JLG G5-18A Service Manual - Manual (Page 90)

Engine
7-12 G5-18A, 2505H, 25.5
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: If the 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
cover the transfer of original engine components to the
replacement engine.
7.7.3 Engine Installation
Note: Refer to Section 2.2, “Torque Charts,” for specific
fastener torque specifications.
1. Position engine (3) in engine compartment being
sure to line up the four motor mount holes. Replace
bolts and torque to 185 lb-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 & debris.
10. Refill the hydraulic reservoir (Refer to the
appropriate Operation & Safety Manual for
information concerning the hydraulic oil and filter
change).
11. Properly connect the battery.
12. Check that all hydraulic, electrical, cooling, fuel 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.
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.
NOTICE
During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep the transmission in NEUTRAL (N).