JLG Telehandler 1075 4523 Service Manual 3122550100 2025

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JLG Telehandler 1075 4523 Service Manual 3122550100 2025
Size: 56.84 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: JLG 1075, 4523 Telehandler
Part Number: 3122550100
Publication Date: 2025
Number of Pages: 640 Pages

Contents:
Safety

General (concept)​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards (task)​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals (concept)​

Machine Verification (concept)​

General Machine Information and Specifications

Specifications (reference)​

2.1.1 Travel Speed​

2.1.2 Hydraulic Cylinder Performance​

2.1.3 Cylinder Drift​

2.1.4 Steering Angle Specifications​

2.1.5 Electrical System​

2.1.6 Engine Performance Specifications​

2.1.7 Tires​

Machine Temperature Chart (reference)​

Serial Number Location​

Fluids and Lubrication (reference)​

2.4.1 General Information​

2.4.2 Hydraulic Oil​

2.4.3 Changing Hydraulic Oil​

2.4.4 Lubrication Specifications​

2.4.5 Fluids​

2.4.6 Capacities​

2.4.7 Lubrication Schedule​

After Treatment System​

2.5.1 Automatic Exhaust System Cleaning (In-Mission)​

2.5.2 Stationary Exhaust System Cleaning (Non-Mission)​

ClearSky Smart Fleet​

2.6.1 General​

2.6.2 ClearSky Smart Fleet™ – Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance (reference)​

3.1.1 Preparation, Inspection, and Maintenance​

3.1.2 Pre-Start Inspection​

3.1.3 Pre-Delivery Inspection​

Service and Guidelines (reference)​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Welding on JLG Equipment​

Preventive Maintenance and Inspection Schedule (reference)​

3.3.1 Every 10 Hours​

3.3.2 First 50 Hours​

3.3.3 Every 50 Hours​

3.3.4 First 250 Hours​

3.3.5 Every 250 Hours​

3.3.6 First 500 Hours or 6 Months​

3.3.7 Every 500 Hours​

3.3.8 Every 1000 Hours or 1 Year​

3.3.9 Every 1500 Hours​

3.3.10 Every 2000 Hours or 2 Years​

3.3.11 Every 4000 Hours or 3 Years​

3.3.12 Every 5000 Hours​

Pins and Composite Bearing Repair Guidelines (task)​

3.4.1 Filament Wound Bearings​

Tires and Wheels (task)​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Brake Maintenance (reference)​

