake lines as soon as the brake valve is installed on the machine Air in the system will not allow the brakes to apply properly There are two brake bleeder locations 1 on the front axle The outside bleeder is used for the park b
116. VER work machine that is parked on a soft surface or slope The machine must be on a hard level surface with the wheels blocked before performing any service FLUID TEMPERATURE NEVER work on a machine when engine cooling or hydraulic systems are hot Hot components and fluids can cause severe burns Allow systems to cool before proceeding FLUID PRESSURE Before loosening any hydraulic or diesel fuel component hose or tube turn the engine OFF Wear heavy protective gloves and eye protection NEVER check for leaks using any part of your body use a piece of cardboard or wood instead If injured seek medical attention immediately Diesel fluid leaking under pressure can explode Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin cause infection gangrene and other serious personal injury Engine fuel lines are pressurized DO NOT attempt repairs unless specific training has been completed Refer to the engine manufacturers manual for specific details concerning the fuel system Relieve all pressure before disconnecting any component part line or hose Slowly loosen parts and allow release of residual pressure before removing any part or component Before starting the engine or applying pressure use components parts hoses and pipes that are in good condition connected properly and are tightened to the proper torque Capture fluid in an appropriate container and dispose of in accordance with
117. Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC HEX HEAD BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS 5 Torque du Dus porgue Size Pitch Stress ole on Dry or Loctite 26 3 242 or 271 dd 26 K 0 20 Vibra TITE 111 140 Me COM K 0 18 hs Sq mm KN N m N m N m 3 0 5 5 03 3 13 3 5 0 6 6 78 4 22 4 0 7 8 78 5 47 5 0 8 14 20 8 85 6 1 20 10 12 5 7 1 28 90 18 0 25 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 45 1120 698 0 5865 5275 4395 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 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 10 G5 18A 2505H 25 5 General Information and Specifications 2 3 2 Metric Fasten
118. 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 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 Inspection Note lf a leak is suspected between the fuel and hydraulic oil tank contact the local JLG dealer 1 d Inspect the fuel hydraulic oil tank thoroughly for any cracks slices leaks or other damage 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 Disassembly and Assembly The fuel hydraulic oil reservoir is a one piece unit integral to the chassis frame and cannot be disassembled 7 4 1 2 3 After Fuel System Service Drain and flush the fuel tank if it was contaminated Fill the fuel tank with fresh clean diesel fuel as required Note If bleeding of the fuel system is required contact the local JLG dealer 7 5 ENGINE EXHAUST SYSTEM 7 5 1 1 Exhaust System Removal Park the machine on a firm level surface level the machine fu
119. ad 1104 4341 3 SCR heater urea supply line short circuit to battery 1105 4341 4 SCR heater urea supply line short circuit to ground 1106 523719 5 SCR heater relay urea supply module primary side open load 1108 523719 3 SCR heater urea supply module short circuit to battery 1109 523719 4 SCR heater urea supply module short circuit to ground 1110 4366 5 SCR tank heating valve primary side open load 1111 4366 12 SCR heater relay urea tank powerstage output over temperature 1112 4366 3 SCR Tank heating valve short circuit to battery 1113 4366 4 SCR Tank heating valve short circuit to ground 1118 4375 5 Urea pump motor open load 1120 4375 3 Urea pump motor short circuit to battery 9 50 G5 18A 2505H 25 5 Electrical System rd n Dd Deutz Description 1121 4375 4 Urea pump motor short circuit to ground 1122 4334 0 Physical range check high for Urea Pump Pressure 1123 4334 1 Physical range check low for Urea Pump Pressure 1124 4334 0 Urea pump pressure sensor high signal not plausible 1125 4334 1 Urea pump pressure sensor low signal not plausible 1127 4334 3 Sensor error urea pump pressure signal range check high 1128 4334 4 Sensor error urea pump pressure signal range check low 1129 4376 5 SCR reversing valve open load 1130 4376 12 SCR reversing valve over tem
120. agreement operation only available via the issue on a CAN bus LSI Cancel switch Creep message to the Ground Mode operation Module 2 Ground module has Functions Locked Gut Remote input detected that Remote input Deactivate all Latched Check ground 99161 module software is not and remote module software versions G5 18A 2505H 25 5 9 37 Electrical System Received from Power Module expired and has not received parameters from the Power Module Trigger Possible T Latch Reset Help Message DTC Symptom Actions Condition This fault can only occur if the machine detects itself to Latched Check wiring to Seat Switch be a Tier 4 configuration Pins J2 7 on Ground 23119 Disagreement Disagreement between seat and Remote switch inputs is present IO modules for 5 seconds Default machine to LSI This fault can only occur if Cutout if not in passive the machine detects itself to mode or not in LSI Ground Module 5 be Tier 4 configuration calibration mode with 6643 startup delay of 1500ms has operation only available Not Latched LSI Override switch Creep Mode operation This fault shall suppress DTC 9924 from being set 9 38 G5 18A 2505H 25 5 Electrical System 9 14 ENGINE DIAGNOSTIC TROUBLE
121. al seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 6 Install the solenoid valve and cartridge in the variable speed fan valve housing c Variable Speed Fan Valve Installation 1 Connect the hydraulic hoses fittings solenoid wire terminal leads etc to the variable fan valve 2 Refer to Section 7 2 2 Radiator Oil Cooler Replacement for detailed installation instructions 3 Properly connect the battery 4 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 5 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 6 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 7 Close and secure the battery and engine covers 8 Remove the Do Not Operate Tags from both the ignition key and the steering wheel d Variable Speed Fan Valve Test 1 Turn the ignition switch to the ON position activate the variable speed fan switch to the ON position 2 Place a piece of paper over the face of the radiator core If the paper is held in place the fan is rotati
122. aler Registration activates the warranty period and helps to assure that warranty claims are promptly processed to guarantee full warranty service 2 2 2 2 THREAD LOCKING COMPOUND JLG P N Loctite ND Industries Description 0100011 242 Vibra TITE 121 Medium Strength Blue 1001095650 243 Vibra TITE 22 Medium Strength Blue 0100019 2711 Vibra TITE 140 High Strength Red 0100071 2621 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 General Information and Specifications 2 3 TORQUE CHARTS 2 3 1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Tensil Cl T T L faeces 271 Size TPI gun y ee Loctite 2627 or 111 or 140 Vibra TITE 131 In Sq In LB IN LB N m IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 380 8 0 9 6 0 7 48 0 1120 0 00661 420 9 1 0 7 0 8 6 32 0 1380 0 00909 580 16 1 8 12 1 4 40 0 1380 0 01015 610 18 2 0 13 1 5 8 32 0 1640 0 01400 900 30 3 4 22 2 5 36 0 1640 0 01474 940 31 3 5 23 2 6 10 24 0 1900 0 01750 1120 43 4 8 3
123. ammi inj 560 523896 13 11 R g injector adjustment value programming IMA injector 2 check of missing injector adjustment value programming IMA injector 901 19 in firing order udi d check of missing injector adjustment value programming IMA injector 4 982 825898 13 in firing order m ewe heck of missing injector adjustment val rogrammi inj 563 523899 13 11 ne g injector adjustment value programming IMA injector 5 check of missing injector adjustment value programming IMA injector 90d 904900 18 in firing order ii di MUR 565 523350 4 Injector cylinder bank 1 short circuit 566 523352 4 Injector cylinder bank 2 short circuit 567 523354 12 Injector powerstage output defect 568 651 5 Injector 1 in firing order interruption of electric connection 569 652 5 Injector 2 in firing order interruption of electric connection 570 653 5 Injector 3 in firing order interruption of electric connection 571 654 5 Injector 4 in firing order interruption of electric connection 572 655 5 Injector 5 in firing order interruption of electric connection 573 656 5 Injector 6 in firing order interruption of electric connection 580 651 3 Injector 1 in firing order short circuit 581 652 3 Injector 2 in firing order short circuit 582 653 3 Injector 3 in firing order short circuit 583 654 3 Injector 4 in firing order short circuit 584 655 3 Injector 5 in firing order short circuit 585 656 3
124. and exhaust system connections are correct and connected tightly 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 operate any hydraulic function DO steer or apply any pressure to the steering wheel Keep the transmission in NEUTRAL 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 21 Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 Section 8 Hydraulic System Contents PARAGRAPH TITLE PAGE 8 1 Hydraulic Component 8 3 8 2 Safety 8 4 8 3 General Information
125. arging lamp short circuit to ground 1247 524019 11 Air Pump air lines blocked 1248 523910 9 Air Pump CAN communication lost 1249 523910 7 Air pump CAN communication interrupted no purge function available 1250 523910 12 Air Pump internal error 1251 523910 0 Air Pump power stage over temperature 1252 523910 0 Air Pump operating voltage error 1253 523911 7 Burner dosing valve DV2 blocked closed 1254 524014 1 Air pressure glow plug flush line below limit 1255 524013 7 Burner operation is interrupted too often 1256 523915 7 HCI dosing valve DV1 blocked closed 1257 523915 7 HCI dosing valve DV1 blocked open 1258 524016 11 HFM sensor electrical fault 1259 524016 2 Amount of air is not plausible to pump speed 1260 524016 2 Calculated amount of air is not plausible to HFM reading 1261 523910 6 Air Pump over current 1262 523922 7 Burner Shut Off Valve blocked closed 1263 524021 11 Burner fuel line pipe leak behind Shut Off Valve 1264 523922 7 Burner Shut Off Valve blocked open 9 52 G5 18A 2505H 25 5 Electrical System EUN EMI Deutz Description Codes Codes Codes P 1265 524017 12 Spark plug control unit SPCU electrical fault 1266 524017 12 Spark plug control unit SPCU internal error 1267 523989 0 Fuel Balance Control integrator injector 7 in firing order maximum value exceeded 1268 523990
126. assemblies from the axle that is being removed Refer to Section 5 6 1 Hemoving Wheel and Tire Assembly from Machine Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 14 Remove drive shaft assembly Refer to Section 5 5 3 Drive Shaft Removal 15 Remove capscrews locknuts and axle plates securing axle to frame 16 Remove axle from machine using jack hoist or overhead crane and sling supporting axle DO NOT raise or otherwise disturb machine while removing axle Balance axle and prevent it from tipping turning or falling while removing it from beneath machine Place the axle on a suitable support or holding stand G5 18A 2505H 25 5 Axles Drive Shafts Wheels and Tires hs 5 4 6 1 Axle Installation Before proceeding ensure that the machine will remain in place during axle installation Block the front and rear of both tires on the axle that is already installed on the machine If applicable raise the machine using a suitable jack or hoist Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation Using a suitable jack hoist or overhead crane and sling remove the axle from its support or holding stand Balance the axle and prevent it from
127. balance cab during installation WARNING Torque upper cab bolts to 340 Ib ft 461 Nm Avoid breathing exhaust fumes and prevent engine Install cab to frame hardware 2 N Oo operation from becoming a cause of toxic emissions Torque lower cab bolts to 530 Ib ft 719 Nm Remove eye bolts from top of cab 1 E o Uncap and reconnect hydraulic hoses at cab locations 11 Install cab to wiring harness connectors on side of the cab 12 Uncap and connect heater hoses to engine 13 Secure with hose clamps 14 If equipped with a cab heater Refer to Section 4 4 8 Heater Air Conditioning System If Equipped 15 Properly connect battery 16 Carefully examine all cab components fasteners etc one last time before engine start up Rectify any faulty conditions 17 Start engine and check operation of all controls 18 Check for hydraulic fluid leaks 19 Check hydraulic fluid level in tank and add fluid as required When the engine is initially started run it briefly at low idle and check the machine for any visual sign of fluid leakage STOP the engine immediately if any leakage is noted and make any necessary repairs before continuing 20 If equipped with optional heater operate engine until operating temperature is achieved ensuring that thermostat has opened G5 18A 2505H 25 5 4 11 Cab 4 12 This Page Intentionally Left Blank G5 18A 2505
128. burner temperature plausibility error 1398 1136 0 Physical range check high for ECU temperature 1399 1136 1 Physical range check low for ECU temperature 1400 1136 3 Sensor error ECU temperature signal range check high 1401 1136 4 Sensor error ECU temperature signal range check low 1402 4769 5 ind exhaust gas temperature OxiCat downstream normal operation plausibility 1403 4769 exhaust gas temperature OxiCat downstream regeneration plausibility 1404 3248 Sensor exhaust gas temperature downstream DPF plausibility error 1405 3248 0 Physical range check high for exhaust gas temperature particulate filter downstream Physical range check high for exhaust gas temperature particulate SEM 9 filter downstream shut off regeneration Physical ran heck high for exhaust temperatur rticulat 1408 3248 1 Physical range check low for exhaust gas temperature particulate filter downstream Physical range check low for exhaust gas temperature particulate filter downstream 159 8219 1 shut off regeneration 9 54 G5 18A 2505H 25 5 Electrical System p D Deutz Description 1410 3248 1 Physical range check low for exhaust gas temperature particulate filter downstream warning 1411 1188 11 Wastegate actuator internal error 1412 1188 11 Wastegate actuator EOL calibration not performed c
129. c transmission to 32 41 Ib ft 44 56 Nm 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 Ib ft 95 115 Nm 13 Release pressure from auxiliary hydraulic power supply and remove auxiliary hydraulic power supply 14 The parking brake should now be reactivated and front wheels locked 15 Remove blocks from four tires 16 Verify that parking brake works 17 If parking brake does not work check all activation operations step by step 5 13 Axles Drive Shafts Wheels and Tires This Page Intentionally Left Blank G5 18A 2505H 25 5 Section 6 Transmission Contents PARAGRAPH TITLE PAGE 6 1 Transmission Assembly Component Terminology 6 2 6 2 Safety 6 3 6 3 Transmission Description 6 3 6 4 Transmission Specifications 6 3 6 4 1 Transmission 6 3 6 5 Transmission 6 3 6 5 1 Transmission
130. cautions as outlined in the Safety Practices section of this manual 8 3 GENERAL INFORMATION Petroleum based hydraulic fluids are used in this machine The temperature of hydraulic fluid increases during the operation of various hydraulic functions A heated petroleum based hydraulic fluid presents a fire hazard especially when an ignition source is present Accordingly periodically inspect all hydraulic system components hoses tubes lines fittings etc Carefully examine any deterioration and determine whether any further use of the component would 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 involved A hissing sound or slow seepage of hydraulic fluid may occur in most cases After the hissing sound has ceased continue removing the part Any escaping oil should be directed into an appropriate container Cap or otherwise block off the part to prevent further fluid seepage Hydraulic system maintenance will at times require that the engine be operated Always follow safety precautions A major cause of hydraulic component failure is contamination Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs Sand grit and other contaminants can damage the finely machined surfaces within hydraulic components If operating in an exceptionally dirty environment
131. cohol among others For optimal safety encourage everyone to think and to act safely Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work for the safety of the operator and for the safe reliable operation of the machine All references to the right side left side front and rear are given from the operator s seat looking in a forward direction Supplementary information is available from JLG in the form of Service Bulletins Service Campaigns Service Training Schools the JLG website other literature and through updates to the manual itself 1 2 DISCLAIMER All information in this manual is based on the latest product information available at the time of publication JLG reserves the right to make changes and improvements to its products and to discontinue the manufacture of any product at its discretion at any time without public notice or obligation 1 3 OPERATION amp SAFETY MANUAL The mechanic must not operate the machine until the Operation amp 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 amp 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 amp Safety Manual is missing consult the local JLG Dealer befo
132. cription Engine Make Model Deutz TD L4 Displacement 177 in 2 91 Low Idle 975 1075 rpm High Idle 2300 2400 rpm Horsepower 74 HP 55 kW 2300 rpm Peak Torque 192 Ib ft 260 Nm 1800 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements 2 4 5 Tires Note Standard wheel lug nut torque is 220 Ib ft 300 Nm Note Pressures for Foam filled tires are for initial fill ONLY Minimum Ply Star Rating Fill Type Pressure Pneumatic 80 psi 5 5 bar 12 16 50 305 70016 5 Puraforce Bias 12 ply DT Foam Approximately 220 Ib 100 kg Pneumatic 70 psi 4 8 bar 14 17 50 355 70017 5 Outrigger Bias 14 Ply Foam Approximately 220 Ib 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 2 15 General Information and Specifications 2 5 2 5 1 Fluids a If Equipped for ULS FLUIDS LUBRICANTS AND CAPACITIES Ambient Temperature Range Compartment Type and Classification Viscosities F System Min Max Min Max SAE OW 30 20 0 29 18 SAE 5W 30 15 70 26 21 Engine Crankcase API CJ 4 Plus SAE 10W 30 9 70 22 21 SAE 15W 40 5 120 15 49 MobilFluid 424 10W 30 0 104 20
133. d engine covers Allow the engine to cool 4 Properly disconnect the battery 5 Disconnect the wiring connector at the coolant temperature sender lead 6 The coolant temperature sender is threaded into the engine block Remove the sender b Coolant Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part c Coolant Temperature Sender Installation and Testing 1 Thread the coolant temperature sender into the engine housing snugly then connect the sender connector to the wiring harness connector 2 Properly connect the battery 3 Check for proper fluid level 4 Start the engine allow it to reach operating temperature and observe the operator s instrument cluster for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine improper or low coolant obstructed or faulty radiator coolant pump loose fan belt defective instrument display etc 5 Close and secure the battery and engine covers 6 Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 Electrical System 9 10 6 Oil Pressure Sender 8820 oil pressure sender 3 is located on the engine near the oil filter a 1 Oil Pressure Sender Removal Park the machine o
134. d 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 COMPENSATING LP SECOND BOOM SECTION PIVOT PIN LIFT LOWER CYLINDER TILT CYLINDER EXTEND RETRACT CYLINDER AUXILIARY HYDRAULIC QUICK CONNECTS Nap lt MY8380 3 2 G5 18A 2505H 25 5 Pe 3 2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the Safety Practices section of this manual 3 3 TWO SECTION BOOM SYSTEM 3 3 1 Boom operates via an interchange among electrical hydraulic and mechanical systems Components involved include joystick tilt cylinder extend retract cylinder lift lower cylinder compensating cylinder electronic sensors various pivots supporting hardware and other components Boom System Description A WARNING 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 sec
135. damaged 2 Replace brake discs 11 Brakes will not engage Brake hydraulic system not 1 Refer to the appropriate Axle operating properly Repair Manual Brake piston o rings and seals 2 Replace o rings and seals damaged leaking 12 Brakes will not hold the Brake discs worn 1 Check brake discs for wear machine or braking power Refer to the appropriate Axle reduced Repair Manual Brake hydraulic system not 2 Refer to the appropriate Axle operating properly Repair Manual Brake piston o rings and seals 3 Replace o rings and seals damaged leaking 5 8 G5 18A 2505H 25 5 Axles Drive Shafts Wheels and Tires hs 5 5 DRIVE SHAFTS 5 5 1 Whenever servicing the machine conduct a visual inspection of the drive shaft and cross and bearing assembly universal joints or U joints A few moments spent doing this can help prevent further problems and down time later Drive Shaft Inspection 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 or other damage Worn or damaged drive shaft and cross and bearing assembly may cause an excessive amount of vibration or noise Note Any bolt removed from the drive shaft assembly MUST be replaced Do Not re torque 5 5 2 Refer to Section 2 7 Lubrication Schedule for information regarding the
