JLG Boom Lift 1200SJP, 1350SJP Service & Maintenance Manual 31225622 2026

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JLG Boom Lift 1200SJP, 1350SJP Service & Maintenance Manual 31225622 2026
Size: 83.77 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 1200SJP, 1350SJP Boom Lift
Part Number: 31225622
Publication Date: 2026
Number of Pages: 894 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​

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 Machine Specifications​

2.1.2 Machine Dimensional Data​

2.1.3 Engine Data​

2.1.4 Tires​

2.1.5 Chassis Specifications​

2.1.6 Major Component Weights​

2.1.7 Torque Requirements​

2.1.8 Pressure Settings​

Machine Temperature Chart​

Serial Number Location​

Fluids and Lubrication​

2.4.1 Hydraulic System​

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​

Machine Characteristics​

2.5.1 Axle Extension System​

2.5.2 Drive System​

2.5.3 Steering Control System​

2.5.4 Drive/Steering Speed Control​

2.5.5 Traction Control System​

2.5.6 Drive Orientation System​

2.5.7 Oscillating Axle System​

2.5.8 Swing Speed Proportioning​

2.5.9 Chassis Tilt Indicator System​

2.5.10 Auxiliary Power System​

2.5.11 HRC Engine Emission Characteristics​

2.5.12 Diesel Particulate Filter (If Equipped)​

2.5.13 Broken Cable Indicator System​

2.5.14 Platform Control Enable System​

2.5.15 Transport Position Sensing System​

2.5.16 Beyond Transport - Drive Speed Cutback System​

2.5.17 Drive/Steer – Boom Function Interlock System (CE/UKCA ONLY)​

2.5.18 Jib Stow System​

2.5.19 Envelope Tracking System​

2.5.20 Moment Control System​

2.5.21 Boom Control System (BCS) Functional Check (Push to Test) System​

2.5.22 Controlled Arc System​

2.5.23 Controlled Boom Angle System​

2.5.24 Envelope Tracking​

2.5.25 Slow Down System​

2.5.26 Dual Capacity System​

2.5.27 Platform Load Sensing System (LSS)​

2.5.28 Electronic Platform Leveling​

2.5.29 Boom Control Select​

2.5.30 Electronic Platform Leveling​

2.5.31 Normal Operation​

Clearsky Smart Fleet (If Equipped)​

2.6.1 General​

2.6.2 ClearSky Smart Fleet™ — Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventive Maintenance​

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 Daily​

3.3.2 First 50 Hours​

3.3.3 First 150 Hours​

3.3.4 Every 150 Hours or 3 Months​

3.3.5 Every 300 Hours or 6 Months​

3.3.6 Every 500 Hours or 6 Months​

3.3.7 Every 600 Hours or 1 Year​

3.3.8 Every 1000 hours or 2 years​

3.3.9 Every 1200 Hours or 2 Years​

Pins and Composite Bearing Repair Guidelines​

Tires and Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Fuel Tank Inspection​

Boom Inspection and Maintenance​

3.7.1 Wire Rope Tensioning Adjustment​

3.7.2 Wire Rope Tensioning Procedure​

3.7.3 Wire Rope​

3.7.4 Boom Cleanliness Guidelines​

3.7.5 Boom Wear Pad Inspection​

Hydraulic Filter Replacement​

3.8.1 Hydraulic Filter Removal​

3.8.2 Hydraulic Filter Installation​

Turntable Bearing Inspection​

3.9.1 Turntable Bearing Mounting Bolt Condition Check​

3.9.2 Wear Tolerance​

Engine General Inspection​

3.10.1 General Maintenance​

3.10.2 Deutz TD2.9L4 and Deutz TCD2.9L4 (China IV) Engine​

3.10.3 Deutz Engine TCD2.9L4 (T4F and Stage V)​

Bio Fuel In Deutz Engines​

3.11.1 General​

3.11.2 Bio Fuel​

3.11.3 Biological Contamination In Fuels​

Deutz EMR5​

Generator Inspection​

3.13.1 Every 250 hours​

3.13.2 Every 500 hours​

3.13.3 Overload Protection​

3.13.4 Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Starter​

4.2.2 SkyGuard​

4.2.3 LSS Testing and Evaluation​

4.2.4 System Test​

Calibration Procedures​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Load Sensing System Calibration​

