JLG Telehandler 1644 1732 7013 8010 Service Manual 3122350000 2025

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JLG Telehandler 1644 1732 7013 8010 Service Manual 3122350000 2025
Size: 60.46 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: JLG 1644, 1732, 7013, 8010 Telehandler
Part Number: 3122350000
Publication Date: 2025
Number of Pages: 648 Pages

Contents:
Safety

General​

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​

Machine Verification​

General Machine Information and Specifications

Specifications​

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​

Serial Number Location​

Fluid and Lubrication​

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 Stationary Exhaust System Cleaning​

ClearSky Smart Fleet​

2.6.1 General​

2.6.2 ClearSky Smart Fleet™ – Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 Preparation, Inspection, and Maintenance​

3.1.2 Pre-Start Inspection​

3.1.3 Pre-Delivery Inspection​

Service and Guidelines​

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​

3.3.1 Service and Maintenance Schedules​

3.3.2 Axle Specifications and Maintenance Information​

3.3.3 Transmission Specifications and Maintenance Information​

3.3.4 Engine Specifications and Maintenance Information​

Pins and Composite Bearing Repair Guidelines​

3.4.1 Filament Wound Bearings​

Tires and Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Brake Maintenance​

3.6.1 Service Brake Bleeding​

3.6.2 Park Brake Bleeding​

3.6.3 Brake Inspection​

DEF Tank Inspection​

3.7.1 DEF Tank Inspection​

Boom Inspection and Maintenance​

3.8.1 Wear Pad Inspection​

Hydraulic Filter Replacement​

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​

4.2.1 Engine​

4.2.2 Fuel Level Sender​

Calibration Procedures​

4.3.1 JLG Analyzer​

4.3.2 Inching System Calibration​

4.3.3 Boom Angle Sensor Calibration​

4.3.4 Load Stability Indicator (LSI) System Calibration​

4.3.5 LMIS (Load Moment Indicator System) Calibration​

4.3.6 Attachment Recognition Calibration​

4.3.7 Park Brake Calibration/Maximum Drive Traction Test​

4.3.8 Brake Pedal Calibration​

Special Procedures​

4.4.1 Emergency Lowering Procedure​

4.4.2 Towing a Disabled Machine​

4.4.3 Transmission Oil Replacement​

4.4.4 Charge Air Cooler (CAC) Hose Replacement​

4.4.5 Diesel Exhaust Fluid (DEF) System Cleaning (If Equipped for ULS)​

4.4.6 Fuel Tank​

4.4.7 Hydraulic Pressure Checks and Adjustments​

4.4.8 Hydraulic Circuits​

4.4.9 Hydraulic Pressures​

4.4.10 Pressure Specifications​

4.4.11 Hydraulic Reservoir​

4.4.12 Accumulators​

System Software

Load Stability Indicator (LSI)​

5.1.1 Load Stability Indicator​

5.1.2 LSI Sensor​

Analyzer​

5.2.1 Machine Data Access​

5.2.2 JLG Hand Held Analyzer​

5.2.3 JLG Mobile Analyzer and ClearSky SmartFleet Bluetooth Analyzer​

5.2.4 PC Analyzer/Loglifter​

5.2.5 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)​

5.9.1 Technical Specification​

5.9.2 Multifunction Display and Control Buttons​

5.9.3 Main Menu​

5.9.4 Setup and Maintenance​

5.9.5 Troubleshooting​

ClearSky (CS550) Configuration and Troubleshooting​

5.10.1 ClearSky Smart FleetTM CS550 Configuration​

5.10.2 Troubleshooting​

Fault Codes

Introduction​

Engine Diagnostic​

6.2.1 EMR5 Diagnosis and Error codes​

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)​

Air Shutoff Valve (ASOV) Controller​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

General Information and Safety​

Theories Of Operation (reference)​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Components​