136. draulic system G5 18A 2505H 25 5 29 Loosen and remove the lower hydraulic oil cooler hose Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system Remove the bottom radiator hose 13 Cap all fittings and openings to keep dirt amp debris from entering the cooling system Slowly remove the radiator oil cooler from the machine Cooler Fan Motor Removal MY8940 Turn the radiator cooler assembly over and place on a secure location Remove the four bolts 14 securing the fan motor guard to the radiator cooler shroud NUS S S MY8950 3 Turn the fan motor guard over to access the fan assembly Loosen and remove the center bolt and washer 15 securing the fan to the motor shaft Engine Note Retain the key located the fan motor shaft 8960 5 Turn the fan motor guard over to access the two fan motor mounting bolts 16 6 Loosen and remove both mounting bolts securing the fan motor to the fan guard 7 Remove the fan motor as necessary c Cooler Fan Motor Installation 1 Apply Loctite 242 to all mounting bolts 2 Install the fan motor to the fan guard The fan motor can only be installed one way 3 Install the two previously removed mounting bolts and torque to 31 35 Ib ft 41 47 Nm 4 Verify the key is in place on the fan motor shaft and install the previously removed fan Ins
137. e wheels steered straight and park brake ON Note The following procedure MUST BE performed to finalize the LSI System Calibration Start the machine AB Press the C and OK buttons simultaneously on the analyzer Goto ACCESS LEVEL 3 and press OK Enter the proper access code and press OK ACCESS LEVEL 2 is now visible Goto CALIBRATIONS menu press OK Scroll to LSI CAN CHECK PT SET LSI CAN CHECK POINT use the arrow keys to change NO to YES 11 Follow and execute the screen instructions Remove Weights and Attachments press b TELESCOPE IN and FULLY LIFT UP press c STOP WAIT ONE MINUTE wait at least one minute and press OK d PRESS ENTER TO SET CHECK POINT press OK e Screen defaults back to CALIBRATIONS LSI CAN CHECK POINT f Press for approximate two seconds to return to normal display screen g LSI Can Check is now complete 12 Remove the analyzer 13 Return machine to service G5 18A 2505H 25 5 9 31 Electrical System 9 11 6 500 Hour LSI UGM Calibration Check 1 The machine must be on a level surface wheels steered straight and park brake ON 9 12 HAND HELD ANALYZER 2505H amp 25 5 2 Start machine 1 P
138. e ne eer ASEGURO Pade dae 3 9 3 6 Quick Attach Assembly s 3 10 3 7 ed uut eet da de UR RET e ae Ra 3 11 3 8 Boom Prop 3 12 3 9 Emergency Boom Lowering 3 13 3 10 Troubleshooting bx rnb bg 3 15 Section 4 CaD Eee ete Sir ME ER X RIEN SR 4 1 4 1 Operator Cab Component 4 2 4 2 Safety Information 2 2 2 4 3 4 3 Operator Cabs 4 3 4 4 1 2 7 4 3 4 5 Cab Removals cieee kia 4 10 4 6 Cab Installation 4 11 G5 18A 2505H 25 5 Section Subject Page Section 5 Axles Drive Shafts Wheels 5 1 5 1 Axle Drive Shaft and Wheel Component Terminology 5 2 5 2 Safety Information 5 3 5 3 General 5 3 5 4 Axle 5
139. e park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool Properly disconnect the battery Remove the wiper arm assembly Loosen and remove the rear wiper cover Disconnect the cab harness connectors from the wiper motor 8 Remove the wiper motor in question Note Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing b Disassembly DO NOT disassemble the motor The motor is not serviceable Replace motor if found to be defective c Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found 9 20 d Installation and Testing 1 Install all required hardware to the motor assembly 2 Align motor with the mounting holes and bolt the motor to the proper location Note Align the wiper to ensure wiper stroke covers window area and it does not swipe past the glass area 3 Connect the cab harness connectors to wiper motor connectors Install rear wiper cover Install wiper arm assembly Properly connect the battery Turn ignition key switch to the RUN position and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved 8 Instal
140. e park brake housing Clean all components with a suitable cleaner before inspection 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 Inspect internal passageways of the park brake manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 6 Install the solenoid valves and cartridges in the park brake housing Park Brake Valve Installation Install the park brake valve with the two lockwashers and two capscrews to the cover Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 2 3 Use new oiled o rings as required Uncap reattach and secure the three hoses Check the routing of all hoses for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required G5 18A 2505H
141. e the side skirt on the engine pod 11 Loosen and remove the rear fender along with the air cleaner 12 Disconnect the plug from the bracket and remove the bracket from the engine 13 Loosen and remove the turbocharger drain tube 14 Plug or cap the turbocharger drain tube openings to prevent dirt and or debris from entering the engine Note Replace the o ring at the base of the turbocharger drain tube during re assembly 15 Remove the positive cables from the starter 9 15 Electrical System 16 Remove the top bolt securing the starter to the engine Note Use a 13mm deep well socket on a 6 in extension to remove the top starter mounting bolt 17 Remove the bottom bolt securing the starter to the engine 18 Remove the starter 1 from the machine d Starter Cleaning and Drying 1 While the starter is being removed wipe away any grease or dirt that has accumulated around the starter mounting opening 2 If reinstalling the starter clean the exterior of the starter with an approved solvent DO NOT submerse the starter or allow the solvent to contact the starter bushings 3 Dry the starter with a clean lint free cloth e Starter Periodic Maintenance A starter requires no routine maintenance beyond the occasional inspection of the electrical connections which must be clean and tight Note DO NOT disassemble the starter The starter is not serviceable and must be replaced in its
142. e upstream turbine shut off threshold exceeded 1463 1180 1 Exhaust gas temperature upstream turbine shut off threshold exceeded 1474 524037 5 Ash lamp open load 1474 524037 5 Ash lamp open load 1475 34 2 Sensor vehicle speed plausibility error 1475 84 2 Sensor vehicle speed plausibility error 1477 524037 3 Ash lamp short circuit to battery 1477 524037 3 Ash lamp short circuit to battery 1478 524037 4 Ash lamp short circuit to ground 1478 524037 4 Ash lamp short circuit to ground 1479 524062 12 Regeneration inhibit switch not available ComInhSwtNA 1479 524062 12 Regeneration inhibit switch not available ComInhSwtNA 1480 524062 12 Regeneration release switch not available ComRegSwtNA 1480 524062 12 Regeneration release switch not available ComRegSwtNA 1481 524025 5 DPF system operating voltage error 1482 524044 9 CAN message ComMS_Sys7 not received from slave 1483 523632 2 Metering control is not performed in time error 1484 524068 2 Master ECU and Slave ECU have been identified as the same types 1484 524068 2 Master ECU and Slave ECU have been identified as the same types 1485 524052 11 Master ECU and Slave ECU data sets or software are not identical 1485 524052 11 Master ECU and Slave ECU data sets or software are not identical 1486 523718 5 SCR main relay open load only CV56B 1487 523718 12 SCR main relay powerstage over temperature only CV56B 1487 523718 12 SCR main relay powerstage over temperature only CV56B
143. eam cat DPF system downstream cat 168 523935 12 Time out Error of CAN Transmit Frame EEC3VOL1 Engine send messages 169 523936 12 Time out Error of CAN Transmit Frame EEC3VOL2 Engine send messages 171 523212 9 Time out Error of CAN Receive Frame ComEngPrt Engine Protection 179 523240 9 Time out CAN message FunModCtl Function Mode Control Time out Error of CAN Receive Frame PrHtEnCmd pre heat 138 vedere 3 command engine command 202 523793 9 Time out Error of CAN Receive Frame UAA10 AGS sensor service message 203 523794 9 Time out Error of CAN Receive Frame UAA11 AGS sensor data 212 523803 9 Time out Error of CAN Receive Frame RxEngPres Status burner air pump 281 523766 9 Time out Error of CAN Receive Frame Active TSC1AE 282 523767 9 Time out Error of CAN Receive Frame Passive TSC1AE 283 523768 9 Time out Error of CAN Receive Frame Active TSC1AR 284 523769 9 Time out Error of CAN Receive Frame Passive TSC1AR 285 523770 9 Time out Error of CAN Receive Frame Passive TSC1DE 291 523776 9 Time out Error of CAN Receive Frame TSC1TE active G5 18A 2505H 25 5 9 41 Electrical System SEIN Deutz Description Codes Codes Codes 292 523777 9 Passive Time out Error of CAN Receive Frame TSC1TE Set point 293 523778 9 Active Time out Error of CAN Receive Frame TSC1TR 294 523779
144. ect battery 8 Open engine cover Allow system fluids to cool 9 Remove quick attach assembly Refer to Section 3 6 1 Quick Attach Assembly Removal 10 Label and disconnect tilt hoses and if equipped auxiliary hydraulic hoses attached to machine at boom head Plug and cap hose ends to prevent dirt and debris from entering hydraulic system Note Tag or identify each hose to corresponding fitting it was removed from 11 Label and disconnect extend retract hydraulic tubes on extend retract cylinder at the rear of boom Plug and cap hose ends to prevent dirt and debris from entering hydraulic system 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 MY 1960 13 Remove lock bolt and nut 10 from rear of extend retract cylinder 14 Remove extend retract cylinder mounting pin 11 15 Support front of boom by placing a sling behind boom head 16 17 18 Pull second boom section out of first boom section approximately 6 in to 8 in 15 cm to 20 cm Pull tilt hoses and if equipped auxiliary hydraulic hoses through rear of boom Remove top side and bottom wear pads from front of first boom section Note Tag each pad backing plate shim and bolts from each location Note The use of two
145. egular intervals and or wear Refer to Section 2 7 Lubrication Schedule Replace worn pins as needed 2 Worn bushing s 2 Replace bushing s and lubricate at regular intervals Refer to Section 2 7 Lubrication Schedule 5 Boom will not raise or lower 1 Broken hydraulic hoses ortubes 1 Locate break replace hose s and or connection leaks or tube s tighten connections 2 Lift lower hydraulic system not 2 Refer to Section 8 7 Hydraulic operating properly Schematic 3 Faulty lift cylinder 3 Repair cylinder Refer to Section 8 12 Hydraulic Cylinders 4 Seized boom pivot pin bushing 4 Replace bushing G5 18A 2505H 25 5 3 15 D Boom Cy Problem Possible Causes Remedy 6 Rapid boom pad wear 1 Incorrect wear pad gap 2 Rapid cycle times with heavy loads 3 Contaminated corroded or rusted wear pad sliding surfaces 4 Operating in extremely dusty abrasive conditions 1 Check wear pad gaps correct as needed Refer to Section 3 5 2 Wear Pad Installation and Lubrication Reduce cycle times Remove contamination and or corrosion from wear pad sliding surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s Clean equipment frequently 7 Auxiliary hydraulics will not operate 1 Auxiliary hydraulic system not operating properly Refer to Sectio
146. embly Cleaning Inspection and Assembly 1 Place the pilot select assembly on a suitable work surface 2 Remove the solenoid valves and cartridges 3 4 amp 5 from the steer select housing 3 Clean all components with a suitable cleaner before 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 manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 6 Install the solenoid valves and cartridges in the pilot select housing G5 18A 2505H 25 5 Hydraulic System n Pilot Select Valve Installation Attach the pilot select manifold valve to the mounting plate on the frame using the socket head capscrews Connect the hydraulic hoses fittings solenoid wire terminal leads etc to the pilot select valve Check the routing of all hoses wiring and tubing fo
147. en for regeneration 58 523911 0 Burner dosing valve DV2 over current at the end of the injection phase 59 523911 12 Burner dosing valve DV2 powerstage over temperature 60 523911 3 Burner dosing valve DV2 short circuit to battery 61 523911 3 Burner dosing valve DV2 short circuit to battery on high side 62 523911 4 Burner dosing valve DV2 short circuit to ground 63 523911 11 Burner dosing valve DV2 short circuit high side powerstage 64 523912 2 Burner dosing valve DV2 downstream pressure sensor plausibility error Physical range check high for burner dosing valve DV2 downstream pressure shut 66 552315 off regeneration Physical range check low for burner dosing valve DV2 downstream pressure shut off regeneration When burner injector is actuated the measured pressure does not 69 523912 1 rise above ca 1250mbarabs expected ca 2400mbar 72 523912 3 burner dosing valve DV2 downstream pressure sensor signal range 73 523912 4 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check low 74 523913 3 Sensor error glow plug control diagnostic line voltage signal range check high G5 18A 2505H 25 5 9 39 Electrical System Deutz Description Codes Codes Codes d P 75 523913 4 Sensor error glow plug control diagnostic line
148. engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the engine to cool Properly disconnect the battery Pull the frame out of the dash disconnect the harness connector to the switch in question and push the switch out of the frame Disassembly DO NOT disassemble the dash switch Replace defective switch with a new part Inspection and Replacement Inspect the switch terminals for continuity in both the engaged and disengaged positions Replace a defective or faulty switch with a new switch G5 18A 2505H 25 5 Switch Installation 1 Connect the switch to the cab harness connector Position the switch over the rectangular switch bezel and snap into position Replace the frame into the dash Properly connect the battery Start the machine and check the replaced switch for proper function Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel 9 10 3 Fuel Level Indicator and Fuel Level Sender a Fuel Level Indicator Testing b The fuel level sender wiring harness leads can be accessed from the top of the fuel tank Disconnect the fuel level sender wiring harness leads With the help of an assistant touch both harness leads together From the operator s
149. entirety if defective f Starter Installation 1 Position the starter in its mounting opening on the flywheel housing Install the bottom bolt securing the starter to the flywheel housing Note Do Not tighten the bottom bolt until the top bolt is installed 2 Using tape or a magnetic socket secure the top starter mounting bolt to the socket Install the top bolt securing the starter to the flywheel housing 3 Tighten and torque the starter mounting bolts to 25Nm 18 Ib ft 4 If necessary install a new o ring on the turbocharger drain tube 5 Remove the plugs or caps from the turbocharger drain tube openings 6 Install the turbocharger drain tube to the engine Torque the turbocharger drain tube mounting bolt to 8 5 Nm 7 Ib ft 7 Install the previously removed bracket to the engine and connect the electrical connector 9 16 10 11 12 13 14 15 16 17 Install the previously removed rear fender along with the air cleaner to the engine pod Install the previously removed side skirt on the engine pod Connect the diagnostic plug to the air cleaner bracket and securing the wire harness to the rear fender Connect the two connectors on the ECM Install the previously removed exhaust tube between the turbocharger and muffler Tighten as required Install the previously removed air intake hose Tighten as required Install the previously removed belly pan Tighten as re
150. environment temperature signal range check high 418 171 4 Sensor error environment temperature signal range check low 419 190 8 Sensor camshaft speed disturbed signal 420 190 12 Sensor camshaft speed no signal 421 190 2 Offset angle between crank and camshaft sensor is too large 422 190 8 Sensor crankshaft speed disturbed signal 423 190 12 Sensor crankshaft speed no signal 424 703 5 Engine running lamp open load 425 703 12 Engine running lamp powerstage over temperature 426 703 3 Engine running lamp short circuit to battery 427 703 4 Engine running lamp short circuit to ground 450 975 5 Digital fan control open load 451 975 12 Digital fan control powerstage over temperature 452 975 3 Digital fan control short circuit to battery 453 975 4 Digital fan control short circuit to ground 455 975 5 Fan actuator PWM output open load 456 975 12 Fan actuator PWM output powerstage over temperature 9 42 G5 18A 2505H 25 5 Electrical System pann pu EMI Deutz Description Codes Codes Codes 457 975 3 Fan actuator PWM output short circuit to battery 458 975 4 Fan actuator PWM output short circuit to ground 460 1639 0 Sensor error fan speed signal range check high 461 1639 1 Sensor error fan speed signal range check low 462 523602 0 High fan speed warning threshold exceeded 46
151. er Torque Chart Continued Values for Magni Coated Fasteners Ref 4150701 CLASS 8 8 METRIC HEX SOCKET HEAD BOLTS CLASS 8 METRIC NUTS Torque Torque Torque Lub or Loctite Size Pitch E ito Dry or ue 263 242 271 ven 225 0 17 Vibra TITE 111 or 140 K 0 15 K 0 16 Sq KN N m N m N m 3 0 5 5 03 2 19 14 14 1 0 3 5 0 6 6 78 2 95 1 8 17 1 5 4 0 7 8 78 3 82 2 6 24 2 3 5 0 8 14 20 6 18 53 4 9 4 6 6 1 2010 8 74 9 84 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 25 245 106 5 362 340 320 22 25 303 132 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 45 1120 487 0 3477 3275 3070 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 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 G5 18A 2505H 25 5 General Information and Specifications
152. erformance 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 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 8 6 1 Pressure Checks and Adjustments In general follow the steps below whenever conducting pressure checks and performing adjustments 1 Park the machine on a firm level surface Engage the park brake place the transmission control lever in N NEUTRAL place the neutral lock lever in the N NEUTRAL LOCK position level the boom and turn the engine OFF 2 Pressure tee fittings are conveniently located in each hydraulic circuit Install a pressure gauge capable of measuring at least 10 more pressure than that which the circuit being checked operates under 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 Ful
153. es can be accessed by pressing the ENTER key while viewing the current Help message The Help message shall be EVERYTHING OK when no fault is present The Analyzer cable plugs into the connector located behind the access panel on the right side of the dash For more information contact the local JLG Dealer 12 Remove the analyzer 13 Return machine to service 9 32 G5 18A 2505H 25 5 Electrical System 9 12 2 Analyzer Software Version 1 0 NOTE THE LAYOUT SHOWS ALL POSSIBLE ANALYZER SCREENS PLEASE NOTE SOME SCREENS MAY NOT BE AVAILABLE DEPENDING UPON MACHINE CONFIGURATION MENU 001 HELP PRESS ENTER EVERYTHING OK 109 X 0000000000 MENU DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS 2 DIAGNOSTICS DIAGNOSTICS DRIVE CAB INPUTS BOOM FUNCTIONS FAN SYSTEM LOAD MOMENT CAN STATISTICS CALIBRATION DATA VERSIONS TRANS MTR OUTPUT LB
154. ess connector to the variable speed fan control Install the control panel screws Properly connect the battery Turn the ignition key switch to the RUN position fan switch Verify that the fan operates at variable speeds 10 Close and secure the battery and engine covers 11 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 9 22 Install the setscrew securing the knob to the control 9 10 SWITCHES SOLENOIDS AND SENDERS 9 10 1 Ignition Key Switch a Ignition Switch Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery 5 Remove lower dash panel 6 Remove the hex nut securing the ignition key switch to the dash 7 Reach up under the dash to work the ignition switch and wiring out of the mounting hole 8 Disconnect the ignition switch connectors from the cab harness connectors and remove the switch from the machine b Disassembly DO NOT disassemble the ignition switch Replace a defective switch with a new part c Inspection and Replacement To determi