3.6.1 Service Brake Bleeding​

3.6.2 Park Brake Bleeding (SAHR)​

DEF Tank Inspection (task)​

Boom Inspection and Maintenance (reference)​

3.8.1 Boom Sections Adjustment​

3.8.2 Boom Extend and Retract Chains​

3.8.3 Inspection Guidelines​

3.8.4 Expose Chains for Inspection​

3.8.5 Chain Lubrication​

3.8.6 Boom Wear Pads​

Hydraulic Filter Replacement (task)​

3.9.1 Hydraulic Filter Removal​

3.9.2 Hydraulic Filter Installation​

Testing, Calibrations and Special Procedures

Special Tools (reference)​

4.1.1 Multimeter​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

Testing Procedures (reference)​

4.2.1 Starter​

4.2.2 Fuel Level Sending Indicator Testing​

Calibration Procedures (reference)​

4.3.1 JLG Analyzer​

4.3.2 Boom Angle Sensor Calibration​

4.3.3 Load Stability Indicator (LSI) System Calibration​

4.3.4 Park Brake Calibration/Maximum Drive Traction Test​

Special Procedures (task)​

4.4.1 Emergency Lowering Procedure​

4.4.2 Lowering Procedure with Precision Gravity Lower System (PGLS)​

4.4.3 Towing a Disabled Machine​

4.4.4 Releasing Parking Brake for Towing When Engine is not Running​

4.4.5 Transmission Fluid Replacement​

4.4.6 Charge Air Cooler (CAC) Hose Draining​

4.4.7 Hydraulic Oil Reservoir​

4.4.8 Diesel Exhaust Fluid (DEF) System Cleaning​

4.4.9 Fuel Tank Cleaning and Drying​

4.4.10 Accumulators​

4.4.11 Hydraulic Pressure Settings and Adjustments​

4.4.12 Cylinder Checking Procedure​

4.4.13 Cylinder Drift Test​

4.4.14 Hydraulic Circuits​

4.4.15 Hydraulic Pressures​

4.4.16 Pressure Specifications​

System Software

Load Stability Indicator (LSI)​

5.1.1 Load Stability Indicator​

5.1.2 LSI Sensor​

High Integrity Rear Axle Stabilization (HiRAS)​

5.2.1 RAS Cylinder and Pressure Reducing Valve and Key Sub-components​

5.2.2 HiRAS Integrity Check Procedure (Recommended)​

5.2.3 HiRAS Health Check Failure Troubleshooting​

5.2.4 Alternate Gauge Locations​

Analyzer​

5.3.1 Machine Data Access​

5.3.2 JLG Hand Held Analyzer​

5.3.3 JLG Mobile Analyzer​

5.3.4 PC Analyzer/Loglifter​

5.3.5 Analyzer Software (Version P27.0)​

Access Level​

Diagnostics (Software Version P27.0)​

Machine Setup (Software Version P27.0)​

Personalities (Software Version P27.0)​

Operator Tools (Software Version P27.0)​

Calibrations (Software Version P27.0)​

Multifunction Display(If Equipped)​

5.10.1 Technical Specification​

5.10.2 Multifunction Display and Control Buttons​

5.10.3 Main Menu​

5.10.4 Calibrations​

5.10.5 Setup and Maintenance​

5.10.6 Troubleshooting​

ClearSky (CS550) Configuration and Troubleshooting​

5.11.1 ClearSky Smart FleetTM CS550 Configuration​

5.11.2 Troubleshooting​

Fault Codes

Fault Codes Introduction​

Engine Diagnostic (reference)​

Fault Codes - Help Comment (00x)​

Fault Codes - Power-Up (21x)​

Fault Codes - Ground Inputs (23x)​

Fault Codes - Other Inputs (24x)​

Fault Codes - Function Prevented (25x)​

Fault Codes - Line Contactor, Open-Circuit (31x)​

Fault Codes - Line Contactor, Short-Circuit (32x)​

Fault Codes - Output Drivers (33x)​

Fault Codes - Engine (43x)​

Fault Codes - Battery Supply (44x)​

Fault Codes - Transmission and Drive System (46x)​

Fault Codes - Communications (66x)​

Fault Codes - Telematics (68x)​

Fault Codes - Tilt Sensor (81x)​

Fault Codes - Envelope Control (84x)​

Fault Codes - Load Moment (85x)​

Fault Codes - Steering (86x)​

Fault Codes - Service Required (87x)​

Fault Codes - Hardware (99x)​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

General Information and Safety (reference)​

Theories Of Operation (reference)​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Components (concept)​

Torque Values (reference)​

7.4.1 Cylinder Torque Specifications​

Electricals

General Information (reference)​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