7.3.1 1644, 7013​

7.3.2 1732, 8010​

Torque Values​

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​

Board Layouts​

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​

Removal and Installation

Wheels​

9.1.1 Removing Wheel and Tire Assembly from Machine​

9.1.2 Installing Wheel and Tire Assembly onto Machine​

Drive Assembly​

9.2.1 Axle Serial Number​

9.2.2 Axle​

9.2.3 Steering Angle Adjustment​

9.2.4 Axle Assembly and Drive Shaft Troubleshooting​

9.2.5 Drive Shaft​

Boom​

9.3.1 Component Terminology​

9.3.2 Boom System Operation​

9.3.3 Complete Boom​

9.3.4 Precision Gravity Lower System (PGLS)​

9.3.5 Accumulator​

9.3.6 Quick Coupler​

9.3.7 Forks​

9.3.8 Boom Wear Pad Installation, Lubrication​

9.3.9 Boom Angle Sensor​

9.3.10 Boom Prop (If Equipped)​

9.3.11 Troubleshooting​

Cab​

9.4.1 Component Terminology​

9.4.2 Operator Cab Safety​

9.4.3 Serial Number Plate​

9.4.4 Cab Removal and Installation​

9.4.5 Steering Wheel​

9.4.6 Steering Column/Orbital Valve​

9.4.7 Service Brake​

9.4.8 Electronic Throttle Pedal​

9.4.9 Joystick Assembly​

9.4.10 Ignition Key Switch​

9.4.11 Dash Switches​

9.4.12 Window Wiper Assembly (IF Equipped)​

9.4.13 Multifunction Display (If Equipped)​

9.4.14 Heater System​

9.4.15 Heater and Air Conditioning System (If Equipped)​

Engine​

9.5.1 Component Terminology​

9.5.2 Engine Serial Number​

9.5.3 Surge Tank Cap​

9.5.4 Thermostat Replacement​

9.5.5 Radiator Assembly Replacement​

9.5.6 Engine Coolant Temperature Sensor​

9.5.7 Engine Electrical System​

9.5.8 Diesel Fuel​

9.5.9 Diesel Exhaust Fluid (DEF) Tank (If Equipped for ULS)​

9.5.10 Diesel Exhaust Fluid (DEF) System Header (If Equipped for ULS)​

9.5.11 Diesel Exhaust Fluid (DEF) Pump Filter (if equipped for ULS)​

9.5.12 Hydraulic Oil Reservoir Removal/Installation​

9.5.13 Fuel Tank​

9.5.14 Engine Exhaust System​

9.5.15 Air Cleaner Assembly​

9.5.16 Engine Replacement​

9.5.17 Starter​

9.5.18 Alternator​

9.5.19 Troubleshooting​

Transmission​

9.6.1 Component Terminology​

9.6.2 Transmission Serial Number​

9.6.3 Transmission Removal/Installation​

9.6.4 Hydrostatic Transmission Pump Replacement​

9.6.5 Dual Pump Drive Replacement​

9.6.6 Drive Motor​

9.6.7 Gearbox Replacement​

9.6.8 Reverse Alarm​

Hydraulic Cylinders​

9.7.1 General Cylinder​

9.7.2 Steering Cylinders​

Hydraulic Valves​

9.8.1 Main Control Valve​

9.8.2 Priority Valve​

9.8.3 Service Brake Valve​

9.8.4 Steering Orbital Valve​

9.8.5 Frame Leveling Valve or Outrigger/ Frame Leveling Valve (if equipped)​

9.8.6 Steer Select Valve​

9.8.7 Inching Valve​

Hydraulic Pump​

9.9.1 Implement Pump​

Electrical Components​

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​

10.1.1 Axle Assembly​

10.1.2 Transmission Assembly​

Boom​

10.2.1 Boom Assembly Maintenance - 1644, 7013​

10.2.2 Boom Assembly Maintenance - 1732, 8010​

Cab​

Engine Components (reference)​

10.4.1 Fuel Tank​

Transmission​

10.5.1 Implement Pump​

Hydraulic Cylinders​

10.6.1 General Cylinder​

Hydraulic Valves​

10.7.1 Main Control Valve​

10.7.2 Priority Valve​

Hydraulic Components​

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​

12.1.1 1644, 7013​

12.1.2 1732, 8010​

Electrical Schematics​