155. ever in N NEUTRAL engage 2 the park brake switch 2 Raise the boom to an angle of approximately 20 degrees Shut engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel 4 Before installing boom prop inspect prop for damage Do not use if prop is damaged or if o rings are damaged or missing 5 Install boom prop 1 onto lift lower cylinder Install o rings 2 Align lift cylinder lock so o rings are 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 G5 18A 2505H 25 5 3 9 EMERGENCY BOOM LOWERING PROCEDURE WARNING 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 extend retract cylinder first lower the lift cylinder the minimum amount necessary and resume retraction of the extend retract cylinder as soon as possible A WARNING Properly support the boom before attempting to proceed with the emergency boom lowering procedure A WARNING If possible safely remove and or secure the load on the machine before starting the boom lowering procedure If load cannot be removed the machine load chart MUST be followed G5 18A 2505H 25 5 3 9 1
156. ey switch and steering wheel Power Steering Test 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 G5 18A 2505H 25 5 Cab a 4 a 4 3 Brake Pedal and Valve Brake Valve Removal Refer to Section 8 11 2 a Service Brake Valve Removal for removal information b Brake Valve Installation Refer to Section 8 11 2 b Service Brake Valve Installation for installation information 1 2 gt Service Brake Pedal Removal Park machine on a hard level surface Fully retract boom lower boom place transmission control lever in N NEUTRAL Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool Remove the lower dash cover 8860 G5 18A 2505H 25 5 8 Remove hardware 10 9 Remove pin 11 and return spring securing service ON DO brake pedal to cab Remove service brake pedal from cab Service Brake Pedal Installation Position service brake pedal in its mounting location within cab Install brake pedal being careful to reposition brake plunger yoke Install return spring and pin 11 Install hardware 10 securing pin Adjust brake pedal as needed Install and
157. f 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 bore and cylinder barrel Secure with hardware 18 removed earlier 4 Remove plugs in bottom of extend retract cylinder and install previously removed fittings 17 5 Uncap and connect tubes 16 to previously labeled fittings at extend retract cylinder Apply locking compound to fittings 6 Uncap and reconnect tilt hoses and if equipped auxiliary hoses 15 to their appropriate fittings until wrench tight Mark the fitting and torque to specification Refer to Section 2 3 3 Hydraulic Hose Torque Chart 7 Install cover plate 14 and hose clamps at rear of boom assembly 8 Reinstall any miscellaneous parts such as mirror if removed previously 9 Properly connect battery 10 Start machine and extend the extend retract cylinder until rod eye of cylinder aligns with pin bore in second boom section 11 Shut the engine OFF 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 16 Clean up all debris hydraulic fluid etc in on nea
158. fore continuing Add hydraulic fluid to the reservoir as needed 6 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 7 Close and secure the battery and engine covers 8 Remove the Do Not Operate Tags from both the ignition key and the steering wheel d Quick Attach Valve Test 1 Turn the ignition switch to the ON position activate the quick attach switch to switch the auxiliary position or the quick attach position 2 If further troubleshooting is required refer to Section 8 7 Hydraulic Schematic or Section 9 4 Electrical System Schematics 8 11 11 The variable speed fan valve is located on the bottom side of the Radiator assembly Variable Speed Fan Valve 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 The housing of the variable fan valve is not serviceable and must be replaced if defective a Variable Speed Fan Valve Removal 1 Park the machine on a firm level surface fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Properly support the boom 8 24 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the system fluids to cool Pro
159. fuel may be used however fuel economy will be reduced If equipped for ULS use ultra low sulfur content fuel with a cloud point temperature at which wax crystals form in diesel fuel at least 10 below lowest expected fuel temperature Viscosity of fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication If equipped for LS use low sulfur content fuel with a cloud point temperature at which wax crystals form in diesel fuel at least 10 below lowest expected fuel temperature Viscosity of fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication 7 4 2 Fuel Hydraulic Oil Tank a Cleaning and Drying If contaminated fuel hydraulic oil or foreign material is in the tank the tank can usually be cleaned b Ifa leak is suspected between the fuel and hydraulic oil tank contact the local JLG dealer To clean the fuel hydraulic oil tank O Engine Have dry chemical Class B fire extinguisher near the work area Depending on which side of the tank is contaminated fuel or hydraulic oil 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 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 For the fuel tank side add
160. g equipment if possible Avoid using excessive force when clamping the cylinder in a vise Apply only enough force to hold the cylinder securely Excessive force can damage the cylinder tube 160 DO NOT tamper with or attempt to adjust the counterbalance valve cartridge If adjustment is necessary replace the counterbalance valve with a new part 4 Extend the rod 5 to allow access to the base of the cylinder Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 3 If applicable remove the counterbalance valve from the side of the cylinder barrel 8 26 5 Using a pin spanner wrench unscrew the head gland 6 from the barrel 1 A considerable amount of force will be necessary to remove the head gland Carefully slide the head gland down along the rod toward the rod eye end away from the cylinder barrel G5 18A 2505H 25 5 Hydraulic System 8 When sliding the rod piston assembly out of the tube 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 8 Remove the set screw 3 from the piston 4
161. gs and plug hoses to keep dirt amp debris from entering hydraulic system Label disconnect and cap all fuel lines Install a plug in the end of each line Remove hydraulic and fuel filters and radiator oil cooler assembly bracket assembly 2 Label and disconnect all wire connections on the engine and transmission Secure the engine 3 with a lifting strap or chain from the appropriate lifting points Use a suitable hoist or overhead crane Remove the four motor mount bolts that attach the engine to the frame Carefully lift the engine from the machine Avoid causing damage to the surrounding parts Lift the engine clear of the machine and lower it onto suitable supports or stand Secure the engine so that it will not move or fall 7 11 Engine 7 7 2 Engine Disassembly Inspection and Service Engine disassembly internal inspection service repair and assembly procedures are covered in the Deutz Engine manual Several special engine service tools are required to properly service the Deutz engine Contact the local JLG dealer for further information Note Ifthe engine is being replaced there may be external components that will be required to be transferred from the original engine to the replacement engine depending upon who you purchase the new engine from and the configuration of your replacement engine Refer to the appropriate JLG user manual for detailed procedures that cove
162. he boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the battery and engine covers Allow the engine to cool 5 Properly disconnect the battery 6 Disconnect the LSI modules electrical connectors 9 28 G5 18A 2505H 25 5 Electrical System 9 11 4 LSI System Calibration a Standard Calibration To calibrate the LSI certain conditions must be met sensors must be installed according to Section 9 11 1 LSI Axle Sensor and Section 9 11 2 LSI Boom Sensors The machine control system must be powered on for at least 10 minutes before calibration The operator must remain in the cab The calibration shall be conducted with the standard carriage and forks attached and weights as necessary a range of 60 8096 of maximum weight capacity The machine must be on a level surface with the wheels steered straight and park brake off with straight driving over a distance of at least 2 m 6 5 ft being the last movement before entering a calibration point While utilizing the LSI override button 10 times lift and lower the boom stopping suddenly to induce the rear axle to bounce Position the rear tires centrally on the scales The calibration must be completed within
163. he flywheel may be defective Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine 3 If the starter only clicks it may indicate that the battery is discharged or that there is a loose or corroded battery cable connection Check the battery state of charge and battery condition first then check the cables and cable connections 4 Foradditional information on the starting circuit refer to Section d Base Frame Schematic A c Starter Removal Remove the starter only if it fails To remove the starter 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Note Park the machine on blocks to allow proper access under the machine 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool Properly disconnect the battery Remove the belly pan Disconnect and remove the air intake hose 2 Disconnect remove the exhaust tube between the turbocharger and muffler 8 Disconnect the two connectors on the ECM 9 Disconnect the diagnostic plug from the air cleaner bracket and remove the nylon ties securing the wire harness to the rear fender 10 Loosen and remov
164. hoses 7 and fittings on steering orbitrol valve 8 Remove four hex flange capscrews 9 three if machine is equipped with tilt column connecting orbitrol valve to steering column Pull steering column assembly and orbitrol valve from machine cab The steering orbitrol valve is not serviceable and must be replaced in its entirety if defective b 1 Steering Column and Valve Installation Install four hex flange capscrews three if machine is equipped with tilt column through steering column mounting bracket and into top of orbitrol valve Note ALWAYS use new o rings when servicing the machine 2 Uncap and install new o rings into fittings Lubricate o rings with clean hydraulic oil Uncap and reconnect previously labeled hydraulic hoses to their appropriate locations 4 Install dash cover Install steering column cover Install steering wheel Refer to Section 4 4 1 Steering Wheel accessory lever and transmission control lever 7 Properly connect battery 10 11 12 Carefully examine all connections last time before engine start up Rectify any faulty conditions Start engine and check operation of all controls Check for fluid leaks Check hydraulic fluid level in tank and add fluid as required Clean up all debris hydraulic fluid etc in on near and around the machine Close and secure engine cover Remove a Do Not Operate Tag on both ignition k
165. ible indication is provided and the automatic function cut out and or slow down fea ture is disabled 9 26 Travel in accordance with the requirements set forth in Section 1 General Safety Practices When placing a load ensure axles are not fully steered in either direction WARNING TIP OVER HAZARD If the green orange and red LEDs flash and warning buzzer sounds retract and lower boom immediately Determine cause and correct before continued use Test the LSI 6 at the beginning of each work shift 1 Fully retract and level the boom with no load Do not raise the boom during this test 2 Level frame using level in cab 3 Press the system check button on the LSI display This will cause all LEDs to flash on and an audible warning to sound This indicates that the system is functioning properly If the test gives a different result the system is not functioning properly and the machine must be removed from service and repaired before continued operation 9 11 1 LSI Axle Sensor Ze jar SNY 6 7 00 2 lt 2 SX I Ao LSI axle sensor 1 is bolted on the top left of the rear axle MAM2900 Note If the rear axle is removed or replaced the LSI Sensor must be installed AFTER the rear axle is installed and setting on all four wheels G5 18A 2505H 25 5 Electrical System a LSI Axle Sensor Removal 1
166. idth center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability Foam filled tires have a positive effect on the weight stability and handling characteristics of the machine especially under load The use of hydrofill as a tire fill substance is not recommended because of possible environmental impact Large bore valve stems are used to help expedite tire inflation and deflation An inner tube may be used if a tire does not provide an airtight seal Check tire inflation pressures when the tires are cold When mounting a tire on the wheel the tire must be mounted on the wheel respective of the directional tread pattern of the tire this produces a left or right tire and wheel assembly 5 10 The wheel and tire assemblies must be installed with the directional tread pattern arrows 1 facing in the direction of forward travel 5 6 1 Removing Wheel and Tire Assembly from Machine 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed 4 Place a suitable jack under the axle pad closest to the
167. ift the cylinder into it s mounting position General Cylinder Installation 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 5 Properly connect the battery 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 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 10 Close and secure the battery and engine covers 11 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 8 12 7 The steering cylinders are attached to each axle center housing Detailed axle service instructions are provided in the Axle Disassembly amp Assembly Manual P N 31200451 Steering Cy
168. il as required DO NOT use flushing compounds for cleaning purposes 17 Carefully remove transmission and pump from the machine Avoid causing damage to transmission or surrounding parts 18 Lift transmission and pump clear of machine and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service Secure transmission and pump so that it will not move or fall 6 5 2 Transmission Disassembly Contact an authorized Rexroth Repair center for transmission disassembly internal inspection service repair and assembly procedures 6 5 3 Transmission Installation A 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 Ib 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 11 12 13 14 15 16 17 Run engine for two m
169. ine 5 10 5 6 2 Installing Wheel and Tire Assembly onto 5 11 5 7 Steering Angle Adjustment 5 11 5 8 5 11 5 8 1 Brake Disc 5 11 5 9 Towing a Disabled 5 12 5 9 1 Equipment and Supplies Required 5 12 5 9 2 Towing 5 13 G5 18A 2505H 25 5 5 1 ay Axles Drive Shafts Wheels and Tires 5 1 AXLE DRIVE SHAFT AND WHEEL 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 axles drive shafts wheels and tires The following illustration identifies the components that are referred to throughout this section FRONT AXLE ASSEMBLY DRIVE SHAFT REAR STEERING CYLINDER FRONT STEERING CYLINDER FRONT AXLE WHEEL HUBS 2 REAR AXLE MY8880 ASSEMBLY REAR AXLE WHEEL HUBS 2 5 2 G5 18A 2505H 25 5 Axles Drive Shafts Wheels and Tires 5 2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in
170. ing table is achieved Model Weight on Rear Axle 2505H amp 25 5 CE 700 20 Ib 318 9 kg 2505H amp 25 5 AUS 1102 29 Ib 500 9 kg 12 13 Press the SYSTEM CHECK button on the LSI display and release As the calibration point is recorded buzzer sounds and the LEDs will flash and perform a sequence until all are flashing Perform the LSI CAN Check PT to finalize the calibration Refer to Section 9 11 5 LSI CAN Check PT 9 29 Electrical System b Field Calibration To calibrate the LSI certain conditions must be met The sensor must be installed according to Section 9 11 1 LSI Axle Sensor and Section 9 11 2 LSI Boom Sensors The test weight matches the model being calibrated in the table shown on page 9 30 The calibration shall be conducted with standard carriage and forks attached to the machine While utilizing the LSI override button 10 times lift and lower the boom stopping suddenly to induce the rear axle to bounce Note If the test weight is not known follow steps 1 amp 2 Test Model Market Weight Xtip 1 Xcal 2 W With Manual Quick Attach 2505H CE amp 2000kg 1225 978mm amp 25 5 AUS 4408 Ib 48 25 in 38 5 in With Hydraulic Quick Attach 2505H CE amp 2000kg 1200mm 952mm amp 25 5 AUS 440810 47 25 in 37 5 in
171. ings with fresh filtered hydraulic oil from a clean container before attaching the hoses 4 Use new oiled o rings as required Uncap and reattach and secure all hoses clamps etc to the main control valve 5 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 6 Properly connect the battery 8 14 7 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 8 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 10 Install the rear panel 11 Close and secure the battery and engine covers 12 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 9 Main Control Valve Test Conduct a pressure check of the hydraulic system in its entirety Adjust pressure s as required Refer to Section 8 6 2 Main Control Valve Pressure Checking 8 11 2 The service brake valve is at the base of the steering column support concealed by the lower dash cover Service Brake Valve The service brakes themselves are part of the front axle Refer to Section 5 8 Brakes for further information a Ser
172. inutes at idle to help bleed any air from hydraulic system Operate all boom functions to ensure any air is removed from hydraulic system Retract and level boom recheck level of the fluid in the reservoir Add oil as necessary to bring fluid level up until it reaches FULL mark on reservoir Recheck oil level when it reaches operating temperature 180 200 83 94 Recheck all drain plugs lines connections etc for leaks and tighten where necessary Close and secure the engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 Section 7 Contents PARAGRAPH TITLE PAGE 7 1 INntrOdUCTIONN ee ee i ee ee ee 7 2 7 14 Disclaimer and 7 2 7 1 2 Engine Serial 1 7 2 7 1 8 Specifications and Maintenance Information 7 2 7 1 4 Component 1 7 3 7 2 Engine Cooling System 7 4 7 2 1 Surge Tank Cap 7 4 7 2 2 Radiator Oil Cooler 7 4 7 3 Engine Electrical 7 7 7 4 Fuel Systemi mim Nes Pe Oe eae eee a 7 7 7 4 1 Diesel FUGI 7 7 7
173. ion Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 4 Install the previously labeled fittings in the priority valve housing Priority Valve Installation Attach the priority valve to the mounting plate on the frame using the socket head capscrews Connect the hydraulic hoses fittings etc to the priority valve Check the routing of all hoses for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all hose clamps 4 Properly connect the battery 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 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 7 8 9 d 1 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel Priority Valve Test Start the machine and slowly depress the throttle to 1 2 throttle Turn the steering and engage a boom function The steering will continue
174. ions and detailed specifications contact an authorized Rexroth Repair center More information can be obtained from the serial number plate directly mounted on the transmission Information specified on the serial number plate includes the transmission model number the transmission serial number and other data Information on the serial number plate is required in correspondence regarding the transmission 6 4 TRANSMISSION SPECIFICATIONS 6 4 1 The transmission is a hydraulic component and requires the same maintenance as the hydraulic system Refer to Section 2 6 Maintenance Schedule Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable Transmission Maintenance G5 18A 2505H 25 5 6 5 TRANSMISSION REPLACEMENT Note Contact the local JLG Dealer if internal transmission repair is required during warranty period Cleanliness is of extreme importance Before attempting to remove the transmission thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components 6 5 1 Transmission Removal 1 Park machine on a hard level surface 2 Fully retract boom lower boom place transmission control lever in N NEUTRAL 3 Engage park brake and shut engine OFF Place Do Not Operate Tag
175. ittings and openings to keep dirt and debris from entering the hydraulic system Note Loss of hydraulic oil is limited to amount trapped within each hose 4 Using hoses and fittings specified previously connect jumper hoses between auxiliary hydraulic power supply and steel tubes 4 and 5 connected to extend retract cylinder of affected machine Ensure that supply and return lines are installed in proper order to ensure cylinder is retracted not extended 5 Use the auxiliary power supply to retract the extend retract cylinder 6 Loosen and remove the jumper hoses and reconnect extend retract cylinder hoses 7 Transfer any hydraulic oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility 8 Clean up all debris hydraulic fluid etc in on near and around machine 3 14 6 and 7 from main control valve Install plugs in hoses to prevent fluid loss Cap all fittings and openings to keep dirt and debris from entering hydraulic system Note Loss of hydraulic oil is limited to amount trapped within each hose 3 Using hoses and fittings specified connect hoses between auxiliary hydraulic power supply and hoses removed from main control valve lift lower section of affected machine Hose 7 is supply lower and hose 6 is return Connect hoses in proper order to ensure that boom is lowered not raised Use auxiliary power supply to ret
