JLG Telehandler AG313 Service Manual 3122327100 2025

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JLG Telehandler AG313 Service Manual 3122327100 2025
Size: 30.13 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: JLG AG313 Telehandler
Part Number: 3122327100
Publication Date: 2025
Number of Pages: 382 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 & Specifications

Specifications​

2.1.1 Travel Speeds​

2.1.2 Hydraulic Cylinder Performance​

2.1.3 Cylinder Drift​

2.1.4 Battery​

2.1.5 Engine Specifications​

2.1.6 Tires​

2.1.7 Dimensions​

2.1.8 Machine Specifications​

Machine Temperature Chart​

Serial Number Locations​

Fluids 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 Schedules​

Maintenance & 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 Every 8 Hours​

3.3.2 First 50 Hours​

3.3.3 Every 50 Hours​

3.3.4 Every 200 Hours​

3.3.5 Every 400 Hours​

3.3.6 Every 600 Hours​

3.3.7 Every 1000 Hours​

3.3.8 Every 1500 Hours​

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 Inching Valve Bleeding Procedure​

Boom Inspection and Maintenance​

3.7.1 Boom Wear Pads​

Hydraulic Filter Replacement​

3.8.1 Removal​

3.8.2 Installation​

Engine General Inspection​

3.9.1 General Maintenance​

3.9.2 Glow Plugs​

3.9.3 Replacing Engine Oil​

3.9.4 Replacing the Oil Filter​

3.9.5 Replacing the Fuel Filters​

3.9.6 Replace the Fuel Pump and Fuel In-Line Filter​

3.9.7 Checking Belt Tension​

Transmission Filter Replacement​

Testing, Calibrations, & Special Procedures

Special Tools​

4.1.1 Multimeter​

4.1.2 Thread Locking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Starter​

Calibration Procedures​

4.3.1 Load Stability Indicator (LSI) System Calibration​

4.3.2 Boom Sensor Calibration​

Special Procedures​

4.4.1 Emergency Lowering Procedure​

4.4.2 Towing a Disabled Machine​

4.4.3 Fuel Tank Cleaning and Drying​

4.4.4 Pressure Checks and Adjustments​

4.4.5 Cylinder Drift Test​

4.4.6 Hydraulic Circuits​

4.4.7 Pressure Specification​

System Software

Load Stability Indicator (LSI)​

5.1.1 LSI Sensor​

5.1.2 Boom Sensor​

5.1.3 Troubleshooting​

Fault Codes

Introduction​

Engine Fault Codes​

Machine Fault Codes​

Transmission Fault Codes​

Hydraulic Pump Fault Codes​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Component​

Torque Values​

7.4.1 Cylinder Torque Specifications​

Electricals

General Information​

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 Fuses​

8.5.2 Engine Fuses​

8.5.3 Relays​

Removal and Installation

Wheels​

9.1.1 Wheel and Tire Assembly​

Drive Assembly​

9.2.1 Axle Assembly and Drive Shaft Troubleshooting​

9.2.2 Axle​

9.2.3 Drive Shaft​

Boom​

9.3.1 Component Terminology​

9.3.2 Troubleshooting​

9.3.3 Boom Systems​

9.3.4 Hydraulic Coupler​

9.3.5 Forks​

9.3.6 Boom Prop​

9.3.7 Boom Wear Pad Installation and Lubrication​

9.3.8 Boom Proximity Sensor​

Cab​

9.4.1 Serial Number Plate​

9.4.2 Cab​

9.4.3 Steering Wheel​

9.4.4 Steering Column and Steering Valve​

9.4.5 Brake System​

9.4.6 Throttle Pedal​

9.4.7 Joystick Assembly​

9.4.8 Front Wiper Assembly​

9.4.9 Windshield Wiper Fluid Reservoir​

9.4.10 Heater System​

9.4.11 Instrument Panel​

9.4.12 Ignition key Switch​

9.4.13 Dash Switches​

Engine​

9.5.1 Component Terminology​

9.5.2 Diesel Fuel​

9.5.3 Engine Serial Number​

9.5.4 Engine​

9.5.5 Engine Electrical System​

9.5.6 Radiator/Cooler Assembly​

9.5.7 Pump Coupling Assembly​

9.5.8 Air Cleaner Assembly​

9.5.9 Alternator​

9.5.10 Starter​

9.5.11 Fuel Tank Assembly​

9.5.12 Hydraulic Tank​

9.5.13 Fuel Filter and Pump​

9.5.14 Engine Exhaust Assembly​

Transmission​

9.6.1 Drive Motor​

9.6.2 Gearbox​

Hydraulic Cylinders​

9.7.1 Lift Cylinder Assembly​

9.7.2 Compensation Cylinder​

9.7.3 Tilt Cylinder​

Hydraulic Valves​

9.8.1 Hydraulic Function Manifold​

9.8.2 4 Wheel / 2 Wheel Drive Selector Valve and Park Brake Valve​

9.8.3 Transmission Filter​

Hydraulic Pumps​

9.9.1 Transmission and Gear Pump​

Electrical Components​

9.10.1 Battery​

Counterweight​

9.11.1 Removal​

9.11.2 Installation​

Disassembly and Assembly

Drive Assembly​

10.1.1 Axle Assembly​

10.1.2 Transmission Assembly​

Boom​

10.2.1 Disassembly​

10.2.2 Assembly​

Cab​

Engine Components​

10.4.1 Engine Disassembly, Inspection and Service​

10.4.2 Fuel Tank​

Transmission​

10.5.1 Drive Motor​

10.5.2 Gearbox​

10.5.3 Gear Pump​

10.5.4 Transmission Pump​

Hydraulic Cylinders​

10.6.1 General Cylinder Disassembly​

10.6.2 Hydraulic Cylinder Repair Information​

Hydraulic Valves​

10.7.1 Hydraulic Function Manifold​

Hydraulic Components​

10.8.1 Hydraulic Tank​

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​

Electrical Schematics​