JLG Telehandler AG823 AG832 AG925 Service Manual 3122554900 2025

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JLG Telehandler AG823 AG832 AG925 Service Manual 3122554900 2025
Size: 57.27 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: JLG AG823, AG832, AG925 Telehandler
Part Number: 3122554900
Publication Date: 2025
Number of Pages: 642 Pages

Contents:
Coverpage
Effectivity Page
Read This First

Modifications​

Machine Configuration​

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 Specification​

2.1.5 Electrical System​

2.1.6 Engine Performance Specifications​

2.1.7 Tires​

2.1.8 Transmission Performance Specifications​

Machine Temperature Chart​

Serial Number Location​

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 Schedule​

After Treatment System​

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 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 Every 500 Hours​

3.3.7 Every 750 Hours​

3.3.8 Every 1000 Hours​

3.3.9 Every 1500 Hours​

3.3.10 Every 3000 Hours​

3.3.11 Every 3000 Hours or 2 Years​

3.3.12 Every 6000 Hours or 4 Years​

3.3.13 Every 10000 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​

DEF Tank Inspection​

Boom Inspection and Maintenance​

3.8.1 Boom Wear Pads​

Hydraulic Filter Replacement​

3.9.1 Hydraulic Filter Removal​

3.9.2 Hydraulic Filter Installation​

Transmission Fluid/Filter Replacement​

Transmission Fluid Level Check​

Brake Inspection​

Specification and Maintenance Information​

3.13.1 Axle​

3.13.2 Transmission​

3.13.3 Engine​

Testing, Calibrations and 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​

4.2.2 Charging Circuit​

Calibration Procedures​

4.3.1 Analyzer​

4.3.2 Boom Angle Sensor Calibration​

4.3.3 Load Stability Indicator (LSI) System Calibration​

4.3.4 LMIS (Load Moment Indicator System) Calibration​

4.3.5 Brake Pedal Calibration​

4.3.6 Reversing Camera Calibration​

Special Procedures​

4.4.1 Emergency Boom Lowering Procedure​

4.4.2 Towing a Disabled Machine​

4.4.3 Charge Air Cooler (CAC) Hose Draining​

4.4.4 Hydraulic Oil Reservoir​

4.4.5 Diesel Exhaust Fluid (DEF) System Cleaning​

4.4.6 Fuel Tank Cleaning and Drying​

4.4.7 Accumulators​

4.4.8 Hydraulic Pressure Settings and Adjustments​

4.4.9 Cylinder Checking Procedure​

4.4.10 Cylinder Drift Test​

4.4.11 Hydraulic Circuits​

4.4.12 Hydraulic Pressures​

4.4.13 Pressure Specifications​

4.4.14 Steering Angle Adjustment​

4.4.15 Steering Cylinders​

4.4.16 Extend/Retract Cylinder Bleeding Procedure - AG832​

System Software

Load Stability Indicator (LSI) (If Equipped)​

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)​

Premium Display (If Equipped)​

5.9.1 Home Screen and Touch Screen Soft Buttons​

5.9.2 Main Menu​

5.9.3 Reprogramming Menu​

Reprogramming the Premium Display​

5.10.1 Software Installation​

5.10.2 Load Charts Programming​

5.10.3 Premium Display Reassembly​

ClearSky (CS550) Configuration and Troubleshooting​

5.11.1 ClearSky Smart FleetTM CS550 Configuration​

5.11.2 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)​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Component​

7.3.1 AG823​

7.3.2 AG832​

7.3.3 AG925​

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​

Solenoids and Sensors and Senders​

8.6.1 Transmission Solenoid Valves​

8.6.2 Fuel Level Sender​

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 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 Accumulator​

9.3.5 Manual Quick Coupler​

9.3.6 Hydraulic Quick Coupler​

9.3.7 Forks​

9.3.8 Boom Prop (If Equipped)​

9.3.9 Boom Wear Pad Installation, Lubrication​

9.3.10 Boom Angle Sensor​

9.3.11 Boom Retract Sensor​

Cab​

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 Brake Accumulator​

9.4.6 Electronic Throttle Pedal​

9.4.7 Joystick Assembly​

9.4.8 Ignition Key Switch​

9.4.9 Dash Switches​

9.4.10 Front Windshield Wiper Motor​

9.4.11 Rear Window Wiper Motor​

9.4.12 Roof Window Wiper Motor​

9.4.13 Washer Fluid Reservoir​

9.4.14 Cab Heater and A/C (If Equipped)​

9.4.15 Heater System (If equipped)​

9.4.16 Heater/Air Conditioning System (If equipped)​

9.4.17 Premium Display (If Equipped)​

9.4.18 Reversing Camera​

Engine​

9.5.1 Component Terminology​

9.5.2 Engine Serial Number​

9.5.3 Diesel Fuel​

9.5.4 Engine Replacement​

9.5.5 Surge Tank Cap​

9.5.6 Thermostat Replacement​

9.5.7 Engine Coolant Temperature Sensor​

9.5.8 Radiator Assembly Replacement​

9.5.9 Hydraulic Oil Reservoir Removal/ Installation​

9.5.10 Diesel Exhaust Fluid (DEF) Tank​

9.5.11 Diesel Exhaust Fluid (DEF) Filter​

9.5.12 Diesel Exhaust Fluid (DEF) Pump Filter​

9.5.13 Fuel Tank​

9.5.14 Engine Exhaust System (ULS)​

9.5.15 Engine Exhaust System (LS)​

9.5.16 Air Cleaner Assembly​

9.5.17 Starter​

9.5.18 Alternator​

9.5.19 Air Conditioner (AC) Compressor (If Equipped)​

Transmission​

9.6.1 Component Terminology​

9.6.2 Transmission Serial Number​

9.6.3 Transmission Removal/Installation​

9.6.4 Reverse Alarm​

9.6.5 Torque Converter Diaphragm​

9.6.6 Transmission Oil Temperature Sensor​

9.6.7 Transmission Mounted Speed Sensor​

Hydraulic Cylinders​

9.7.1 General Cylinder Instructions​

9.7.2 Steering Cylinders​

Hydraulic Valves​

9.8.1 Main Control Valve​

9.8.2 Priority Valve​

9.8.3 Steering Column/Orbital Valve​

9.8.4 Steering Orbital Valve​

9.8.5 Steer Select Valve​

Hydraulic Pumps​

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

Boom​

10.1.1 Boom Assembly Maintenance - AG823/AG925​

10.1.2 Boom Assembly Maintenance - AG832​

10.1.3 Third Boom Section Removal/Installation Only - AG832​

Drive Assembly​

10.2.1 Axle Assembly​

10.2.2 Transmission Assembly​

Cab​

Engine Components​

10.4.1 Engine Disassembly, Inspection and Service​

10.4.2 Fuel Tank​

10.4.3 Diesel Exhaust Fluid (DEF) Tank Header Element Cleaning​

10.4.4 Diesel Exhaust Fluid (DEF) Tank​

Transmission​

10.5.1 Implement Pump​

Hydraulic Cylinders​

10.6.1 General Cylinder Instruction​

10.6.2 Hydraulic Cylinder Repair Information​

Hydraulic Valves​

10.7.1 Main Control Valve​

10.7.2 Priority Valve​

10.7.3 Steer Select Valve​

Hydraulic Components​

10.8.1 Hydraulic Oil 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​