176. k bolt 2 and pin 1 from compensating cylinder Ge Boom 8580 10 Lower the boom to a position that allows for the removal of rod end pin 3 connecting lift lower cylinder to boom 11 Support boom by placing a sling s around boom head Support lift lower cylinder and remove lock bolt 4 and rod end 3 Lower lift lower cylinder onto frame rails 12 Properly disconnect battery 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 15 If equipped disconnect the LSI boom proximity sensor at rear of first boom section Note Tag or identify each hose to the corresponding fitting it was removed from MY8590 3 4 16 Lower boom to a level position and place a suitable support under rear of boom Reposition slings to each end of boom 17 Remove capscrew 5 and locknut 6 securing boom pivot pin 7 and remove boom pivot pin 18 Lift complete boom off machine and set on level ground or supports being careful not to damage tubes on bottom of boom 3 4 2 Note Lubrication of boom wear surfaces with grease is recommended to keep boom wear surfaces lubricated proper
177. l right side defroster hose to the dash panel hose connector 9 If previously removed install hydraulic hoses under the dash 10 Install the lower dash panel 11 Close and secure the battery and engine covers 12 Remove the Do Not Operate Tags from both the ignition key and the steering wheel Windshield Washer Reservoir and Pump 9 8 3 The windshield washer motor and reservoir is located in the dash area as a unit and cannot be serviced separately a Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery 5 Remove the nuts and the lockwashers from the washer mounting studs 6 Pull the washer reservoir out and away from the mounting studs G5 18A 2505H 25 5 Electrical System 7 Rotate the washer reservoir label and remove the cab harness connectors from the washer reservoir connectors 8 Remove the windshield washer hoses from the reservoir b Disassembly DO NOT disassemble the pump The pump is not serviceable Replace pump if found to be defective c Installation and Testing 1 C
178. lace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil 6 Install the cartridge in the inching valve housing c Inching Valve Installation 1 Attach the inching valve to the mounting plate on the 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 Tighten all hose clamps 4 Properly connect the battery 5 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions 6 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 7 4 Wipe any hydraulic fluid spillage on near around the machine work area and tools Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel Inching Valve Bleeding Procedure Carefully bleed the inching valve as soon as the inching valve is installed on the machine Air in the system will not allow the brakes to apply properly There is one bleeder locati
179. lausibility error 1524 2659 0 Physical range check high for EGR exhaust gas mass flow 1524 2659 0 Physical range check high for EGR exhaust gas mass flow 1525 2659 1 Physical range check low for EGR exhaust gas mass flow 1525 2659 1 Physical range check low for EGR exhaust gas mass flow 1526 2659 12 Exhaust gas recirculation AGS sensor has burn off not performed 1526 2659 12 Exhaust gas recirculation AGS sensor has burn off not performed 1527 2659 2 AGS sensor temperature exhaust gas mass flow plausibility error 1527 2659 2 AGS sensor temperature exhaust gas mass flow plausibility error 1615 3699 14 Maximum stand still duration reached oil exchange required 1615 3699 14 Maximum stand still duration reached oil exchange required 1616 3699 2 DPF differential pressure sensor and a further sensor or actuator CRT system defective 1616 3699 2 DPF differential pressure sensor and a further sensor or actuator CRT system defective 1617 3699 2 Temperature sensor us and ds DOC simultaneously defect 1617 3699 2 Temperature sensor us and ds DOC simultaneously defect 1659 524114 9 Time out error of CAN Transmit Frame A1DOC 1659 524114 9 Time out error of CAN Transmit Frame A1DOC 1660 524115 9 Time out error of CAN Transmit Frame AT1S 1660 524115 9 Time out error of CAN Transmit Frame AT IS 1661 524116 9 Time out error of CAN Transmit Frame SCR2 1661 524116 9 Time out error of CAN Transmit Frame SCR2 1662 524117 9 Time out error of C
180. lausibility error cold start condition 916 523721 Sensor urea supply module temperature plausibility error normal condition 917 523721 2 Sensor urea supply module temperature plausibility error cold start condition 918 523981 11 Urea tank without heating function heating phase 919 523330 14 Immobilizer status fuel blocked 925 523720 8 Urea supply module heater temperature duty cycle in failure range G5 18A 2505H 25 5 9 47 Electrical System FEN Deutz Description Codes Codes Codes 926 523720 8 Urea supply module heater temperature duty cycle in invalid range 927 523721 11 Urea supply module temperature measurement not available 928 523722 8 Urea supply module PWM signal period outside valid range 929 523722 8 Detect faulty PWM signal from Supply Module 930 523721 8 Urea supply module temperature duty cycle in failure range 931 523721 8 Urea supply module temperature duty cycle in invalid range 932 29 3 Hand throttle idle validation switch short circuit to battery 935 91 3 Sensor error accelerator pedal signal range check high 936 29 3 Sensor error hand throttle signal range check high 937 29 4 Hand throttle idle validation switch short circuit to ground 940 91 4 Sensor error accelerator pedal signal range check low 941 29 4 Sensor error hand throt
181. le Disassembly amp Assembly Manual P N 31200419 5 11 hs Axles Drive Shafts Wheels and Tires 5 9 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted after exhausting all other options Make every effort to repair the machine and move it under its own power Towing is only possible by using the towing feature built into hydrostatic pump and disengaging park brake on the front axle Maximum towing distance is 200 ft 60 m Maximum towing speed is 5 mph 8 kmh Maximum towing grade is 25 DO NOT attempt to tow a machine that is loaded or boom attachment is raised above 1 2 m 4 ft A WARNING MACHINE HAS NO TOWING BRAKES Towing vehicle must be able to control machine at all times On highway towing is NOT permitted WARNING BLOCK ALL FOUR WHEELS TO PREVENT MACHINE FROM MACHINE ROLL AWAY Failure to follow instructions could cause death or serious injury 5 9 1 Equipment and Supplies Required EQUIPMENT DAMAGE Auxiliary Hydraulic Power Supply hydraulic oil must be compatible with hydraulic oil shown in Section 2 5 Fluids Lubricants and Capacities Auxiliary Hydraulic Power Supply Portable hydraulic unit with capability of producing 300 psi 20 7 bar minimum pressure to release park brake Hose One Hydraulic Hose Approximately 5 ft 1 5 m with a minimum 1 0 of 0 25 in 6 3 mm and a minimum rating of 2
182. le Manual P N 31200419 Rear Axle Manual P N 31200981 Axle Internal Service G5 18A 2505H 25 5 5 4 4 Axle Maintenance CLEANING Clean parts with machined or ground surfaces such as gears bearings and shafts with emulsion cleaners or petroleum based cleaners DO NOT steam clean internal components and the interior of the planetary hub and axle housing Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Remove old gasket material from all surfaces DRYING Use clean lintless towels to dry components after cleaning DO NOT dry bearings by spinning them with compressed air this can damage mating surfaces due to lack of lubrication After drying coat components with oil or a rust preventive chemical to help protect them from corrosion If storing components for a prolonged period wrap them in wax paper PERIODIC OPERATION REQUIREMENT Every two weeks drive the machine far enough to cause the drive train components to make several complete revolutions This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity SUBMERSION If the machine has been exposed to water deep enough to cover the hubs disassemble the wheel ends and inspect for water damage and contamination If the carrier housing was submerged in water especially if the water level was above the vent tube breather
183. lic Hose Torque Chart 11 Uncap and reconnect tilt hoses and if equipped auxiliary hoses Attach both sets to their appropriate fittings until wrench tight Mark fitting then torque to specification Refer to Section 2 3 3 Hydraulic Hose Torque Chart 12 Raise boom to height that allows for installation of compensating cylinder pin 8 and lock bolt 9 Apply locking compound and torque to 66 Ib 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 MY8570 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 3 4 3 Second Boom Section Removal 1 Remove any attachment from quick attach assembly 2 Be sure there is enough room in front of machine to allow boom sections to be removed 3 Park machine on a hard level surface 4 Fully retract boom lower boom place transmission control lever NEUTRAL 5 Engage park brake and shut engine OFF 6 Place a Do Not Operate Tag on both ignition key switch and steering wheel 7 Properly disconn
184. linders G5 18A 2505H 25 5 Hydraulic System n 8 12 8 Specifications Lift Lower Cylinder Hydraulic Cylinder Torque Head Piston CB Valve Valve Screw FC Valve Set Screw 300 400 Ib ft 1800 2000 Ib ft 45 50 Ib ft 20 25 Ib ft 30 35 Ib 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 Extend Retract Cylinder Head Piston Valve Valve Screw Set Screw 200 250 Ib ft 200 240 Ib ft 44 lb ft 10 12 5 60 69 lb ft 271 339 Nm 271 325 Nm 60 Nm 14 16 Nm 81 94 Nm Tilt Cylinder Head Piston Valve Valve Screw Set Screw 300 400 Ib ft 1400 1500 Ib ft 44 lb ft 10 12 6 11 lb ft 15 Nm 406 542 Nm 1898 2034 Nm 60 Nm 14 16 Nm Compensating Cylinder Head Piston Valve Valve Screw Set Screw 300 400 16 1400 1500 16 44 lb ft 10 12 lb ft 11 lb ft 15 Nm 406 542 Nm 1898 2034 Nm 60 Nm 14 16 Nm G5 18A 2505H 25 5 Use Loctite 262 on all Piston Applications Use Loctite 242 on all Set Screws 8 29 Hydraulic System 8 30 This Page Intentionally Left Blank G5 18A 2505H 25 5 Section 9 Electrical System PARAGRAPH TITLE 9 1 Electrical Component 9 2 Safety 9 3 Fuses and
185. llow the system fluids to cool 4 Thoroughly clean the engine and surrounding area including all hoses and fittings before proceeding Open the battery cover Properly disconnect the battery Support or secure the hood assembly Remove the mounting nuts from the rod end of each hood gas strut 9 Remove the two bolts and washers securing each hinge from the hood side of the hood Mark each bolt location before removing to aid in aligning the hood during reassembly 10 Remove the hood assembly 11 Remove the inside firewall plate 1 to access the back side of the cooling package 12 Remove the engine pod side skirt 2 and belly pan 13 Disconnect the ECM connectors and remove any nylon ties that may be securing the wire harness mounted to the right front fender 14 Remove the right front fender 3 Note It may be required to remove the right front tire to access hydraulic hose fittings 15 Slowly turn the coolant surge tank cap and allow any pressure to escape 4 16 Place a suitable container beneath the radiator petcock 5 G5 18A 2505H 25 5 Engine 20 21 22 23 24 25 26 27 28 Place a funnel at the base of the radiator to channel the drained coolant into the container Open the radiator petcock and drain the coolant into the funnel Transfer the fluid into a properly labeled container Dispose of properly if coolan
186. lly 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 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Properly disconnect the battery 8980 Loosen and remove the bolts 1 connecting the muffler bracket to the frame brackets on the side of the frame Loosen and remove the exhaust pipe flange nuts 2 at the turbocharger Remove the exhaust system as an assembly G5 18A 2505H 25 5 Engine 7 5 2 Exhaust System Installation Note Keep all clamps loosened until entire exhaust system is in place Note Replace the nuts and the exhaust studs on the turbocharger if damaged 1 Install the exhaust assembly in place at the turbocharger with the previously used hardware Torque the flange nuts 2 on the turbo charger to 22 5 lb ft 30 7 Nm Install the muffler brackets 1 to the frame brackets with the previously used hardware Adjust the muffler exhaust and tail pipes for proper clearance then tighten all clamps Properly connect the battery Start engine and check for exhaust leaks at all exhaust connections Adjust or repair as needed Close and secure the engine cover Remove the Do Not Operate Tags from both the ignition key a
187. lubrication of the grease fittings on the drive shafts Drive Shaft Maintenance 5 5 3 1 Park machine on a hard level surface Drive Shaft Removal 2 Fully retract boom lower boom place transmission control lever in N NEUTRAL 3 Engage park brake and shut engine OFF 4 Place a Do Not Operate Tag on both ignition key switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool Block the wheels The drive shaft assembly is a balanced assembly Mark yoke and axle transmission and shaft and slip yoke so that these components can be returned to their original positions when reinstalled 9 Yokes at both ends of drive shaft must be in same plane to help prevent excessive vibration G5 18A 2505H 25 5 TO REAR AXLE MY8900 TO FRONT AXLE 10 Remove hardware 1 securing drive shaft to rear axle flange 11 Remove hardware 2 securing drive shaft to front axle flange 12 Remove drive shaft assembly 3 5 5 4 1 Disassemble and clean all parts Allow to dry Drive Shaft Cleaning and Drying 2 Remove any burrs or rough spots from all machined surfaces Re clean and dry as required 5 5 5 1 Raise drive shaft assembly 3 into position The slip yoke 4 end of drive shaft mounts toward rear axle If reinstalling a drive shaft previously removed align flange yokes according to alignment marks made during removal Drive Shaf
188. ly Lubrication of boom wear surfaces is also recommended when machine is stored to help prevent rusting Refer to Section 2 5 Fluids Lubricants and Capacities Complete Boom Installation Park machine on a hard level surface Place transmission control lever in NEUTRAL Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel gt O 5 Allow system fluids to cool Note Grease the boom pivot bore compensating cylinder rod ends lift lower cylinder rod end and pins before installing 6 Balance boom assembly using suitable slings and 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 Ib 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 Ib ft 90 Nm Note Raising boom up or down with sling may be necessary so boom compensating and lift lower cylinder bores can be aligned for easier pin installation G5 18A 2505H 25 5 i M Ac 10 Uncap and reconnect extend retract cylinder fittings and plugs to extend retract cylinder tubes and tighten until wrench tight Mark fitting then torque to specification Refer to Section 2 3 3 Hydrau
189. ly depress the accelerator pedal as required Place and hold the joystick in the position needed to operate the particular machine function being checked Continue holding the joystick in position until pressure readings are taken 5 Check the pressure gauge reading It should read as described in the appropriate section If the reading is not as specified turn the engine OFF and check other components in the system Verify that all related hydraulic components and electrical switches sensors solenoids etc are operating correctly G5 18A 2505H 25 5 As a last resort adjust the appropriate relief valve if applicable Turning the adjustment screw clockwise will increase the pressure turning the screw counterclockwise will decrease the pressure 8 6 2 Main Control Valve Pressure Checking 8640 Attach 5000 psi 345 bar gauge to the test port 1 at the rear of the implement pump to check the system pressure Make sure the gauge is visible from inside the cab See Section 8 6 Hydraulic Pressure Diagnosis for start up procedure Check the main control pressure with the park brake on and the service brake off at full throttle Retract a boom circuit function until the cylinder bottoms The main control valve pressure should be 3585 3665 psi 247 252 7 bar at full throttle Repeat for each boom circuit to verify the correct main control valve pressure 4 Ic AEN 2110
190. m value exceeded 116 523930 1 Fuel Balance Control integrator injector 2 in firing order minimum value exceeded 117 523931 1 Fuel Balance Control integrator injector 3 in firing order minimum value exceeded 118 523932 1 Fuel Balance Control integrator injector 4 in firing order minimum value exceeded 119 523933 1 Fuel Balance Control integrator injector 5 in firing order minimum value exceeded 120 523934 1 Fuel Balance Control integrator injector 6 in firing order minimum value exceeded 121 1109 2 Engine shut off demand ignored 122 523698 11 Shut off request from supervisory monitoring function 125 523717 12 Time out Error of CAN Transmit Frame AmbCon Weather environments 126 523603 9 Time out Error of CAN Receive Frame AMB Ambient Temperature Sensor 9 40 G5 18A 2505H 25 5 Electrical System EE Pics Deutz Description DLC Error of CAN Receive Frame AT1IG1 NOX Sensor SCR system upstream 127 Seed 2 cat DPF system downstream cat length of frame incorrect 128 3224 9 Time out Error of CAN Receive Frame 1161 NOX sensor upstream 429 3224 2 DLC Error of CAN Receive Frame ATIIGIVol Sensor SCR system upstream cat DPF system downstream cat length of frame incorrect Time out Error of CAN Receive Frame ATIIGIVol NOX sensor SCR system 130 3224 9 upstream cat DPF system downstream cat Time out Error BAM
191. m Installation 7 Loosen and remove the two bolts holding the LSI 1 Mount the LSI sensor to the side of the first boom modules to the side of the frame section with the previously removed hardware Do 8 Remove each module Not tighten the mounting bolts at this time DO NOT disassemble the module s The module s are 2 Shim the LSI sensor within 2 3 mm 0 08 0 11in of not serviceable Replace module s if found to be the second boom section Tighten and torque the defective mounting bolts as required 3 Plug the electrical connector into the sensor pu Eo Monue Installation assembly 1 Mount the LSI modules to the side of the frame with 4 Properly connect the battery the previously removed hardware Tighten and torque the mounting bolts as required 5 Close and secure the battery and engine covers 6 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 2 Plug the electrical connector into the module assemblies 3 Properly connect the battery 9 11 3 LSI Modules 4 Close and secure the battery and engine covers 5 Remove the Do Not Operate Tag from the ignition key switch and the steering wheel 2920 LSI modules 3 are bolted to the frame at the inside left rear corner a LSI Module Removal 1 Remove any fork carrier or attachment from the machine 2 Park the machine on a firm level surface level the machine fully retract the boom fully raise t
192. machine should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery 5 Remove the drain plug at the bottom of the hydraulic oil reservoir 6 Transfer the used hydraulic oil into a suitable covered container and label as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the drain plug 7 Wipe up any spilled hydraulic oil 8 10 8 8 3 1 Be sure the reservoir is clean and free of all debris Hydraulic Oil Reservoir Filling 2 Install new hydraulic oil filters 3 Fill the reservoir with Cat HDO oil Refer to Section 2 5 Fluids Lubricants and Capacities 4 Properly connect the battery 5 Close and secure the battery and engine covers 6 Remove the Do Not Operate Tags from both the ignition key and the steering wheel 7 Start the machine Run engine to normal operating temperature Operate all hydraulic functions G5 18A 2505H 25 5 Hydraulic System n 8 9 8 9 1 8 9 1 HYDRAULIC SYSTEM PUMP 1 Implement Pump Removal Park the machine on a firm level surface fully retract the boom support the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery a
193. mately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions Inspect for leaks and check all fluid levels Install the front fender and belly pan Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel Note Check for leaks and repair as required before continuing 13 14 8 9 3 1 2 Close and secure the engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel Pump Test Perform a flow meter test on the pump Check the system functions 8 11 n Hydraulic System 8 10 FRONT DRIVE MOTOR For internal service instructions and detailed specifications contact the local JLG Dealer 8 10 1 1 8 Front Drive Motor Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the system fluids to cool Properly disconnect the battery Drain the hydraulic reservoir or attach a vacuum adapter fitting to the reservoir fill tube to reduce oil spillage Label and disconnect all hydraulic hoses attached to
