JLG G5-18A Service Manual - Manual (Page 143)

9-23 G5-18A, 2505H, 25.5
Electrical System
d. Ignition Switch Installation
1. Connect the ignition key switch to the cab harness
connectors.
2. 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.
3. 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.
4. Install the lower dash panel.
5. Properly connect the battery.
6. Turn the ignition key switch to the START position to
verify proper operation.
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.
9.10.2 Dash Switches
a. 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. Pull the frame out of the dash, disconnect the
harness connector to the switch in question and
push the switch out of the frame.
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
c. 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.
d. Switch Installation
1. Connect the switch to the cab harness connector.
2. Position the switch over the rectangular switch bezel
and snap into position.
3. Replace the frame into the dash.
4. Properly connect the battery.
5. Start the machine and check the replaced switch for
proper function.
6. Close and secure the battery and engine covers.
7. 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
1. 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.
2. From the operator’s 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.
3. Turn the ignition key switch to the OFF position. The
fuel level indicator needle should return to the
EMPTY position.
b. 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.
2. Check for loose or defective wiring, faulty ground
connections or corrosion on the fuel tank sender and
wiring lead.
3. 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.
4. 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.