JLG G5-18A Service Manual - Manual (Page 135)

9-15 G5-18A, 2505H, 25.5
Electrical System
9.5 ENGINE START CIRCUIT
9.5.1 Starter
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.
If 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. If the 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. If a “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
the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section d, “Base Frame Schematic "A".”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. 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.
4. Properly disconnect the battery.
5. Remove the belly pan.
6. Disconnect and remove the air intake hose.
7. Disconnect and 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 remove 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.
MY8810
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