194. me For this reason neither tank can be removed For cleaning instructions see Section 7 4 2 Fuel Hydraulic Oil Tank 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 when pressure reaches 22 psi 1 5 bar and return to the reservoir unfiltered Carefully examine fluid seepage or leaks from the hydraulic reservoir to determine the exact cause Clean the reservoir and note where any seepage occurs Leaks from a cracked or damaged reservoir require that the reservoir be flushed completely with water and repaired by a certified welder using approved techniques If these conditions cannot be met the reservoir must be replaced in its entirety Contact the local JLG dealer should reservoir welding be required 8 8 1 The fill cap will allow the hydraulic oil reservoir to pressurize to 2 psi 0 14 bar Inspect the condition of the cap seal to maintain proper reservoir pressure Pressurized Hydraulic Oil Fill Cap 8 8 2 1 Park the machine on a firm level surface fully retract the boom support the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Hydraulic Oil Reservoir Draining 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the
195. ment 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 5 Fluids Lubricants and Capacities 8 Axle housing damaged 8 Replace damaged parts 2 Intermittent noise when 1 Universal joint s worn or 1 Repair or replace universal traveling damaged joints as needed 2 Differential ring and or pinion 2 Determine cause and repair as gears damaged needed when traveling 3 Vibration or intermittent noise 1 Drive shaft universal joint s assembly incorrectly tightened Drive shaft universal joint s worn or damaged Drive shaft damaged unbalanced e Tighten capscrews to correct torque Repair or replace universal joints as needed Replace drive shaft as needed 5 6 G5 18A 2505H 25 5 hs Axles Drive Shafts Wheels and Tires 5 4 7 Axle Assembly and Drive Shaft Troubleshooting Continued Problem Possible Causes Remedy 4 Oil leaking from axle differential housing and or axle housings 1 Drain plugs loose and or o rings damaged or missing 1 Replace o rings as needed and tighten plugs 59
196. mit LSI CAN display to calibrated sequence calibration is required control its internal alarm performed LSI display indicates completion Machine automatically in LSI Cutout with operation LSI Load Cell A LSI module detects condition Only available via LSI Latched Check LSI 8516 5 Cancel Switch Creep 52 of Range and OMD reading is 100 gauge and sensor wiring Mode operation Permit LSI CAN display to control its internal alarm Machine automatically in LSI Cutout with operation only available via LSI LSI Load Cell B 8517 LSI module detects condition Cancel Switch Creep Latched Check LSI Mode operation Permit LSI CAN display to control its internal alarm gauge and sensor wiring 9 36 G5 18A 2505H 25 5 Electrical System Module Software Version Improper compatible Major version does not match Module Outputs Trigger Possible Latch Reset Help Message DTC Symptom Actions Condition Machine automatically in LSI module detects condition FS Cutout Latched Check LSI Short to Battery or 8518 and OMD readina is 100 only available via LSI Auce and sensor Wirin Open Circuit 9 Cancel Switch Creep gaug 9 Mode operation Activate LSI Cutout if not in passive mode or not in LSI calibration mode LSI h t librat ae 00 baan iia Note If fault is set due to Not Latched fault via CALIBRATION a LSI LSI CAN CHECK PT not clears
197. mounts on boom head Quick attach assembly should be centered in boom head Coat quick attach pivot pin 9 with an anti seize compound Insert quick attach pivot pin through quick attach assembly and boom head Align pivot pin and quick attach assembly Install lock bolt 8 Torque to 72 Ib ft 97 Nm Align quick attach assembly with tilt cylinder rod end and insert tilt cylinder pin 7 Align tilt cylinder pin and quick attach assembly Install lock bolt 6 Torque to 72 Ib ft 97 Nm If equipped uncap and reconnect hydraulic quick attach assembly device hoses 5 to valve on left side of boom head Clean up all debris hydraulic fluid etc in on near and around machine Properly connect battery Close and secure engine cover Remove a Do Not Operate Tag on both ignition key switch and steering wheel G5 18A 2505H 25 5 3 7 FORKS Forks should be cleaned and inspected prior to being attached to carriage If the following criteria is not met forks must be removed from service immediately Daily Inspection 12 15 16 14 13 1 N L 11 10 mmm 20 19 MH6460 1 Inspect forks 10 for cracks paying special attention to heel 11 and mounting tubes 12 2 Inspect forks for broken or bent tips 13 and twisted blades 14 and shanks 15 Yearly Inspection 1 Straightness of the upper face of blade 14 and the front face of shank 15 should n
198. mponents with a suitable cleaner before inspection 4 Inspect the solenoid 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 Inspect internal passageways of the decompression valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 8 23 Hydraulic System 6 Install the solenoid valve and cartridge in the quick attach valve housing c Quick Attach Installation 1 Attach the quick attach valve to the fittings on the boom head 2 Connect the hydraulic hoses fittings solenoid wire terminal leads etc to the quick attach 3 Properly connect the battery 4 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 5 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required be
199. mri I 1 7 Re _ 8 jom oi 8 i Zing P6900 184 amp a FD Toone 33 H 83 a aR AS oikee gt Sbt Hamia leare bres 5 doe Noudo er Fala IH gt rrr gt gt VOL vama 21 gt ena ivan bio m Z gt gt ma Lar se a lez kaeeug VO mere oem aoe LEE 112 111 AR WoL VERE NOK n sa MAWA MIN L1 Worveep ma _ NA 78 IEEE HX GNO 2000787 5 moons m PA dC mona mio iA NU 13 EL onion ram im gt rons ammora oL LA sm reso sa Ld MIS SUO MIS MP 9390 IAM IS MP ZEO AM MISAZVEREIHM Pur rad 24 recone 8 4 LI 7T gi ZINMMHIIOIRM e 00 ME swozzvo 1 coerce 5 BIST noo ma rior ij TINE FIM ER TOTEM 2 VAN 900 IH gi owr gt Sirtema MMOXOMSSQDIHM Pame Se seid ov sin Tam Md V TIO d E HE on d
200. n 8 7 Hydraulic Schematic 3 16 G5 18A 2505H 25 5 Section 4 Cab Contents PARAGRAPH TITLE PAGE 4 1 Operator Cab Component Terminology 4 2 4 2 Safety 4 3 4 3 Operator Cab nieces ete eet thai eee 4 3 4 3 1 Operator Cab 4 3 4 3 2 Serial Number 4 3 4 4 Cab 2 5 4 3 4 4 1 Steering 4 3 4 4 2 Steering Column Valve 4 4 4 4 8 Brake Pedal and 4 5 4 4 4 Accelerator Pedal 4 6 4 4 5 Joystick 4 7 4 4 6 Windshield Wiper Assembly If Equipped 4 7 4 4 7 Windshield Washer Assembly 4 7 4 4 8 Heater Air Conditioning System If Equipped 4 8 4 4 9 Air Conditioning 4 8 4 4 10 Air Filter System If Equipped 4 9 4 5 Cab ee Ex 4 10 4 6 Cab Installatiori
201. n a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery b Disconnect the wiring connector at the oil pressure sender lead The oil pressure sender is threaded into the engine Remove the sender Oil Pressure Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part 1 Oil Pressure Sender Installation and Testing Thread the oil pressure sender into the engine housing snugly then connect the sender connector to the wiring harness connector Properly connect the battery Check for proper fluid level G5 18A 2505H 25 5 Start the engine and observe the operator s display for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine low oil obstructed or faulty oil pump defective instrument display Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel 9 25
202. n both ignition key switch and steering wheel 5 Properly disconnect battery 6 Open engine cover Allow system fluids to cool Q MY9020 SS 7 Remove access panel 1 8 Remove cab air filter 2 and inspect If required replace with new filter 9 Place filter back under seat and secure 10 Replace and secure access panel 11 Properly connect battery 12 Close and secure engine cover 13 Remove a Do Not Operate Tag on both ignition key switch and steering wheel G5 18A 2505H 25 5 a ce 45 REMOVAL WARNING The protection offered by this ROPS FOPS will be impaired if subjected to any modification or structural damage at which time replacement is necessary ROPS FOPS must be properly installed using fasteners or correct size and grade and torqued to their specified value Note To help ensure safety and optimum performance replace cab if it is damaged Refer to appropriate parts manual for ordering information Inspect cab its welds and mounts If modification damage a cracked weld and or fatigued metal is discovered replace cab Contact local JLG Dealer with any questions about suitability or condition of a cab Note Remove and label cab components as needed before removing cab from machine Label disconnect and cap hydraulic hoses Transfer cab parts to replacement cab after replacement cab is securely mounted on machine 1 Park machine
203. n key Switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool Support the boom by installing the lift cylinder lock or a suitable support Label disconnect and cap hydraulic hoses and electrical connections 14 to joystick Lift rubber boot 15 from base of joystick and remove capscrews 16 Remove joystick Joystick Installation Uncap and reconnect previously labeled hydraulic hoses to their appropriate locations Reconnect electrical connections Install capscrews in joystick base Re seat rubber boot to joystick base Remove lift cylinder lock if previously installed Properly connect battery Close and secure engine cover Start engine and test joystick for proper functions Remove a Do Not Operate Tag on both ignition key Switch and steering wheel G5 18A 2505H 25 5 4 4 6 Windshield Wiper Assembly If Equipped Refer to Section 9 8 1 Windshield Wiper Motor for removal and installation information 4 4 7 Windshield Washer Assembly If Equipped Refer to Section 9 8 3 Windshield Washer Reservoir and Pump for removal and installation information 4 4 8 Heater Air Conditioning System If Equipped a Removal 1 Park machine on a hard level surface 2 Fully retract boom lower boom place transmission control lever in N NEUTRAL 3 Engage park brake and shut e
204. n the injector 8 in firing order 1337 2797 4 Injector diagnostics time out error of short circuit to ground measurement Bank 0 1338 2798 4 Injector diagnostics time out error of short circuit to ground measurement Bank 1 1339 2798 4 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 0 1340 2798 4 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 1 1341 524035 12 Injector diagnostics time out error in the SPI communication 1342 524036 12 Injector diagnostics Slave time out error in the SPI communication 1343 524004 12 Too many recognized misfires in cylinder 7 in firing order 1344 524005 12 Too many recognized misfires in cylinder 8 in firing order 1345 524069 9 MSMon_FidFCCTO Master Slave Error memory Slave reports FID MSMonFC2 Shut Off Path test error of fuel 7987 220092 11 injection i Error memory Slave reports FID MSMonFC3 time out of engine state messages 1389 H ComMS Sysl 7 from is ECU i 1378 523919 2 Sensor air pump airpressure plausibility error 1379 523920 2 Sensor exhaust gas back pressure burner plausibility error 1380 3253 2 Sensor differential pressure DPF plausibility error 1381 164 2 Rail pressure safety function is not executed correctly 1389 523922 5 Burner Shut Off Valve open load 1390 523922 12 Burner Shut Off Valve powerstage over temperature 1392 523922 4 Burner Shut Off Valve short circuit to ground 1395 523921 2 Sensor
205. nd engine covers Allow the system fluids to cool Properly disconnect the battery Loosen and remove the belly pan and front fender Drain the hydraulic oil reservoir Refer to Section 8 8 2 Hydraulic Oil Reservoir Draining 8640 Thoroughly clean the pump 1 and surrounding area including all hoses and fittings before proceeding From under the machine label disconnect and cap all hydraulic hoses attached to the pump cap all fittings and plug hoses to keep dirt amp debris from entering the hydraulic system Remove the two bolts and washers 2 securing the pump in place 2 Implement Pump Installation Position pump in the mounting position Note Use new o rings where required Never reuse o rings 2 Use the two previously removed bolts and washers to secure the pump into place Torque to 64 Ib ft 87 Nm G5 18A 2505H 25 5 N 9 10 11 12 Uncap and reconnect previously labeled hydraulic hoses to their proper locations Fill the hydraulic reservoir with clean filtered hydraulic oil Prime the pump by filling the case drain port with fresh filtered hydraulic oil from a clean container before installing the case drain connector and hose Check all routing of hoses and tubing for sharp bends or interference with any rotating members All tube and hose clamps must be tight Properly connect the battery Start the engine and run at approxi
206. nd the steering wheel G5 18A 2505H 25 5 Engine 7 6 AIR CLEANER ASSEMBLY 5 Loosen the clamp 3 securing the air intake elbow to the air cleaner assembly Pull the air intake elbow off the air cleaner A CA UTI 6 Remove the hardware securing the air cleaner to the air cleaner mounting plate 4 Remove the air NEVER run the engine with only the inner safety cleaner assembly 5 element installed Note Refer to the machine Operation amp Safety Manual 7 6 2 Air Cleaner Assembly Installation for the correct element change procedure 1 Install the air cleaner assembly 5 to the air cleaner mounting plate with the previously used hardware 7 6 1 Air Cleaner Assembly Removal 4 Hand torque mounting bolts to 10 12 Ib ft 1 Park the machine on a firm level surface level the 13 5 16 3 Nm machine fully retract the boom lower the boom 2 Place the loosened clamp 3 over the air intake place the travel select lever in the N NEUTRAL elbow and install elbow on the air cleaner assembly position engage the parking brake and shut the 3 Adjust and tighten clamps before starting the engine OFF machine 2 Place a Do Not Operate Tag on both the ignition key 4 Properly connect the battery switch and steering wheel stating that the machine should not be operated 5 Close and secure the engine cover 3 Open the engine cover Allow the system fluids to 6 Remove the Do Not Operate Tags from both the c
207. ne should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery 5 Remove the two capscrews holding the cover below the seat The hand brake valve is mounted on the mounting plate attached to the seat base 6 Label disconnect and cap the hydraulic hoses on each side and bottom of the hand brake valve Disconnect and cap all hoses fittings etc 7 Remove the four capscrews and lockwashers mounting the hand brake valve to the mounting plate G5 18A 2505H 25 5 b Hand Brake Valve Disassembly Cleaning Inspection and Assembly 1 Place the hand brake valve on a suitable work surface S7 SyA N 19 2 Clean all components with suitable cleaner before inspection 3 Inspect internal passageways of the hand brake manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil c Hand Brake Valve Installation 1 Install the Hand brake valve with the four lockwashers and capscrews to the
208. ne the proper operation of the ignition key switch test the wires on the back of the switch for continuity with an ohmmeter MY2340 Test the ignition key switch for continuity by checking from the BAT terminal 1 to each of the remaining terminals in their corresponding switch position If all terminals do not show proper continuity replace the ignition switch G5 18A 2505H 25 5 Electrical System Ignition Switch Installation Connect the ignition key switch to the cab harness connectors Reach up and under the dash to work the ignition switch into the ignition switch mounting hole on the lower right side of the dash Align the ignition switch so that when it is in the OFF position the key slot is positioned vertically straight up and down Install the hex nut securing the ignition switch to the dash DO NOT overtighten Install the lower dash panel Properly connect the battery Turn the ignition key switch to the START position to verify proper operation 7 Close and secure the battery and engine covers 9 10 2 b Remove the Do Not Operate Tags from both the ignition key and the steering wheel Dash Switches Switch Removal Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the
209. ng in the right direction 3 If further troubleshooting is required refer to Section 8 7 Hydraulic Schematic or Section 9 4 Electrical System Schematics G5 18A 2505H 25 5 8 25 Hydraulic System n 8 12 HYDRAULIC CYLINDERS 8 12 1 General Cylinder Removal Instructions 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Chock the wheels 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the battery and engine covers Allow the system fluids to cool 5 Properly disconnect the battery 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 9 Remove the cylinder 10 Wipe up any hydraulic fluid spillage in on near or around the machine 8 12 2 General Cylinder Disassembly 1 Clean the cylinder with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder 2 Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holdin
210. ng cylinder o rings and or 2 Replace o rings and seals seals worn or damaged 3 Piston rod seal worn or 3 Replace piston rod seal damaged 4 Oylinder tube damaged 4 Replace cylinder tube G5 18A 2505H 25 5 hs Axles Drive Shafts Wheels and Tires 5 4 7 Axle Assembly and Drive Shaft Troubleshooting Continued Problem Possible Causes Remedy 7 Axle overheating 1 Oil level too high 1 Fill oil to correct level Refer to Section 2 5 Fluids Lubricants and Capacities 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 5 Fluids Lubricants and Capacities 8 High steering effort required Steering hydraulic system not 1 Refer to the appropriate Axle operating properly Repair Manual Excessive joint housing swivel 2 Correct bearing preload by bearing preload adding or removing shims as needed Worn or damaged swivel 3 Replace swivel bearings as bearings needed 9 Slow steering response Steering hydraulic system not 1 Refer to the appropriate Axle operating properly Repair Manual Steering cylinder leaking 2 Repair or replace steering internally cylinder as needed 10 Excessive noise when brakes Brake discs worn 1 Check brake discs for wear are engaged Refer to appropriate Axle Repair Manual Brake discs
211. ng to Use double wrench method while tightening to avoid hose twist After connection has been properly tightened mark a straight line across the connecting parts not covering dots indicating that connection has been properly tightened 2 13 amp General Information and Specifications 2 4 SPECIFICATIONS 2 4 1 Travel Speed Tires Approximate Speed 12 16 50 305 70016 5 15 mph 24 km h 14 17 50 355 70D17 5 17 mph 27 km h 10 5 18 17 27 2 4 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 aaa ANSI CE amp 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 4 3 Electrical System Note Refer to Section 9 3 Fuses and Relays for more information Battery Type Rating 12 BCI Negative Ground Maintenance Free Cold Cranking Amps 0 F 18 C 950 Cranking Amps 32 F 18 C 1190 Reserve Capacity Minutes 25 Amps 185 Group Series Group 31 Alternator 14V 95 Amps G5 18A 2505H 25 5 General Information and Specifications 2 4 4 Engine Performance Specifications Des
212. ngine OFF 4 Place a Do Not Operate Tag on both ignition key switch and steering wheel 5 Properly disconnect battery 6 Open engine cover Allow system fluids to cool 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 coolant into container 10 Open radiator petcock and allow coolant to drain 11 Close the radiator petcock 12 Transfer coolant into a suitable covered container and label as Used Coolant 13 Dispose of used coolant at an approved recycling facility Note If equipped with Air Conditioning contact the local JLG dealer or certified air conditioning service center for proper draining of the air conditioner system Note Label all hoses to ensure correct installation MY2430 14 Remove front cover to expose heater defroster element 17 4 8 15 Loosen hose clamps and disconnect the two heater hoses 16 Remove capscrews nuts and lockwashers securing heater assembly to cab 17 Carefully pull out heater assembly 18 Label and disconnect wiring harness connections at blower 18 Remove heater assembly b Installation 1 Install heater assembly 18 to original orientation 2 Connect wiring harness connections at blower 3 Install capscrews nuts and lockwashers to secure heater assembly to cab 4 Reco
213. nnect 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 5 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 5 2 Capacities for refrigerant type and capacity 6 Properly connect battery 7 Start engine run it briefly at low idle and check machine for any visual sign of fluid leakage STOP the machine immediately if any leakage is noted and make any necessary repairs before continuing 8 Install front cover 17 in cab 9 Check coolant level Add or remove fluid as required 10 Close and secure engine cover 11 Remove a Do Not Operate Tag on both ignition key switch and steering wheel 4 4 9 If the air conditioning system requires servicing contact the local JLG dealer or certified air conditioning service center Refer to Section 2 5 2 Capacities for refrigerant type and capacity Air Conditioning If Equipped G5 18A 2505H 25 5 Cab 4 4 10 Filter System If Equipped 1 Park machine a hard level surface 2 Fully retract boom lower boom place transmission control lever in N NEUTRAL 3 Engage park brake and shut engine OFF 4 Place a Do Not Operate Tag o