4.3.4 Calibrating Tilt Sensor​

4.3.5 Calibrating Platform Level​

4.3.6 Calibrating Lift Crack Point​

4.3.7 Calibrating Telescope Crack point​

4.3.8 Calibrating the Boom Sensors​

4.3.9 Calibrating Steer​

4.3.10 Calibrating Drive​

Special Procedures​

4.4.1 Drive Cutout Override Service Mode​

4.4.2 Fuel Tank Cleaning and Drying​

4.4.3 Cylinder Drift​

4.4.4 Oscillating Axle Bleeding Procedure and Lockout Test​

4.4.5 Axle Limit Switch Adjustment Procedure​

System Software

Load Sensing System (LSS)​

5.1.1 Theory of Operation​

5.1.2 Load Sensing Gauge Removal/ Installation​

5.1.3 Diagnostic Menu​

JLG Analyzer​

5.2.1 Introduction​

5.2.2 Hand Held Analyzer​

5.2.3 To Connect the JLG Control System Analyzer​

5.2.4 Using the Analyzer​

5.2.5 Changing the Access Level Of The Hand Held Analyzer​

5.2.6 Adjusting Parameters Using The Hand Held Analyzer​

5.2.7 Machine Setup​

5.2.8 Analyzer Flow Chart​

Analyzer Software Accessibility​

5.3.1 Machine Set-Up​

5.3.2 Machine Personality Settings/Function Speeds​

Function Test​

5.4.1 Machine Orientation When Setting Function Speeds​

CANbus Communications (reference)​

5.5.1 CANbus Communication Failure​

Service Mode​

5.6.1 Load Sensing System​

5.6.2 Drive Cutout Override​

Electronic Platform Leveling​

5.7.1 Platform Leveling Fault Warning​

5.7.2 Fault Response​

5.7.3 CAN Errors​

5.7.4 Additional Platform and Jib Valves​

5.7.5 Platform Leveling Calibration Procedure​

ClearSky (CS550) Configuration and Troubleshooting​

5.8.1 ClearSky Smart FleetTM CS550 Configuration​

5.8.2 Troubleshooting​

Fault Codes

Fault Codes Introduction​

Machine Fault Codes​

6.2.1 General​

6.2.2 ClearSky Smart Fleet DTC Fault Codes​

ClearSky CS550 Troubleshooting Procedures​

Machine Diagnostics Parameters​

Deutz EMR Fault Codes​

6.5.1 EMR5 Fault Codes​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Components​

7.3.1 Hydraulic Oil Tank​

7.3.2 Lubricating O-rings In The Hydraulic System​

7.3.3 Pressure Setting Procedure​

7.3.4 Set Up of the Function Pump​

7.3.5 Adjustments Made at the Main Valve Bank​

7.3.6 Adjustments Made at the Frame Valve Bank​

7.3.7 Adjustments Made at the Platform Valve Bank​

7.3.8 Drive & Function Pump Start Up Procedures​

Torque Values​

Standard Hydraulic Diagram- Boom And Turntable​

7.5.1 Boom​

7.5.2 Turntable (with Rexroth Pump)​

7.5.3 Turntable (with Sauer Pump)​

Hydraulic Diagram - Chassis​

7.6.1 4WD Chassis (with Rexroth Pump)​

7.6.2 4WD Chassis (with Sauer Pump)​

7.6.3 Oscillating Axle​

7.6.4 Axle Extend and Steer​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Component Terminology​

Harness Layouts​

Board Layouts​

AMP Connector​

8.6.1 Applying Silicone Dielectric Compound to AMP Connectors​

8.6.2 Assembly​

8.6.3 Disassembly​

8.6.4 Wedge Lock​

8.6.5 Service - Voltage Reading​

Wiring Harness and Connector Label Diagrams​

Telematics Gateway​

8.8.1 Telematics-Ready (TCU) Plug​

Removal and Installation

Wheel and Tire​

Chassis/Frame Assembly​

9.2.1 Chassis Component​

9.2.2 Drive Hub​

9.2.3 Drive Motor​

9.2.4 Spindle​

9.2.5 Axle​

Boom​

9.3.1 Boom Component​

9.3.2 Boom Removal​

9.3.3 Rotator​

9.3.4 Load Sensing Pin Removal and Installation​

9.3.5 Boom/Jib Sensors and Switches Installation​

9.3.6 Adjusting the Proximity Switch​

9.3.7 Hose Routing Procedure​

Platform​

9.4.1 Platform (Rapid Replaceable Platform)​

9.4.2 Platform Support (Traditional Design)​

9.4.3 Platform Support (Rapid Replaceable Platform)​

9.4.4 Bolt-on External Fall Arrest​

Engine​

9.5.1 Component Terminology​

9.5.2 Deutz TD2.9 L4 Engine​

9.5.3 Deutz TCD2.9L4 Engine​

9.5.4 Deutz TCD2.9L4 (Stage V) Engine​

9.5.5 Deutz TCD2.9L4 (China IV) Engine​

9.5.6 Engine Serial Number​

9.5.7 Engine Replacement​

9.5.8 Surge Tank​

9.5.9 Pump Coupling Kit​

9.5.10 Air Filter Assembly​