8.1.3 Electrical Connector Examples​

Electrical Connectors​

Electrical Component Terminology​

8.3.1 General Overview​

Harness Layouts (reference)​

8.4.1 Harness Layout​

8.4.2 Component Layout​

8.4.3 Harness Layout​

8.4.4 Component Layout​

8.4.5 Harness Layout​

8.4.6 Component Layout​

Board Layouts (reference)​

8.5.1 Cab Power Distribution Board​

8.5.2 Frame Power Distribution Board​

8.5.3 Option 1 Distribution Board​

8.5.4 Option 2 Distribution Board​

8.5.5 Engine Harness Fuses and Relays​

Telematics Gateway​

8.6.1 Telematics Gateway Table​

8.6.2 Component Location​

8.6.3 Telematics-Ready (TCU) Plug​

8.6.4 Telematics Gateway Harness Breakdown​

Removal and Installation

Wheels (reference)​

9.1.1 Removing Wheel and Tire Assembly from Machine​

9.1.2 Installing Wheel and Tire Assembly onto Machine​

Drive Assembly (reference)​

9.2.1 Axle Assembly and Drive Shaft Troubleshooting​

9.2.2 Axle​

9.2.3 Drive Shafts​

9.2.4 Transmission Components​

Boom​

9.3.1 Boom System Component Terminology​

9.3.2 Troubleshooting​

9.3.3 Boom System​

9.3.4 Precision Gravity Lower System (PGLS)​

9.3.5 Accumulator​

9.3.6 Manual Quick Coupler​

9.3.7 Hydraulic Quick Coupler​

9.3.8 Forks​

9.3.9 Boom Prop (if equipped)​

9.3.10 Boom Wear Pad Installation, Lubrication​

9.3.11 Boom Angle Sensor​

Cab Components (reference)​

9.4.1 Serial Number Plate​

9.4.2 Cab Removal/Installation​

9.4.3 Steering Wheel​

9.4.4 Service Brake​

9.4.5 Electronic Throttle Pedal​

9.4.6 Joystick Assembly​

9.4.7 Ignition Key Switch​

9.4.8 Dash Switches​

9.4.9 Front Windshield Wiper Motor​

9.4.10 Rear Window Wiper Motor​

9.4.11 Roof Window Wiper Motor​

9.4.12 Washer Fluid Reservoir​

9.4.13 Heater System (If Equipped)​

9.4.14 Heater and Air Conditioning System(If Equipped)​

9.4.15 Multifunction Display (If Equipped)​

9.4.16 Right Side Cameras​

Engine (reference)​

9.5.1 Component Terminology​

9.5.2 Engine Serial Number​

9.5.3 Engine Replacement​

9.5.4 Surge Tank Cap​

9.5.5 Thermostat Replacement​

9.5.6 Engine Coolant Temperature Sensor​

9.5.7 Radiator Assembly Replacement​

9.5.8 Hydraulic Oil Reservoir Removal/Installation​

9.5.9 Diesel Exhaust Fluid (DEF) Tank​

9.5.10 Diesel Exhaust Fluid (DEF) System Header​

9.5.11 Diesel Exhaust Fluid (DEF) Pump Filter​

9.5.12 Fuel Tank​

9.5.13 Engine Exhaust System​

9.5.14 Air Cleaner Assembly​

9.5.15 Starter​

9.5.16 Alternator​

Transmission (reference)​

9.6.1 Component Terminology​

9.6.2 Transmission Serial Number​

9.6.3 Transmission Removal/Installation​

9.6.4 Hydrostatic Transmission Pump​

9.6.5 Dual Pump Drive​

9.6.6 Drive Motor​

9.6.7 Gearbox​

9.6.8 Back-up Alarm​

Hydraulic Cylinders (reference)​

9.7.1 General Cylinder Removal Instructions​

9.7.2 Steering Cylinders​

Hydraulic Pumps (reference)​

9.8.1 Implement Pump​

Hydraulic Valves (reference)​

9.9.1 Main Control Valve​

9.9.2 Priority Valve​

9.9.3 Steering Column/Orbital Valve​

9.9.4 Frame Leveling Valve or Outrigger/Frame Leveling Valve​

9.9.5 Steer Select Valve​

9.9.6 Ride Control Valve​

Electrical Components (reference)​

9.10.1 Battery​

9.10.2 Electrical Master Switch​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.11.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly (reference)​

10.1.1 Axle Assembly​

10.1.2 Transmission Assembly​

Boom (reference)​

10.2.1 Fifth Boom Section Removal​

10.2.2 Fourth Boom Section Removal​

10.2.3 Third Boom Section Removal​

10.2.4 Second Boom Section Removal​

10.2.5 Hose Carrier Removal - Installation​

10.2.6 Second Boom Section Installation​

10.2.7 Third Boom Section Installation​

10.2.8 Fourth Boom Section Installation​

10.2.9 Fifth Boom Section Installation​

10.2.10 Fifth Boom Section Removal/ Installation Only​

10.2.11 Hose Carrier Assembly​

Cab (concept)​

Engine Components (reference)​

10.4.1 Engine Disassembly, Inspection and Service​

10.4.2 Fuel Tank​

Transmission (reference)​

10.5.1 Hydrostatic Pump​

10.5.2 Gearbox​

10.5.3 Drive Motor​

Hydraulic Cylinders (task)​

10.6.1 General Cylinder Disassembly​

10.6.2 Hydraulic Cylinder Repair Information​

Hydraulic Valves (reference)​

10.7.1 Main Control Valve​

10.7.2 Priority Valve​

Hydraulic Components (reference)​

10.8.1 Hydraulic Oil Reservoir​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Definitions​

11.1.2 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections​

11.1.3 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections​

11.1.4 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.5 Assembly Instructions for 45° SAE Flare Fittings​

11.1.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.8 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.9 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.10 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings​

11.1.11 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings​

11.1.13 Assembly Instructions for Flange Connections (FL61 and FL62)​

11.1.14 Double Wrench Method​

11.1.15 FFWR and TFFT Methods​

11.1.16 Adjustable Stud End Assembly​

11.1.17 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE​

11.2.2 Metric​

Schematics

Hydraulic Schematics (concept)​

Electrical Schematics​