214. not plausible 876 523470 7 Maximum rail pressure in limp home mode exceeded PRV 877 157 3 Sensor error rail pressure signal range check high 878 157 4 Sensor error rail pressure signal range check low 881 523633 11 Nox conversion rate insufficient SCR Cat defect bad AdBlue quality 882 523633 11 ao rate insufficient SCR Cat defect bad AdBlue quality temperature 883 523633 11 rate insufficient SCR Cat defect bad AdBlue quality temperature 887 3234 11 Nox Sensor downstream of SCR Catalysator plausibility error stuck in range 889 3224 1 Nox sensor upstream of SCR Catalysator low signal not plausible 892 4345 11 Sensor back flow line pressure SCR plausibility error 893 4343 11 General pressure check error SCR 894 4374 13 Pressure stabilization error dosing valve SCR 896 523723 11 Detection of AdBlue filled SCR system in Init State 897 523632 16 Pump pressure SCR metering unit too high 898 523632 18 Pump pressure SCR metering unit too low 899 523632 0 Pressure overload of SCR System 900 523632 1 Pressure build up error SCR System 903 4365 0 Urea tank temperature too high 905 3241 0 Sensor SCR catalyst upstream temperature too high plausibility error 906 3241 1 Sensor SCR catalyst upstream temperature too low plausibility error 908 3361 7 AdBlue dosing valve blocked SCR Sensor urea supply module heater temperature plausibility error aig 2 namen 4 915 523720 2 Sensor urea supply module heater temperature p
215. nsions provided herein in such a way that after maintenance service and repair of the engine engine operation does not violate local regulations Disclaimer and Scope 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 1 2 The engine serial number is located on a tag on top of the engine Information contained in the serial number is required in correspondence with the engine manufacturer Engine Serial Number 7 1 3 Specifications and Maintenance Information For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications G5 18A 2505H 25 5 Engine C 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
216. nter button 1 out of steering wheel Mark steering wheel and shaft to ensure proper installation Remove nut 2 securing steering wheel 3 to splined steering column shaft Use a steering wheel puller to remove steering wheel 3 from splined shaft Steering Wheel Installation Install steering wheel 3 onto splined steering column shaft Secure steering wheel with nut 2 Press center button 1 onto steering wheel Properly connect battery Close and secure engine cover Remove a Do Not Operate Tag on both ignition key switch and steering wheel Cab 4 4 2 7 Steering Column Valve Replacement Steering Column and Valve Removal Park machine on a hard level surface Fully retract boom lower boom place transmission control lever in NEUTRAL Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool _4 7 Ge MY2440 Remove steering wheel 4 Refer to Section 4 4 1 Steering Wheel transmission control lever 5 and accessory lever if equipped 6 8 Loosen and remove steering column cover 9 Loosen and remove dash cover 11 12 Note DO NOT disassemble the steering orbitrol valve Label disconnect and cap hydraulic
217. o Section 8 7 Hydraulic Schematic G5 18A 2505H 25 5 Hydraulic System n 8 11 8 Priority Valve The priority valve is attached at the engine pod frame directly beside the engine Verify the correct operation of the priority valve before considering replacement of the valve The priority valve must be replaced if defective a 1 Priority Valve Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the system fluids to cool Properly disconnect the battery MY2971 Label or otherwise mark the hydraulic hoses in relation to the priority valve Disconnect and cap all hoses fittings etc Remove the capscrews that attach the valve to the frame Remove the priority valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine Priority Valve Disassembly Cleaning Inspection and Assembly Place the priority valve assembly on a suitable work surface Label and remove the fittings 3 from the priority valve housing G5 18A 2505H 25 5 3 Clean all components with a suitable cleaner before inspect
218. ock up or support cab so that it does not move or fall Assure that no personnel enter cab while it is being removed from machine 19 Inspect condition of fittings clamps hydraulic hoses etc Replace parts as indicated by their condition 20 Inspect and replace other machine parts that are exposed with cab removed Repair or replace as required G5 18A 2505H 25 5 cab as 4 6 CAB INSTALLATION 21 Turn engine off and wait for engine to cool and check coolant level Add coolant as required to bring 1 Block all four wheels to help prevent machine from coolant to proper level moving Assure that there is sufficient overhead and 22 Install protective cover to front of cab side clearance for cab installation 23 Install mirrors and all other components as needed 2 Attach a sling with minimal lifting capacity of 800 Ib if removed 363 kg through previously installed bolts 9 cae bias 24 Unblock wheels 3 Use a hoist or overhead crane and sling attached to 25 Close and secure engine cover cab Carefully begin to align cab with mounting holes in frame 26 Start engine and test joystick for proper functions 4 Stop and check that wiring hydraulic hoses cables 27 Remove a Do Not Operate Tag on both ignition key etc will not be pinched or damaged as cab is switch and steering wheel positioned Take special note of fuel fill tube as well 5 Readjust position of sling as needed to help
219. omMSMOoFOVRITO error memory Slave 1295 524049 9 Message copy error in the Master Slave data transfer 1297 523788 0 CAN Transmit Frame ComTrbChActr BusOff Satus Wastegate 1298 523788 0 CAN Transmit Frame ComTrbChActr disable error wastegate 1299 523788 0 CAN Transmit Frame ComTrbChActr plausibility error wastegate 1300 523788 0 Time out Error of CAN Transmit Frame ComTrbChActr Wastegate 1302 524024 11 Deviation of the exhaust gas temperature set point to actual value downstream DOC too high 1324 523995 13 ne of missing injector adjustment value programming IMA injector 7 in firing 1325 523996 13 2 of missing injector adjustment value programming IMA injector 8 in firing 1327 523998 4 Injector cylinder bank 2 slave short circuit 1328 523999 12 Injector powerstage output Slave defect 1329 524000 5 Injector 7 in firing order interruption of electric connection 1330 524001 5 Injector 8 in firing order interruption of electric connection 1333 524000 3 Injector 7 in firing order short circuit G5 18A 2505H 25 5 9 53 Electrical System SUN Deutz Description Codes Codes Codes 1334 524001 3 Injector 8 in firing order short circuit 1335 524000 4 High side to low side short circuit in the injector 7 in firing order 1336 524001 4 High side to low side short circuit i
220. on a hard level surface 2 Fully retract boom lower boom place transmission control lever in N NEUTRAL 3 Engage park brake and shut engine OFF 4 Place a Do Not Operate Tag on both ignition key switch and steering wheel 5 Properly disconnect battery 6 Open engine cover Allow system fluids to cool 7 If equipped with a cab heater Refer to Section 4 4 8 b Installation 8 Working underneath cab label disconnect and cap all hydraulic hoses at cab fittings 9 Cap all fittings and openings to keep dirt amp debris from entering hydraulic system 10 Label and disconnect cab harness connectors Move harnesses clear of cab to prevent damage during cab removal 11 Install four lifting eye bolts with a minimal lifting capacity of 800 Ib 363 kg in existing holes at top corners of cab 1 12 Use a hoist or overhead crane and sling with a minimal lifting capacity of 800 Ib 363 kg attached to four lifting eye bolts DO NOT attempt to lift cab at this point 4 10 13 Remove hardware 2 securing cab to frame MY2420 14 Remove mirrors and all other cab components as needed if not previously removed 15 When all wiring hydraulic hoses and fasteners are disconnected or removed carefully and slowly lift cab and remove it from frame 16 Readjust position of sling as needed to help balance cab during removal 17 When cab is completely clear of machine carefully lower it to ground 18 Bl
221. on on the inching valve Work with an assistant to perform this procedure 8 20 Place the transmission control lever in N NEUTRAL engage the park brake start the engine and lower the boom Turn off engine MY2330 Remove the plastic cap 2 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 hydraulic oil The end of the tubing must be below the oil level in the container open the bleeder without holding the tubing firmly on the bleeder Have an assistant depress the brake pedal Carefully open the bleeder with a 10 mm wrench Close the bleeder when air bubbles no longer appear in the oil Release the brake pedal Remove the tubing from the bleeder If brake system bleeding is required refer to Section 8 11 2 Service Brake Valve Check brake fluid level and add fluid if necessary Refer to Section 2 5 Fluids Lubricants and Capacities Inching Test Start the machine engage the shift lever to the forward position and release the parking brake Slowly depress the throttle to 1 2 throttle Slowly apply the service brake The machine will slow but still maintain forward movement Continuing to depress the service brake will disengage the inching brake and engage the service brakes If further troubleshooting is required refer t
222. onnect the windshield washer hoses to the reservoir 2 Connect the cab wiring harness connectors to the reservoir connectors Install the reservoir tank onto the mounting studs Install the lockwashers and nuts and secure Fill the washer fluid reservoir with washer fluid Properly connect the battery amp Turn the ignition key switch to the RUN position and press the washer switch Verify that fluid is sprayed on the windshield Close and secure the battery and engine covers 9 Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 9 9 HEATER AC AND FAN 9 9 1 Cab Heater AC Controls Note If the suspect component is found to be within the heater box the heater box must be removed as a complete unit and replaced For additional information on the removal and installation of the heater box refer to Section 4 4 10 4 4 10 Heater Defroster System If Equipped The cab heater controls are located to the right of the seat The control panel consists of a variable speed fan control knob and a temperature control knob a Cab Heater Controls Removal Note After determining which control knob is not functioning remove only the suspect control knob In order to remove either knob the cab heater and fan control panel must be removed from the dash panel 1 Park the machine on a firm level surface level the machine fully
223. ool ignition key and the steering wheel 4 Properly disconnect the battery MY9010 7 10 G5 18A 2505H 25 5 Engine 7 7 7 7 1 10 ENGINE REPLACEMENT 1 Engine Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Thoroughly clean the engine and surrounding area including all hoses and fittings before proceeding Properly disconnect the battery Remove the radiator oil cooler assembly Refer to Section 7 2 2 Radiator Oil Cooler Replacement for detailed removal instructions Drain hydraulic reservoir Refer to Section 8 8 2 Hydraulic Oil Reservoir Draining Remove the air cleaner assembly Refer to Section 7 6 1 Air Cleaner Assembly Removal for detailed removal instructions Remove the exhaust system Refer to Section 7 5 1 Exhaust System Removal for detailed removal instructions Loosen and remove the rear fender 1 G5 18A 2505H 25 5 14 15 16 17 18 MY8970 Label disconnect and cap all hydraulic hoses attached to engine and transmission cap all fittin
224. order minimum value exceeded 1170 523612 12 Internal software error ECU 1171 175 2 Customer oil temperature signal un plausible 1173 523973 14 SCR Tamper detection derating timer below limit 1 1174 523974 14 SCR Tamper detection derating timer below limit 2 1175 523975 14 Urea quality derating timer below limit 1 1176 523976 14 Urea quality derating timer below limit 2 1177 523977 14 Urea tank level derating timer below limit 1 1178 523978 14 Urea tank level derating timer below limit 2 1180 168 0 Physical range check high for battery voltage 1181 168 1 Physical range check low for battery voltage 1182 172 0 Physical range check high for intake air temperature 1183 172 1 Physical range check low for intake air temperature 1187 523980 14 Bad quality of reduction agent detected 1192 523922 12 Over temperature error on burner shut of valve 1193 1180 0 Physical range check high for exhaust gas temperature upstream turbine 1194 1180 1 Physical range check low for exhaust gas temperature upstream turbine G5 18A 2505H 25 5 9 51 Electrical System eos Deutz Description 1216 523914 5 Glow plug control release line short circuit error 1217 523914 11 Glow plug control internal error DPF wasn t regenerated power reduction phase 1 manual 1548 SERIO 1 oci i
225. orrectly 1413 1188 13 Wastegate actuator calibration deviation too large re calibration required 1414 1188 2 Wastegate status message from ECU missing 1415 1188 7 Wastegate actuator blocked 1416 1188 11 Wastegate actuator over temperature gt 145 C 1417 1188 11 Wastegate actuator over temperature gt 135 C 1418 1188 11 Wastegate actuator operating voltage error 1419 524011 0 Zero fuel calibration injector 7 in firing order maximum value exceeded 1420 524012 0 Zero fuel calibration injector 8 in firing order maximum value exceeded 1421 524011 1 Zero fuel calibration injector 7 in firing order minimum value exceeded 1422 524012 1 Zero fuel calibration injector 8 in firing order minimum value exceeded 1431 524028 2 CAN message PROEGRActr plausibility error 1432 524029 2 um of CAN Receive Frame ComEGRActr exhaust gas recirculation 1436 524034 5 Disc Separator open load 1437 524034 12 Disc Separator power stage over temperature 1438 524034 3 Disc separator short circuit to battery 1439 524034 4 Disc separator short circuit to ground 1440 524030 7 EGR actuator internal error 1441 524031 13 EGR actuator calibration error 1442 524032 2 EGR actuator status message EGRCust is missing 1443 524033 7 EGR actuator due to overload in Save Mode 1444 2621 5 Flush valve burner EPV DPF System open load 1445 2621 12 Flush valve burner EPV DPF System powerstage over temperature 1446 2621 3 Flush valve burner DPF System
226. ort circuit to ground or open load on low side 1080 3361 4 Urea dosing valve short circuit on high side 1081 4345 5 SCR heater relay urea return line secondary side open load 1082 4366 5 SCR main relay secondary side open load 1083 4343 5 SCR heater relay urea pressure line secondary side open load 1084 4366 5 SCR main relay Secondary side Shortcut to battery 1085 4366 5 SCR main relay secondary side shortcut to ground 1086 4341 5 SCR heater relay urea supply line secondary side open load 1087 523719 5 SCR heater relay urea supply module secondary side open load 1088 4366 5 SCR Tank heating valve secondary side open load 1089 4243 11 SCR system heater diagnostic reports error shut off SCR system 1090 4345 5 SCR heater relay urea return line primary side open load 1092 4345 3 SCR heater urea return line short circuit to battery 1093 4345 4 SCR heater urea return line short circuit to ground 1094 4343 5 SCR heater relay urea pressure line primary side open load 1096 4343 3 SCR heater urea pressure line short circuit to battery 1097 4343 4 SCR heater urea pressure line short circuit to ground 1098 523718 5 SCR main relay primary side open load 1099 523718 12 SCR main relay primary side powerstage over temperature 1100 523718 3 SCR main relay primary side short circuit to battery 1101 523718 4 SCR main relay primary side short circuit to ground 1102 4341 5 SCR heater relay urea supply line primary side open lo
227. ot exceed 0 5 percent of the length of blade or height of shank 2 Angle 16 between upper face of blade and front face of shank should not exceed 93 degrees 3 Thickness of blade 17 and shank 18 should not be reduced to 90 percent of original thickness Note Contact local JLG dealer with fork part number to find manufactured dimensions of fork blade 4 Ensure that fork length 19 is adequate for the intended loads 5 Fork markings should be legible re stamp if required 6 Compare fork tips 20 when mounted on a carriage Maximum difference in height of fork tips is 3 percent of length of blade 21 gt Boom CY 3 8 BOOM PROP IF EQUIPPED 3 8 1 Prop Installation EQUIPMENT DAMAGE DO NOT operate with the WA R N G boom prop in place Damage to the boom prop and or the lift lower cylinder could occur A raised boom can fall if a hydraulic component is removed Remove any load retract the boom and 3 82 P R install the boom prop or a suitable supporting stand is before working under a raised boom 1 If needed start machine and slowly raise the boom until the boom prop is clear of the lift lower rod end Remove the o rings 2 and boom prop 1 from the cylinder Return the boom prop to the proper location and secure 3 Lower boom shut engine OFF 1 Park the machine on a firm level surface Place the transmission control l
228. oviding 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 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery 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 openings to keep dirt amp debris from entering the hydraulic system G5 18A 2505H 25 5 9 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 10 Remove the four bolts securing the main control valve to the frame bracket b Main Control Valve Disassembly 1 To disassemble the individual sections of the main control valve remove the nuts from the end of the tie rods Pull
229. perature 1131 4376 3 SCR reversing valve short circuit to battery 1132 4376 4 SCR reversing valve short circuit to ground 1135 3031 0 AdBlue Tank temperature maximum exceeded 1136 3031 1 DEF Tank temperature below minimum 1138 3031 3 Sensor error urea tank temperature short circuit to battery 1139 3031 4 Sensor error urea tank temperature short circuit to ground 1157 97 12 Water in fuel level prefilter maximum value exceeded 1158 523946 0 Zero fuel calibration injector 1 in firing order maximum value exceeded 1159 523947 0 Zero fuel calibration injector 2 in firing order maximum value exceeded 1160 523948 0 Zero fuel calibration injector 3 in firing order maximum value exceeded 1161 523949 0 Zero fuel calibration injector 4 in firing order maximum value exceeded 1162 523950 0 Zero fuel calibration injector 5 in firing order maximum value exceeded 1163 523951 0 Zero fuel calibration injector 6 in firing order maximum value exceeded 1164 523946 1 Zero fuel calibration injector 1 in firing order minimum value exceeded 1165 523947 1 Zero fuel calibration injector 2 in firing order minimum value exceeded 1166 523948 1 Zero fuel calibration injector 3 in firing order minimum value exceeded 1167 523949 1 Zero fuel calibration injector 4 in firing order minimum value exceeded 1168 523950 1 Zero fuel calibration injector 5 in firing order minimum value exceeded 1169 523951 1 Zero fuel calibration injector 6 in firing
230. perly disconnect the battery Refer to Section 7 2 2 Radiator Oil Cooler Replacement for detailed removal instructions VARIABLE SPEED FAN if equipped SN SAA 4 7 IRV VARIABLE SPEED REVERSING FAN if equipped MY8680 Label or otherwise mark the hydraulic hoses relation to the variable speed fan valve 1 Disconnect and cap all hoses fittings solenoid wire terminal leads etc Remove the variable speed fan valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine Variable Speed Fan Valve Disassembly Cleaning Inspection and Assembly Place the variable speed fan valve assembly ona suitable work surface Remove the solenoid valve and cartridge 2 from the variable speed fan valve housing Clean all components with a suitable cleaner before inspection G5 18A 2505H 25 5 Hydraulic System 4 Inspect the solenoid 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 Inspect internal passageways of the variable speed fan valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of intern
231. 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 NEVER drain or store fluids in open container Engine fuel and hydraulic fluid are flammable and can cause a fire and or explosion DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause an explosion PRESSURE TESTING When conducting any test only use test equipment that is correctly calibrated and in good condition Use the correct equipment in the proper manner and make changes or repairs as indicated by the test procedure to achieve the desired result LEAVING MACHINE Lower the forks or attachment to the ground before leaving the machine TIRES Always keep tires inflated to the proper pressure to help prevent tipover DO NOT over inflate tires NEVER use mismatched tire types sizes or ply ratings Always use matched sets according to machine specifications MAJOR
