JLG G5-18A User manual

Operation & Safety
Manual
Original Instructions
Keep this manual with machine at all times.
An Oshkosh Corporation Company
Models
G5-18A &
2505H
SN 0160053000 to Present including
0160051045, 0160051047, 0160051049,
0160051194 & 0160051359
31200743
Revised
June 22, 2016

CALIFORNIA PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of California
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
CALIFORNIA PROPOSITION 65
EXHAUSTWARNING
Diesel Engine exhaust and
some of its constituents
are known to the State of
California to cause cancer,
birth defects and other
reproductive harm.

Revision Log
a31200743
Revision Log REVISION LOG
May 3, 2013 - A - Original Issue of Manual.
June 22, 2016 - B - Revised covers, Section 1 and pages 2-4 thru 2-9, 2-11, 2-13, 3-25, 4-1,
4-2, 5-2, 5-3, 5-11, 5-15, 5-28, 5-29, 6-1, 6-2, 6-3, 7-1, 7-11 thru 7-15, 8-2 & 9-1 thru 9-4.

Read This First
b31200743
Read This First
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees
with the precautions and operating procedures essential for the safe and proper machine
operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make
specification changes without prior notification. Contact JLG Industries, Inc. for updated
information.
Operator Qualifications
The operator of the machine must not operate the machine until this manual has been
read, training is accomplished and operation of the machine has been completed under
the supervision of an experienced and qualified operator. Operation within the U.S.A.
requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in good
physical and mental condition, have normal reflexes and reaction time, good vision and
depth perception and normal hearing. Operator must not be using medication which
could impair abilities nor be under the influence of alcohol or any other intoxicant during
the work shift.
In addition, the operator must read, understand and comply with instructions contained
in the following material furnished with the telehandler:
• This Operation and Safety Manual
• Telehandler Safety Manual (ANSI only)
• All instructional decals and plates
• Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
Modifications
Modifications to this machine may affect compliance with Industry Standards
and/or Governmental Regulations. Any modification must be approved by JLG.

Read This First
c31200743
This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or
the local authorized JLG representative for information regarding safety-related bulletins
which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine.
Contact JLG Industries, Inc. to ensure that the current owner records are updated and
accurate.
JLG Industries, Inc. must be notified immediately in all instances where JLG products have
been involved in an accident involving bodily injury or death of personnel or when
damage has occurred to personal property or the JLG product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
In USA:
Toll Free: 1-877-JLG-SAFE (1-877-554-7233)
Outside USA:
Phone: [phone]
E-mail:
[e-mail]

Read This First
d31200743
Other Publications Available
Service Manual.............................................................................................................................31200926
Illustrated Parts Manual............................................................................................................31200725
Note: The following standards may be referenced in this manual:
ANSI is compliant to ANSI/ITSDF B56.6
AUS is compliant to AS 1418.19
CE is compliant to EN1459
Refer to the machine Serial Number Plate to identify the applicable compliance standard.
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.
• If 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.
•Ifnot 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.
1
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A
OAH2300

Table of Contents
i31200743
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ........................................................................... b
Modifications............................................................................................... b
Other Publications Available ................................................................. d
Machine Configuration............................................................................ d
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System ....................................................................1-1
Safety Alert System and Safety Signal Words...............................1-1
1.2 General Precautions .....................................................................................1-1
1.3 Operation Safety............................................................................................1-2
Electrical Hazards....................................................................................1-2
Tip Over Hazard.......................................................................................1-4
Travel Hazard............................................................................................1-7
Load Falling Hazard ...............................................................................1-8
Lifting Personnel .....................................................................................1-9
Driving Hazards on Slopes................................................................ 1-10
Pinch Points and Crush Hazards..................................................... 1-11
Fall Hazard..............................................................................................1-13
Chemical Hazards ................................................................................ 1-14
1.4 ClearSky (if equipped)...............................................................................1-15
Federal Communications Commission (FCC)
Information for Users..........................................................................1-15
Section 2 - Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection.....................................................2-1
2.2 Safety Decals...................................................................................................2-4
ANSI (G5-18A, if equipped)..................................................................2-4
ISO (2505H) (G5-18A, if equipped)....................................................2-7
2.3 Walk-Around Inspection..........................................................................2-10
2.4 Warm-Up and Operational Checks ......................................................2-12
Warm-Up Check ................................................................................... 2-12
Operational Check...............................................................................2-12
2.5 Operator Cab................................................................................................2-13
2.6 Windows........................................................................................................2-14
Cab Door Window (if equipped) ....................................................2-14
Rear Window .........................................................................................2-15
Table of Contents

