JLG G5-18A Service Manual - Manual (Page 78)

Transmission
6-4 G5-18A, 2505H, 25.5
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.
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
1. Use a lifting strap or chain attached to a hoist or
overhead crane to position transmission and pump
within the chassis.
2. Insert the two bolts that attach transmission to
engine. Torque to 154 lb-ft (210 Nm).
3. Remove hoist or overhead crane and sling.
4. Uncap and reconnect previously labeled hoses and
electrical connections to their appropriate locations.
5. Remove fill port screw and pre-fill transmission to
top of fill port. Install screw and torque to 398 lb-ft
(540 Nm).
6. Install front fender support bar.
7. Install cooling system. Refer to Section 7.2, “Engine
Cooling System.”
8. Fill hydraulic reservoir with clean, fresh oil and bleed
system. DO NOT overfill.
9. Properly connect battery.
10. Check hydraulic oil level and add oil as required.
11. Run engine for two minutes at idle to help bleed any air
from hydraulic system.
12. Operate all boom functions to ensure any air is
removed from hydraulic system.
13. Retract and level boom, recheck level of the fluid in
the reservoir.
14. 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° F
(83–94° C).
15. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
16. Close and secure the engine covers.
17. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
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.
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.
NOTICE
DO NOT use flushing compounds for cleaning
purposes.