232. protective structure The cab itself contains rollover protective and falling object protective structures ROPS FOPS for operator A WARNING DO NOT weld grind drill repair or modify the cab in any way Any modification or damage to cab structural components requires cab replacement To help ensure optimum safety protection and performance replace cab if it is damaged Refer to appropriate parts manual for ordering information The cab contains seat operating controls numerous panels steering and brake components and more Covers and mirrors on machine exist for safety protection and appearance They are relatively simple to remove and replace 4 3 2 The cab serial number decal is located inside cab under the seat Information specified on serial number plate includes cab model number cab serial number and other data Write this information down in a convenient location to use in cab correspondence Serial Number Decal G5 18A 2505H 25 5 4 4 CAB COMPONENTS 4 4 1 a Steering Wheel Steering Wheel Removal 1 Park machine on a hard level surface Fully retract boom lower boom place transmission control lever in N NEUTRAL Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool 430 Carefully pry ce
233. quired Properly connect the battery Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel G5 18A 2505H 25 5 Electrical System 9 6 CHARGING CIRCUIT Before using a battery charger an attempt can be made to recharge the battery by jump starting the machine Refer to the appropriate Operation amp Safety Manual Allow the engine to run which will enable the alternator to charge the battery If the cab gauge shows an alternator issue perform the following checks 1 Check the all battery cable connections at the battery and verify that they are clean and tight Check the external alternator wiring and connections and verify that they are in good condition Check the fan belt condition and tension 4 Verify that the alternator mounting hardware is tight 9 6 1 Run the engine and check the alternator for noise loose drive pulley loose mounting hardware worn or dirty internal alternator bearings a defective stator or defective diodes can cause noise Replace a worn or defective alternator Alternator Alternator Removal Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and
234. r and around the machine 17 Close and secure the engine cover 18 Remove Do Not Operate Tags from both ignition key switch and the steering wheel 19 Install previously removed attachment to quick attach assembly G5 18A 2505H 25 5 3 5 BOOM WEAR PADS A total of 14 wear pads are installed on the boom 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 and auxiliary hose clearance 3 5 1 Wear Pad Inspection In Ma2070 Inspect all wear pads for wear If angle indicators 1 on end 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 3 5 2 Note Inspect all wear pads Replace as necessary Wear Pad Installation and Lubrication The following wear pad procedure must be followed to insure proper wear pad installation Note MUST clean wear pad inserts and mounting bolts of any grease oil or other contaminates before applying locking compound and installing mounting bolts Apply locking compound to all the wear pad mounting bolts MAM1390 Assemble as shown using spacer 2 with holes before any shim 3 is used f required a shim 3 must inserted between the spacer 2 and wear pad support plate block or boom section 4
235. r sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 4 Properly connect the battery 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 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools Close and secure the battery and engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel Pilot Select Valve Test Check boom lift lower auxiliary and tilt for proper function If further troubleshooting is required refer to Section 8 7 Hydraulic Schematic or Section 9 4 Electrical System Schematics for details G5 18A 2505H 25 5 8 11 7 Inching Valve 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 defective a 1 Inching Valve Removal Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine
236. r the transfer of original engine components to the replacement engine 7 7 3 Note Refer to Section 2 3 Torque Charts for specific fastener torque specifications Engine Installation 1 Position engine 3 in engine compartment being sure to line up the four motor mount holes Replace bolts and torque to 185 Ib ft 251 Nm 2 Reattach any previously labeled wire connections on the engine and transmission 3 Install the hydraulic and fuel filters and radiator oil cooler assembly bracket assembly 2 4 Install the previously removed rear fender 1 5 Remove the plugs and connect all previously labeled fuel lines 6 Install the exhaust assembly Refer to Section 7 5 2 Exhaust System Installation for detailed installation instructions 7 Install the air cleaner assembly Refer to Section 7 6 2 Air Cleaner Assembly Installation for detailed installation instructions 8 Install the radiator oil cooler assembly Refer to Section 7 2 2 Radiator Oil Cooler Replacement for detailed installation instructions 9 Uncap and reconnect all hydraulic hoses and fittings to the engine and transmission Keep hoses free of dirt amp debris 10 Refill the hydraulic reservoir Refer to the appropriate Operation amp Safety Manual for information concerning the hydraulic oil and filter change 11 Properly connect the battery 7 12 12 Check that all hydraulic electrical cooling fuel
237. ract lift cylinder After boom has been lowered loosen and remove jumper hoses and reconnect lift lower cylinder hoses at main control valve Transfer any hydraulic oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility Clean up all debris hydraulic fluid etc in on near and around the machine G5 18A 2505H 25 5 1 a V y V 3 10 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom Problem Possible Causes Remedy 1 Boom will not extend or 1 Broken hydraulic hose s or 1 Locate break replace hose s retract tube s and or connections or tube s tighten connections leaking 2 Extend Retracthydraulic system 2 Refer to Section 8 7 Hydraulic not operating properly Schematic 3 Faulty extend retract cylinder 3 Repair cylinder Refer to Section 8 12 Hydraulic Cylinders 2 Boom will not fully extend 1 Extend retract hydraulic system 1 Refer to Section 8 7 Hydraulic not operating properly Schematic 3 Boom shifts to right or left 1 Boom side wear pads 1 Shim wear pads to correct gap when extending improperly shimmed or worn Replace wear pads as needed Refer to Section 3 5 2 Wear Pad Installation and Lubrication 4 Excessive pivot pin noise 1 Insufficient lubrication 1 Lubricate at r
238. rake circuit The inside bleeder is used for the service brake circuit Work with an assistant to perform this procedure 1 Place the transmission control lever in N NEUTRAL engage the park brake and start the engine Raise the boom to access the brake bleeders Support boom and turn off engine 2 Remove the plastic cap from the brake bleeder Attach one end of a length of transparent tubing over the brake bleeder Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil The end of the tubing must be below the oil level in the container 8 15 Hydraulic System 8 11 3 The park brake valve is located in the cab below the seat a 1 DO open the brake bleeder without holding the tubing firmly on the bleeder There is pressure at the brakes Have an assistant depress the brake pedal Carefully open the bleeder with a 12 mm wrench Close the brake bleeder when air bubbles no longer appear in the oil Release the brake pedal Remove the tubing from the brake bleeder If bleeding the service brake circuit install a vacuum pump on the brake reservoir and remove the remainder of the trapped air from the brake system The inching valve may also require bleeding refer to Section 8 11 7 Inching Valve Check brake fluid level and add fluid if necessary Refer to Section 2 5 Fluids Lubricants and Capacities
239. re proceeding 1 2 1 4 DO NOT OPERATE TAGS Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance Remove key and disconnect battery leads 1 5 SAFETY INFORMATION To avoid possible death or injury carefully read understand and comply with all safety messages In the event of an accident know where to obtain medical assistance and how to use a first aid kit and fire extinguisher fire suppression system Keep emergency telephone numbers fire department ambulance rescue squad paramedics police department etc nearby If working alone check with another person routinely to help assure personal safety 1 5 1 Safety Alert System and Signal Words DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury G5 18A 2505H 25 5 Safety Practices 1 66 SAFETY INSTRUCTIONS Following are general safety statements to consider BEFORE performing maintenance procedures on the telehandler Additional statements related to specific tasks and procedures are located throughout this manual and are li
240. retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery 5 Remove the screws and backing locknuts from the cab heater and fan control panel 6 Pull the control panel out from the dash panel and if removing variable speed fan control remove the cab harness connector 7 If removing the temperature control knob disconnect the cable connector and remove control knob 8 Remove the setscrew from the variable speed fan control knob or temperature control knob 9 Remove the hex locknut from the suspect control shaft 10 Remove the control from the panel b Disassembly DO NOT disassemble the cab heater and fan controls The controls are not serviceable Replace controls if found to be defective 9 21 Electrical System c Installation and Testing 1 Check that the variable speed fan control is in the OFF position 2 If installing the temperature control attach the cable connector to the back of the control 3 Insert the control shaft through the panel ensuring that the knob is in the VERTICAL position 4 Install the hex locknut on the shaft and tighten 5 Connect the cab harn
241. revent any damage to the rod Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 4 Lubricate and slide the head gland 6 over the cylinder rod 5 Install the piston head 4 on to the end of the cylinder rod Loctite 243 and install the setscrew 3 in the piston head Refer to Section 8 12 8 Hydraulic Cylinder Torque Specifications for tightening guidelines for the piston head and the set screw Avoid using excessive force when clamping the cylinder barrel in a vise Apply only enough force to hold the cylinder barrel securely Excessive force can damage the cylinder barrel 5 Place the cylinder barrel 1 in a soft jawed vise or other acceptable holding equipment if possible 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 6 Carefully insert the cylinder rod assembly into the tube 7 Screw the head gland 6 into the cylinder barrel 1 and tighten with a spanner wrench Refer to Section 8 12 8 Hydraulic Cylinder Torque Specifications for tightening guidelines for the head gland 8 If applicable thread the new counterbalance valve into the block on the cylinder barrel 8 28 8 12 6 1 Grease the bushings at the ends of the hydraulic cylinder Using an appropriate sling l
242. ring Pressure Checking Section 8 7 Hydraulic Schematic or Section 9 4 Electrical System Schematics 8 11 10 Quick Attach Valve The quick attach valve is located on the left side of the boom head Verify the correct operation of the quick attach valve solenoid before considering replacement of the valve The housing of the quick attach valve is not serviceable and must be replaced if defective a Quick Attach Valve Removal 1 Park the machine on a firm level surface fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery G5 18A 2505H 25 5 MY8670 5 Label or otherwise mark the hydraulic hoses in relation to the quick attach valve 1 Disconnect and cap all hoses fittings solenoid wire terminal leads etc 6 Remove the quick attach valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine b Quick Attach Valve Disassembly Cleaning Inspection and Assembly 1 Place the quick attach valve assembly on a suitable work surface 2 Remove the solenoid valve and cartridge 2 from the quick attach valve housing 3 Clean all co
243. ring wheel 7 3 ENGINE ELECTRICAL SYSTEM The engine electrical system including the starter alternator and primary wiring is described in Section 9 Electrical System G5 18A 2505H 25 5 7 4 FUEL SYSTEM 7 4 1 Fuel represents a major portion of machine operating costs and therefore must be used efficiently ALWAYS use a premium brand of high quality clean diesel fuel Low cost inferior fuel can lead to poor performance and expensive engine repair Diesel Fuel Note Use only diesel fuel designed for diesel engines Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance Note Due to the precise tolerances of diesel injection systems keep the fuel clean and free of dirt and water Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles Use ASTM 2 diesel fuel with a minimum Cetane rating of 40 2 diesel fuel gives the best economy and performance under most operating conditions Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking Inform the owner operator of the machine to use 2 diesel fuel unless ambient temperatures are below 32 F 0 C When temperatures are below 32 F 0 C a blend of 1 diesel and 2 diesel fuels known as winterized 2 diesel may be used Note 1 diesel
244. rvoir Capacity to Full Mark 16 gal 61 L Auxiliary Hydraulic Circuit Max Flow 18 7 71 Brake System System Capacity 0 7 qt 0 7 L Axles Differential Housing Capacity 3 5 qt 3 3 L Friction Modifier Front Axle Only 5 4 oz 0 16 L Wheel End Capacity 24 oz 0 7 L Front Axle Drop Box 21 oz 0 6 L Air Conditioning System if equipped System Capacity 1 7 Ib 771 9 2 18 G5 18A 2505H 25 5 General Information and Specifications amp 2 6 MAINTENANCE SCHEDULE 2 6 1 10 1st 50 amp 50 Hour Maintenance Schedule 10 Check Fuel Check Engine Check Hydraulic Check Tire Additional Level Oil Level Oil Level Condition amp Checks Pressure Section 8 Check Wheel Lug Nut Torque 502 Drain Fuel Check Engine Check Check Brake Water Coolant Level Air Filter Battery Fluid Level Separator Check Washer Fluid Level if equipped 2341 G5 18A 2505H 25 5 2 19 amp General Information and Specifications 2 6 2 1st 250 250 amp 500 Hour Maintenance Schedule Change Axle Change Wheel Change Front Differential Oil End Oil Axle Drop Box Oil 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 Change Engine Change
245. s lubricated properly Lubrication of boom wear surfaces is also recommended when machine is stored to help prevent rusting Refer to Section 2 5 Fluids Lubricants and Capacities Note The first shim under the pad needs to contain holes instead of slots 3 10 3 6 QUICK ATTACH ASSEMBLY 3 6 1 1 2 10 11 Quick Attach Assembly Removal Park machine on a hard level surface Fully retract boom lower boom place transmission control lever in N NEUTRAL Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel Properly disconnect battery Open engine cover Allow system fluids to cool 021 7 2660 If equipped with a hydraulic quick attach device remove both hydraulic hoses 5 from valve on left side of boom head Plug and cap hose ends to prevent dirt and debris from entering system Remove the lock bolt 6 holding tilt cylinder rod end pin 7 to quick attach assembly Remove pin Support quick attach assembly Remove lock bolt 8 holding quick attach pin 9 to quick attach assembly Remove pin Inspect pins for nicks or surface corrosion Use fine emery cloth to fix minor nicks or corrosion Replace pins if damaged or beyond repair G5 18A 2505H 25 5 C x C i is 3 6 2 Quick Attach Assembly Installation 1 Line up quick attach assembly between
246. s Condition This fault can only be present Latched Check wiring to configured for the 2 Conflicting Drive Default machine to Pins J1 5 on Ground ipm 462 market Both passive mode f Direction Signals Active Mode Module and Pin J1 4 on inputs fwd park brake off Remote Module AND rev park brake off are present concurrently Ground Module lost CAN Default machine to LSI M Not Latched bus communication with LSI Cutout if not in passive Revert to normal CAN Bus Failure module and no messages mode with operation only 6638 operation when CAN LSI have been received for a available via LSI Cancel bus communication is period of switch Creep Mode re established 1 second operation This fault can only occur if the machine detects itself to be a Tier 3 configuration Default machine to LSI Ground Module lost CAN not bus corimuriicstierwith mode or not in LSI Not Latched CAN Bus Failure calibration mode with Revert to normal Remote Input Module and Remote Input 6642 operation only available via operation when CAN no messages have been Module LSI Cancel switch Creep bus communication is received for a period of 250 Mode operation re established ms 4 This fault can only occur if the machine detects itself to be a Tier 4 configuration Deactivate all Module Outputs Not Latched Once LSI Not Calibrated 8514 LSI CAN display indicates Per
247. short circuit to battery 1447 2621 4 Flush valve burner EPV DPF System short circuit to ground 1448 175 0 High customer oil temperature warning threshold exceeded 1449 175 0 High customer oil temperature shut off threshold exceeded 1453 411 0 Differential pressure Venturi unit EGR warning threshold exceeded 1454 411 1 Differential pressure Venturi unit EGR shut off threshold exceeded 1455 3711 12 Regeneration temperature PFItRgn LigtOff not reached regeneration aborted 1457 524055 4 Spark Plug Control Unit SPCU short circuit to ground 1458 523960 High exhaust gas temperature EGR cooler downstream warning threshold exceeded High exhaust gas temperature EGR cooler downstream shut off 1239 999989 1460 1180 0 Turbocharger Wastegate CAN feedback warning threshold exceeded 1460 1180 0 Turbocharger Wastegate CAN feedback warning threshold exceeded 1461 1180 1 Turbocharger Wastegate CAN feedback shut off threshold exceeded 1461 1180 1 Turbocharger Wastegate CAN feedback shut off threshold exceeded 1462 1180 0 Exhaust gas temperature upstream turbine warning threshold exceeded G5 18A 2505H 25 5 9 55 Electrical System p 2 Pan 5 sud Deutz Description 1462 1180 0 Exhaust gas temperature upstream turbine warning threshold exceeded 1463 1180 1 Exhaust gas temperatur
248. signal range check low 734 100 0 High oil pressure system reaction initiated 735 100 0 High oil pressure shut off threshold exceeded 736 100 1 Low oil pressure warning threshold exceeded 737 100 1 Low oil pressure shut off threshold exceeded 738 175 2 Sensor oil temperature plausibility error 739 175 2 Sensor oil temperature plausibility error oil temperature too high 740 175 0 Physical range check high for oil temperature 741 175 1 Physical range check low for temperature 743 175 3 Sensor error oil temperature signal range check high 744 175 4 Sensor error oil temperature signal range check low 745 175 0 High oil temperature warning threshold exceeded 746 175 0 High oil temperature shut off threshold exceeded 747 1237 2 Override switch plausibility error 750 107 3 Sensor error air filter differential pressure short circuit to battery 751 107 4 Sensor error air filter differential pressure short circuit to ground 752 107 0 High air filter differential pressure warning threshold exceeded 753 523919 2 Sensor air pump pressure plausibility error 755 523919 0 Physical range check high for air pump pressure shut off regeneration 758 523919 1 Physical range check low for air pump pressure shut off regeneration 761 523919 3 Sensor error air pump pressure signal range check high 762 523919 4 Sensor error air pump pressure signal range check low 763 523920 2 Sensor exhaust gas back pressure plausibility error G5 18A 2505H
249. slings will allow for better stability 19 20 21 22 23 3 6 Pull second boom section halfway out of first boom section reposition sling s balancing second boom section and remove from first boom section Place second boom section on suitable stands to begin tear down Inspect boom and welds Consult local JLG Dealer if structural damage is detected Inspect hoses hardware wear pads mounting points and other components visible with first boom section Replace any item if damaged Inspect all wear pads for wear Refer to Section 3 5 1 Wear Pad Inspection 3 4 4 Second Boom Section Installation Note Lubrication of boom wear surfaces with grease is recommended to keep boom wear surfaces lubricated properly Lubrication of boom wear surfaces is also recommended when machine is stored to help prevent rusting Refer to Section 2 5 Fluids Lubricants and Capacities 1 10 11 If previously removed install extend retract cylinder into rear of second boom section Pin and clip barrel end of cylinder in place 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 Feed the tilt cylinder hoses and if equipped the auxiliary hoses through the channel above the extend retract cylinder Using suitable sling s balance second boom section lift and carefully guide boom into place