9.5.11 Radiator Assembly​

9.5.12 Thermostat​

9.5.13 Coolant Temperature Sensor​

9.5.14 Relay Assembly​

9.5.15 Starter​

9.5.16 Alternator​

9.5.17 Fuel Tank​

9.5.18 Pre- Fuel Filter and Fuel Pump​

Transmission​

Hydraulic Cylinders​

9.7.1 Main Boom Lift Cylinder​

9.7.2 Steer Cylinder​

9.7.3 Axle Extend Cylinder​

9.7.4 Axle Lockout Cylinder​

Hydraulic Valves​

9.8.1 Platform Control Valve (Rapid Replaceable)​

9.8.2 Platform Valve (Traditional Design)​

9.8.3 Main Control Valve​

9.8.4 Traction Valve​

9.8.5 Axle Extend and Steer Valve​

Hydraulic Pumps​

9.9.1 Charge Pump​

9.9.2 Function Pump​

9.9.3 Drive Pump​

9.9.4 Rexroth Pump​

Electrical Components​

9.10.1 Battery​

9.10.2 Cold Weather Package​

Turntable​

9.11.1 Swing Bearing​

9.11.2 Swing Brake​

9.11.3 Procedure for Setting Gear Backlash​

9.11.4 Swing Drive Lubrication​

9.11.5 Rotary Coupling​

Generator Pulley​

9.12.1 Removal​

9.12.2 Installation​

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

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

Disassembly and Assembly

Drive Assembly​

10.1.1 Drive Hub - If Equipped With Reggiana Riduttori​

10.1.2 Tools​

10.1.3 Disassembly​

10.1.4 Assembly​

10.1.5 Drive Motor​

Boom and Jib Assembly​

10.2.1 Disassembly​

10.2.2 Assembly​

10.2.3 Boom Lubrication Application​

10.2.4 Boom Shimming Procedure​

10.2.5 Jib Rotator Orientation​

10.2.6 Jib Lift End of Stroke Dampening​

10.2.7 Required Tools​

10.2.8 Rotary Actuator​

Pumps​

10.3.1 Drive Pumps (Rexroth)​

10.3.2 Charge Pressure Relief Valve Adjustment​

10.3.3 Mechanical Centering of Pump​

10.3.4 Hydraulic Centering of Control Modules​

10.3.5 High Pressure Relief Valve Adjustments​

10.3.6 Removal and Inspection of Charge Pump​

10.3.7 Routine Maintenance​

10.3.8 Removal and Installation of Shaft Seal​

10.3.9 Function Pump (Rexroth)​

10.3.10 Spare Parts​

10.3.11 Sealing the Drive Shaft​

10.3.12 Disassembly and Assembly of the Complete Unit​

10.3.13 Assembly​

10.3.14 Adjustments​

10.3.15 Tightening Torques​

10.3.16 Pump Control Disassembly for Cleaning​

10.3.17 Drive Pumps (SAUER)​

10.3.18 Port Locations and Gauge Installation​

10.3.19 Initial Startup Procedures​

10.3.20 Troubleshooting​

10.3.21 Adjustments​

10.3.22 Removing the Pump​

10.3.23 Inspection​

10.3.24 Replacement​

10.3.25 Electric Control Module​

10.3.26 Shaft, Seal, and Bearing​

10.3.27 Charge Pump​

10.3.28 Charge Check / HPRV​

10.3.29 Charge Pressure Relief Valve​

10.3.30 Control Cutoff Valve​

10.3.31 Function Pump (SAUER)​

10.3.32 Inspection​

10.3.33 Assembly​

10.3.34 Charge pump (Sauer)​

10.3.35 Assembly​

10.3.36 Troubleshooting​

Hydraulic Cylinders​

10.4.1 Disassembly​

10.4.2 Cleaning and Inspection​

10.4.3 Assembly​

10.4.4 Steer Cylinder​

10.4.5 Cleaning And Inspection​

10.4.6 Assembly​

Turntable​

10.5.1 Swing Drive Hub​

10.5.2 Swing Drive​

10.5.3 Swing Brake​

10.5.4 Swing Motor​

10.5.5 Rotary Coupling Seal Kit​

Generator Disassembly and Assembly​

10.6.1 Generator Disassembly and Assembly​

Powertrack​

10.7.1 One Piece Bracket Maintenance​

10.7.2 Two Piece Bracket Maintenance​

10.7.3 Snap Rings and Screws​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

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

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

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

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

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

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

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

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

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

Electrical Schematics​

Deutz EMR5 Schematics​

Generator Schematics​

12.4.1 Lead Connection List​