Table of Contents
ii 31200743
Section 3 - Controls and Indicators
3.1 General..............................................................................................................3-1
3.2 Controls ............................................................................................................3-2
Park Brake..................................................................................................3-4
Parking Procedure..................................................................................3-5
Ignition .......................................................................................................3-6
Transmission Control Lever ................................................................3-7
Load Stability Indicator - LSI (2505H) ..............................................3-8
LSI Override Switch (2505H) ............................................................ 3-10
Steering Column Adjuster (if equipped)..................................... 3-11
Instrument Panel ................................................................................. 3-12
Joystick .................................................................................................... 3-14
Right Hand Console............................................................................ 3-16
Accessory Control Lever (if equipped)......................................... 3-18
Reversing Fan (if equipped)............................................................. 3-19
3.3 Steer Modes ................................................................................................. 3-20
Steer Mode Change............................................................................ 3-20
3.4 Operator Seat .............................................................................................. 3-21
Operator Presence (CE & AUS) ........................................................ 3-21
Adjustments .......................................................................................... 3-22
Seat Belt .................................................................................................. 3-23
3.5 Boom Angle and Extension Indicators ............................................... 3-24
3.6 Reverse Sensing System .......................................................................... 3-25
Section 4 - Operation
4.1 Engine ...............................................................................................................4-1
Starting the Engine................................................................................4-1
Cold Weather Starting ..........................................................................4-2
Battery Boosted Starting......................................................................4-3
Normal Engine Operation ...................................................................4-4
Shut-Down Procedure ..........................................................................4-4
4.2 Operating with a Non-Suspended Load...............................................4-5
Lift Load Safely ........................................................................................4-5
Before Picking Up a Load.....................................................................4-5
Transporting a Load ..............................................................................4-6
Leveling Procedure................................................................................4-6
Placing a Load..........................................................................................4-7
Disengaging a Load...............................................................................4-7

Table of Contents
iii31200743
4.3 Operating with a Suspended Load (ANSI & CE)..................................4-8
Lift Load Safely.........................................................................................4-8
Picking Up a Suspended Load............................................................4-8
Transporting a Suspended Load.......................................................4-9
Leveling Procedure ................................................................................4-9
Placing a Suspended Load ...............................................................4-10
Disengaging a Suspended Load .................................................... 4-10
4.4 Road Operation (2505H) .......................................................................... 4-11
4.5 Loading and Securing for Transport ...................................................4-12
Tiedown...................................................................................................4-12
Lifting .......................................................................................................4-13
Section 5 - Attachments and Hitches
5.1 Approved Attachments...............................................................................5-1
5.2 Unapproved Attachments .........................................................................5-1
5.3 JLG Supplied Attachments.........................................................................5-2
5.4 Telehandler/Attachment/Fork Capacity...............................................5-4
5.5 Use of the Capacity Chart...........................................................................5-5
Capacity Indicator Locations ..............................................................5-5
Sample Capacity Chart (ANSI & CE) ..................................................5-6
Sample Capacity Chart (AUS) .............................................................5-7
Example......................................................................................................5-8
5.6 Attachment Installation ..............................................................................5-9
Standard Quick Attach..........................................................................5-9
Universal Quick Attach (UQC)..........................................................5-12
5.7 Hydraulic Operated Attachment .......................................................... 5-14
5.8 Adjusting/Moving Forks ..........................................................................5-15
5.9 Attachment Operation ............................................................................. 5-16
Carriage with Forks .............................................................................5-18
Fork Mounted Hook (ANSI & CE) .................................................... 5-19
Side Tilt Carriage .................................................................................. 5-20
Side Shift Carriage ............................................................................... 5-22
Bucket ......................................................................................................5-24
Grapple Bucket .....................................................................................5-26
Coupler Mounted Hook..................................................................... 5-28
5.10 Hitches............................................................................................................5-29
Retrieval Hitch....................................................................................... 5-29
Adjustable Auto Hitch........................................................................5-30
Pin Hitch - CUNA C............................................................................... 5-31
EEC Manual Pin Hitch .........................................................................5-32

Table of Contents
iv 31200743
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product .......................................................................6-1
Moving Short Distances.......................................................................6-1
Moving Longer Distances....................................................................6-1
6.2 Emergency Lowering of Boom.................................................................6-2
6.3 Emergency Exit from Enclosed Cab........................................................6-3
Inside Cab..................................................................................................6-3
Outside Cab (if equipped) ...................................................................6-3
Section 7 - Lubrication and Maintenance
7.1 Introduction....................................................................................................7-1
Clothing and Safety Gear.....................................................................7-1
7.2 General Maintenance Instructions..........................................................7-2
7.3 Service and Maintenance Schedule .......................................................7-3
10 & 1st 50 & 50 Hour Maintenance Schedule.............................7-3
1st 250, 250 & 500 Hour Maintenance Schedule ........................7-4
1000 & 1500 Hour Maintenance Schedule....................................7-5
7.4 Lubrication Schedules.................................................................................7-6
250 Hour Lubrication Schedule.........................................................7-6
7.5 Operator Maintenance Instructions.......................................................7-8
Fuel System...............................................................................................7-8
Engine Oil ............................................................................................... 7-10
Hydraulic Oil.......................................................................................... 7-11
Tires .......................................................................................................... 7-12
Air Intake System ................................................................................. 7-14
Engine Cooling System ..................................................................... 7-16
Battery ..................................................................................................... 7-17
Brake System......................................................................................... 7-18
Windshield Washer System (if equipped)................................... 7-19
Section 8 - Additional Checks
8.1 General..............................................................................................................8-1
8.2 Load Stability Indicator System (2505H)...............................................8-1
8.3 Reverse Sensing System (if equipped) ..................................................8-2