250. sted prior to any work instructions to provide safety information before the potential of a hazard occurs For all safety messages carefully read understand and follow the instructions BEFORE proceeding 1 6 1 Personal Hazards PERSONAL SAFETY GEAR Wear all the protective clothing and personal safety gear necessary to perform the job safely This might include heavy gloves safety glasses or goggles filter mask or respirator safety shoes or a hard hat LIFTING NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards LIFTING OF EQUIPMENT Before using any lifting equipment chains slings brackets hooks etc verify that itis of the proper capacity in good working order and is properly attached NEVER stand or otherwise become positioned under a suspended load or under raised equipment The load or equipment could fall or tip DO NOT use a hoist jack or jack stands only to support equipment Always support equipment with the proper capacity blocks or stands properly rated for the load HAND TOOLS Always use the proper tool for the job keep tools clean and in good working order and use special service tools only as recommended G5 18A 2505H 25 5 1 6 3 SOLVENTS Only use approved solvents that are known to be safe for use HOUSEKEEPING Keep the work area and operator s cab clean and remove all hazards debris oil tools etc FIRST
251. t Installation 2 Apply locking compound to all mounting bolts 3 Install hardware securing drive shaft to front axle Torque capscrews to 102 Ib ft 139 Nm 4 Install hardware securing slip yoke to rear axle Torque capscrews to 102 Ib ft 139 Nm Properly connect the battery Unblock the wheels Close and secure the engine covers Remove the Do Not Operate Tags from both the ignition key and the steering wheel Axles Drive Shafts Wheels and Tires 5 6 WHEELS AND TIRES 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 Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim w
252. t needs to be replaced Close the radiator petcock Remove air dam 6 to gain access to the cooling package lifting eye mounts Loosen the mounting bolts and move the surge tank 4 to access the cooling package lifting eye mounts Remove the top radiator hose 7 and hose from the surge tank attached to the radiator Cap all fittings and openings to keep dirt amp debris from entering the cooling system Place a suitable container beneath the hydraulic oil cooler fittings Transfer any hydraulic oil into a properly labeled container Dispose of properly Disconnect and cap the hydraulic hose 8 attached to the radiator oil cooler assembly Allow hydraulic oil to drain from the hydraulic oil cooler Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system Disconnect the hydraulic cooler temperature sensor 9 Loosen and remove the four mounting nuts and rebound washers 9 from the radiator assembly Connect a lifting strap to the radiator oil cooler assembly lifting eyes Slowly lift the radiator assembly to gain access to the fan side hydraulic oil cooler out hose connections and the bottom radiator hose MY9000 Disconnect the connector on the fan solenoid s Loosen and remove the fan solenoid s 11 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 hy
253. tall 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 5 Steering Pressure Checking MY8640 1 Attach a pressure gauge to the test fitting 5 at the rear of the implement pump The pressure reading should be 2490 2590 psi 171 7 178 6 bar with the steering wheel fully turned to the steering stop in one direction 2 There is no adjustment for steering pressure 8 6 6 Fan Speed Pressure and Direction Checking 1 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 2 Attach a pressure gauge to the test fitting 6 at the rear of the implement pump 3 If the machine is equipped with either the variable fan option or the variable reversing fan option run the engine at high idle and measure the fan speed using a suitable portable stroboscope adjustable to fractional RPM and with the ability to distinguish actual RPM from harmonic frequencies The fan speed must be a minimum of 2800 RPM at high idle 4 Connect the JLG Analyzer and activate the Test Mode to drive the fan to the maximum fan RPM Note Refer to 5 The pressure reading should be 2400 psi 166 bar at high idle G5 18A 2505H 25 5 Hydraulic System HYDRAULIC SCHEMATIC 8 7
254. tall the fan mounting washer and bolt Torque to 10 75 lb ft 15 Nm 5 Install the fan motor assembly to the fan shroud Install and torque the mounting bolts to 27 Ib ft 87 Nm d Radiator Oil Cooler Installation 1 Connect lifting strap to the radiator oil cooler lifting eyes 2 Slowly lower the radiator assembly to connect the previously removed hydraulic fan hoses hydraulic oil cooler out hoses and the bottom radiator hose 3 Remove any caps and or plugs and install the previously removed hoses 4 Install the previously removed fan solenoid s Note Verify the fan solenoid s retaining nut is installed with the recess FACING the solenoid 5 Lower the radiator oil cooler assembly into place 6 Remove any caps and or plugs and install the previously removed hydraulic cooler outlet hose 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 temperature sensor 10 Install the previously removed rebound washers and nuts securing the radiator assembly Torque the mounting nuts to 31 34 Ib ft 23 25 Nm 11 Install the previously removed surge tank 12 Install the previously removed top radiator hose 13 Connect the previously removed surge tank hose to the radiator 14 Re fill the surge tank radiator with approximately 2 7 gal 9 9 L of a 50 50 mixture of ethylene glycol and water
255. the fuel level sender on the fuel tank through the wiring in the cab 7 Check the fuel level sender The resistance of the fuel level sender is 31 ohms for a full tank of fuel 101 ohms for 1 2 tank and 255 ohms for an empty tank A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving 9 10 4 The hourmeter is a non repairable instrument that records hours of machine engine operation in tenth of an hour increments and is located in the instrument cluster Hourmeter The hourmeter is an analog device similar to an odometer and will display 99 999 9 hours before resetting to zero If trouble is suspected time the hourmeter for six minutes to verify that a tenth of an hour has been recorded The hourmeter is built into the instrument cluster and cannot be repaired If the hourmeter is suspect replace the instrument cluster 9 10 5 Coolant Temperature Sender MY8820 The coolant temperature sender 2 is located on the top of the engine behind the top radiator hose 9 24 a Coolant Temperature Sender Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery an
256. the steering wheel stating that the machine should not be operated Open the battery and engine covers Allow the engine to cool 4 Properly disconnect the battery Label and disconnect the wires attached to the alternator Note Record how the alternator is installed to ensure correct installation later G5 18A 2505H 25 5 MY8820 Loosen the top mounting bolt 2 but don t remove it at this time This will allow the alternator to swivel during belt removal Loosen the belt tensioning adjustment bolt 3 at the bottom of the alternator to loosen the fan drive belt Remove the fan drive belt from the alternator Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine While supporting the alternator with one hand remove the upper mounting hardware from the upper alternator mount Remove the alternator from the machine Alternator Installation Position the alternator and align with the upper alternator mount on the engine bracket Insert the upper mounting hardware through the alternator mount DO NOT tighten completely at this time Align the lower alternator mount hole with the lower mounting bracket on the engine and insert the lower mounting capscrew Be sure to leave enough room to attach the drive belt Attach the fan drive belt to the alternator Adjust the lower belt tensioning bolt to remove excessive slack from the
257. tins Luiz 580 Distrito Industrial Jo o Narezzi 13347 404 Indaiatuba SP Brazil Phone 55 19 3936 8870 Fax 455 19 3935 2312 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Barcelona Spain Phone 34 93 772 4 700 Fax 34 93 771 1762 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden Phone 46 0 850 659 500 Fax 46 0 850 659 534 www jlg com JLG France SAS 2 1 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493
258. tion carriage or any other attachment must be removed from quick attach assembly Before beginning conduct a visual inspection of machine and work area and review task about to be undertaken Read understand and follow these instructions During service of boom perform following 1 Check wear pads Refer to Section 3 5 1 Wear Pad Inspection 2 Apply grease at all lubrication points grease fittings Refer to Section 2 7 Lubrication Schedule 3 Check for proper operation by operating all boom functions through their full ranges of motion several times Depending on your particular circumstance the following procedures explain removal installation of complete boom or removal installation of individual boom sections G5 18A 2505H 25 5 3 4 1 1 Remove any attachment from quick attach assembly Complete Boom Removal 2 Park machine on a hard level surface 3 Fully retract boom lower boom place transmission control lever in NEUTRAL 4 Engage park brake and shut engine OFF Place a Do Not Operate Tag on both ignition key switch and steering wheel 6 Allow system fluids to cool 7 Remove the quick attach assembly Refer to Section 3 6 1 Quick Attach Assembly Removal Note The use of two slings will allow for better stability 8570 8 Start machine and raise boom to position that will allow for pin 1 to clear frame for removal Remove the loc
259. tion 5 6 2 Installing Wheel and Tire Assembly onto Machine Carefully remove the jack hoist or overhead crane and sling supporting the axle G5 18A 2505H 25 5 11 12 13 14 15 16 17 18 Carefully raise machine using a suitable jack or hoist Remove supports from beneath frame and lower machine to ground Remove blocks from front and rear of both tires on other axle Uncap and reconnect steering and brake lines at their axle fittings Refer to Section 8 11 2 Service Brake Valve for brake bleeding procedures Check hydraulic reservoir oil level Properly connect battery Close and secure the engine covers Start engine Turn steering wheel several times lock to lock and check function of brakes Check for hydraulic leaks and tighten or repair as necessary Remove a Do Not Operate Tag on both ignition key switch and steering wheel hs Axles Drive Shafts Wheels and Tires 5 4 7 Axle Assembly and Drive Shaft Troubleshooting Problem Possible Causes Remedy 1 Excessive axle noise while 1 Oil level too low 1 Fill oil to correct level Refer to driving Section 2 5 Fluids Lubricants and Capacities 2 Axle and or wheel 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 5 Fluids Lubricants and Capacities 3 Incorrect alignment of ring and 3 Correct align
260. tion and Assembly 1 Place the steer select assembly on a suitable work surface 8 22 2 Separate the steer select valve from the manifold by removing the capscrews Discard the old o rings 3 Remove the solenoid valves and cartridges 1 from the steer select housing 4 Clean all components with a suitable cleaner before inspection 5 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 6 Inspect internal passageways of the steer select manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the unit Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 7 Install the solenoid valves and cartridges in the steer select housing 8 Attach the steer select valve to the manifold using new oiled o rings and socket head capscrews c Steer Select Manifold and Valve Installation 1 Attach the steer select manifold and valve to the mounting plate on the frame using the socket head capscrews 2 Connect the
261. tle sensor signal range check low 942 523921 3 Sensor error burner temperature signal range check high 943 3532 3 Sensor error urea tank level signal range check high 944 523921 4 Sensor error burner temperature signal range check low 945 3532 4 Sensor error urea tank level signal range check low 946 1079 13 Sensor supply voltage monitor 1 error ECU 947 1080 13 Sensor supply voltage monitor 2 error ECU 948 523601 13 Sensor supply voltage monitor 3 error ECU 956 677 3 Starter relay high side short circuit to battery 957 677 4 Starter relay high side short circuit to ground 958 677 5 Starter relay no load error 959 677 12 Starter relay power stage over temperature 960 677 3 Starter relay low side short circuit to battery 961 677 4 Starter relay low side short circuit to ground 963 523922 5 Burner shut off valve open load 965 523922 3 Burner shut of valve short circuit to battery 967 523922 4 Burner shut of valve short circuit to ground 969 624 5 SVS lamp open load 970 624 12 SVS lamp power stage over temperature 971 624 3 SVS lamp short circuit to battery 972 624 4 SVS lamp short circuit to ground 973 523612 14 Software reset CPU SWReset 0 974 523612 14 Software reset CPU SWReset 1 975 523612 14 Software reset CPU SWReset 2 976 91 11 Plausibility error between APPI and APP2 or APPI and idle switch 980 523550 12 T50 start switch active for too long 981 172 3 Sensor error intake air signal range check high 982 172 4 Sensor error
262. to packet for CAN Receive Frame ATIIGCVoll information 133 523938 9 factors amp Sensor calibration for NOX Sensor SCR system upstream cat DPF system downstream cat Time out Error BAM to BAM for CAN Receive Frame ATIIGCVoll information 134 523939 9 factors amp Sensor calibration for NOX Sensor SCR system upstream cat DPF system downstream cat Time out Error PCK2PCK for CAN Receive Frame ATIIGCVoll information factors 135 523940 9 amp Sensor calibration for NOX Sensor SCR system upstream cat DPF system downstream cat Time out Error of CAN Receive Frame AT1OG1 NOX sensor SCR system d sea 9 downstream cat DPF system downstream cat 138 3234 2 DLC Error of CAN Receive Frame ATIOIVol NOX Sensor SCR system downstream cat DPF system downstream cat length of frame incorrect Time out Error of CAN Receive Frame ATIOGIVol NOX sensor SCR system 199 3 downstream cat DPF system downstream cat Time out Error BAM to packet for CAN Receive Frame ATIOGCVol2 information 140 523941 9 factors amp Sensor calibration for NOX Sensor SCR system downstream cat DPF system downstream cat Time out Error BAM to BAM for CAN Receive Frame ATIOGCVol2 information 141 523942 9 factors amp Sensor calibration for NOX Sensor SCR system downstream cat DPF system downstream cat Time out Error 2 for CAN Receive Frame ATIOGCVol2 information 142 523943 9 factors amp Sensor calibration for NOX Sensor SCR system downstr
263. to respond along with the engaged boom function If further troubleshooting is required refer to Section 8 7 Hydraulic Schematic 8 21 Hydraulic System n 8 11 9 Steer Select Valve The steer select valve is attached to inside the frame near the front drive motor Verify the correct operation of the steer select valve solenoids before considering replacement of the valve The housing of the steer select valve is not serviceable and must be replaced if defective a Steer Select Manifold and Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery 2180 5 Label or otherwise mark the hydraulic hoses relation to the steer select manifold Disconnect and cap all hoses fittings solenoid wire terminal leads etc 6 Remove the capscrews that attach the manifold to the frame 7 Remove the steer select manifold with attached steer select valve from the machine Wipe up any hydraulic fluid spillage in on near and around the machine b Steer Select Valve and Manifold Disassembly Cleaning Inspec
264. ule 9 34 9 13 1 Gauge Fault Code Display 9 34 9 13 2 Fault Codes sg cree ERR 9 34 Engine Diagnostic Trouble Code EMR4 9 39 9 14 1 Gauge Fault Code 9 39 G5 18A 2505H 25 5 Electrical System 91 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 illustration identifies the components that are referred to throughout this section DIAGNOSTIC CONNECTION CAB FUSE BOX INSTURMENT CLUSTER BACK UP ALARM FRAME HARNESS RELAYS FRAME HARNESS FUSE BOX ENGINE DIAGNOSTIC CONNECTION ENGINE HARNESS BATTERY MY8700 G5 18A 2505H 25 5 Electrical System 9 2 SAFETY INFORMATION WARNING DO service the machine without following all safety precautions as outlined in the Safety Practices section of this manual 93 FUSES AND RELAYS 9 3 1 Engine Compartment Relays and Fuses MY8710 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
265. ustment is needed loosen the tilt tubes and if equipped auxiliary tubes Move tubes to achieve the proper clearance Clean up all debris hydraulic fluid etc in on near and around the machine Close and secure the engine cover Remove Do Not Operate Tags from both ignition key switch and the steering wheel Install previously removed attachment to quick attach assembly G5 18A 2505H 25 5 3 4 5 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 1 Remove any attachment from quick attach assembly 2 Be sure there is enough room in front of machine to allow boom sections to be removed 3 Park machine on a hard level surface 4 Fully retract boom lower boom place transmission control lever in NEUTRAL 5 Engage park brake and shut engine OFF 6 Place a Do Not Operate Tag on both ignition key switch and steering wheel 7 Open engine cover and properly disconnect battery 8 Allow system fluids to cool 9 Remove the quick attach assembly Refer to Section 3 6 1 Quick Attach Assembly Removal MY2680 10 Remove cylinder rod eye retaining clips and mounting pin 13 at side of second boom section 11 12 13 3 8 2670 Loosen and remove hose clamps and cover plate
266. vice Brake Valve Removal 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the battery and engine covers Allow the system fluids to cool 4 Properly disconnect the battery 5 Remove the necessary dash panels G5 18A 2505H 25 5 Hydraulic System n 6 Label disconnect and cap the hydraulic hoses connected to the service brake valve 1 Cap all fittings and openings to keep dirt amp debris from entering the brake system 7 Remove the pin and clip 2 securing the service brake rod to the brake pedal assembly 8 Remove the two bolts and washers 3 securing the service brake valve to the steering column support Note DO NOT disassemble the service brake valve The service brake valve is not serviceable and must be replaced in its entirety if defective b Service Brake Valve Installation 1 Install the service brake valve to the steering column support with the previously removed hardware 3 Torque as required Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil 2 Use new oiled o rings as required
267. w 5 44 aaa 33 3 2 2 4 a 2480 8 6 3 Connect the analyzer cable connector to the connector behind the access panel on the right side of the dash 8 4 Press the C and OK buttons simultaneously on 1 Cable Connector 5 Go to ACCESS LEVEL 3 and press OK 2 Analyzer Display Screen 3 Escape Key return home or access previous 7 ACCESS LEVEL 2 is now visible menu 8 Go to OPERATOR TOOLS menu press 4 Enter Key Stores and selects Top Level Sub Level 9 Scroll to 151 CAN SYSTEM CHECK and Items Menus 10 PERFORM 151 CAN SYSTEM use the 5 Up Down Arrow Keys Change adjustable values arrow keys to change NO to YES 6 Left and Right Arrow Keys Used to move between 11 Follow and execute the screen instructions Top Level Sub Levels and Item Menus a Remove Weights and Attachments press OK b TELESCOPE IN and FULLY LIFT UP press OK c STOP WAIT ONE MINUTE wait at least one minute and press d PRESS ENTER TO START TEST press OK e Screen will show PRESS ENTER TO START TEST PASS Must receive a PASS g Press C for approximate two seconds to return to normal display screen h LSI UGM Calibration Check is now complete 9 12 1 Analyzer Usage Help messages can be viewed using the Analyzer P N 2901443 The Help messag
268. ydraulic System 8 Control Valve Assembly Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil Assemble each Valve Section 1 Reassemble any plugs check valves compensator valves anti cavitation valves shock valves or hydraulic remote positioners from individual valve sections if equipped 2 Install the end covers onto Lift Lower and Crowd sections Assemble the Main Control Valve 1 Place all three tie rods with the washers and nuts through the end main control valve section 2 Stand the end main control valve section on end 3 Install proper o rings on the inner face of the end main control valve section Align the Crowd section over the three tie rods and slide onto the end main control valve section 4 Using proper o rings and load sense shuttle repeat step three for the remaining sections 5 Install the washers and nuts on the tie rods and torque to 18 5 25 Nm f Main Control Valve Installation 1 Loosely install the four main control valve mounting bolts through bracket on the rear of the machine 2 Install the main control valve onto the bracket aligning the bolts with the holes in the end sections of the main control valve Slide the main control valve into position and tighten the bolts 3 Prime the main control valve by filling the inlet open

Download Pdf Manuals

Related Search

Related Contents

IFC-MD15A Interface Free Controller Brush Motor Card User`s Manual  Sony DSC-QX10/B Help Guide  EU - Conexio Genomics  Samsung PL PL50  Klimax DS installation manual  KERN HUS/HUM - PCE Instruments  Quick Reference Guide  

Copyright © All rights reserved. Failed to retrieve file