JLG Boom Lift 1250AJP Service & Maintenance Manual 3122341500 2025

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JLG Boom Lift 1250AJP Service & Maintenance Manual 3122341500 2025
Size: 89.44 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 1250AJP Boom Lift
Part Number: 3122341500
Publication Date: 2025
Number of Pages: 924 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 Specification​

2.1.2 Machine Dimensional Data​

2.1.3 Engine Data​

2.1.4 Chassis Specifications​

2.1.5 Tires​

2.1.6 Torque Requirements​

2.1.7 Pressure Settings​

2.1.8 Major Component Weights​

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​

Machine Characteristics​

2.5.1 Axle Extension System​

2.5.2 Oscillating Axle System​

2.5.3 Swing Speed Proportioning​

2.5.4 HRC Engine Emission Characteristics​

2.5.5 Diesel Particulate Filter (If Equipped)​

2.5.6 Electronic Platform Leveling​

2.5.7 Drive System​

2.5.8 Steering Control System​

2.5.9 Drive/Steering Speed Control​

2.5.10 Traction Control System​

2.5.11 Drive Orientation System​

2.5.12 Chassis Tilt Indicator System​

2.5.13 Auxiliary Power 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 Control System​

2.5.20 Tower Path Control System​

2.5.21 Automatic Main Boom Control System​

2.5.22 Electrical Retrieval System​

2.5.23 Hydraulic Retrieval System​

2.5.24 Controlled Boom Angle System​

2.5.25 Slow Down System​

2.5.26 Dual Capacity System​

2.5.27 Hydraulic System Warm Up​

2.5.28 Reduced Platform Heights​

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 First 300 Hours or 6 Months​

3.3.6 Every 500 Hours or 6 Months​

3.3.7 Every 500 Hours or 1 Year​

3.3.8 Every 600 Hours or 1 Year​

3.3.9 Every 1200 Hours or 2 Years​

Pins and Composite Bearing Repair Guidelines​

Fuel Tank Inspection​

Hydraulic Filter Replacement​

Turntable Bearing Inspection​

3.7.1 Turntable Bearing Mounting Bolt Condition Check​

3.7.2 Wear Tolerance​

Engine General Inspection​

3.8.1 Deutz TCD2.9L4/TD2.9L4 Engines​

3.8.2 Engine and Hydraulic Operating Temperature Specifications​

Bio Fuel In Deutz Engines​

3.9.1 General​

3.9.2 Bio Fuel​

3.9.3 Biological Contamination In Fuels​

Deutz EMR5​

Generator Inspection​

3.11.1 Every 250 hours​

3.11.2 Every 500 hours​

3.11.3 Overload Protection​

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

3.11.5 Troubleshooting​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter Basics​

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 Instructions​

4.3.3 Calibration Preparation​

4.3.4 Load Sensing System Calibration​

4.3.5 Calibrating Platform Level​

4.3.6 Calibrating Tilt Sensor​

4.3.7 Boom Sensor Calibration​

4.3.8 Rotary Angle Sensor Calibration​

4.3.9 Boom Control System (BCS) Violation​

4.3.10 Calibrating Steer​

4.3.11 Calibrating Drive​

4.3.12 Calibrating Boom Valves​

Special Procedures​

4.4.1 Fuel Tank Cleaning and Drying​

4.4.2 Cylinder Drift​

4.4.3 Oscillating Axle Bleeding Procedure and Lockout Test​

4.4.4 Axle Limit Switch Adjustment Procedure​

4.4.5 Tower Boom Drift Test​

4.4.6 Drive Cutout Override Service Mode​

4.4.7 Counterbalance Valve Check​

4.4.8 Air Purge Procedure for Non-Calibrated Machines​

4.4.9 Air Purge Procedure for Calibrated Machines​

System Software

Load Sensing System (LSS)​

5.1.1 Theory of Operation​

5.1.2 Load Sensing Gauge Removal/ Installation​

JLG Analyzer​

5.2.1 Introduction​

5.2.2 Machine Data Access​

5.2.3 Hand Held Analyzer​

5.2.4 Using the Analyzer​

5.2.5 Changing Access Level of Hand Held Analyzer​

5.2.6 Adjusting Parameters Using Hand Held Analyzer​

5.2.7 Machine Setup​

5.2.8 Analyzer Software Version P7.44​

Analyzer Software Accessibility​

5.3.1 Analyzer Diagnostics​

5.3.2 Machine Set-Up​

5.3.3 Machine Personality Settings and Function Speeds​

Machine Orientation When Setting Speeds​

CANBUS Communications​

5.5.1 CANBUS Connections​

5.5.2 CANBUS Communication Failure​

Service Mode​

5.6.1 Load Sensing System​

5.6.2 Drive Cutout Override​

Electronic Platform Leveling​

5.7.1 Description​

5.7.2 Normal Operation​

5.7.3 Platform Leveling Fault Warning​

5.7.4 Fault Response​

5.7.5 CAN Errors​

5.7.6 Additional Platform and Jib Valves​

ClearSky (CS550) Configuration and Troubleshooting​

5.8.1 ClearSky Smart FleetTM CS550 Configuration​

5.8.2 Troubleshooting​

Fault Codes

Fault Codes Introduction​

Engine Diagnostic​

Machine Fault Codes​

6.3.1 General​

6.3.2 ClearSky Smart Fleet DTC Fault Codes​

6.3.3 LSS Troubleshooting​

6.3.4 System Test Messages​

Deutz EMR Fault Codes​

6.4.1 Deutz EMR5 Fault Codes​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Components​

7.3.1 Hydraulic Tank​

7.3.2 Pressure Setting Procedure​

7.3.3 Drive and Function Pump Start Up​

7.3.4 Rotary Coupling Ports​

Torque Values​

7.4.1 Main Valve Torque Specifications​

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​

8.5.1 Chassis Control Module​

8.5.2 BLAM Control Module​

8.5.3 Ground Control Module​

8.5.4 Platform Control Module​

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​

Telematics Gateway​

8.8.1 Telematics-Ready (TCU) Plug​

Removal and Installation

Wheel and Tire​

Chassis/Frame Assembly​

9.2.1 Wheel Drive Assembly​

9.2.2 Spindle​

9.2.3 Axle​

Boom​

9.3.1 Boom Switches​

9.3.2 Main Boom Powertrack​

9.3.3 Tower Boom Powertrack​

9.3.4 Tower Boom Installation and Assembly​

9.3.5 Pin Clamp Installation Procedure​

9.3.6 Boom Sensors​

9.3.7 Rotary Angle Sensor​

9.3.8 Jib Assembly​

9.3.9 Rotator​

9.3.10 Hose Routing Procedure​

Platform​

9.4.1 Platform Support​

9.4.2 Bolt-on External Fall Arrest​

Engine​

9.5.1 Component Terminology​

9.5.2 Engine Serial Number​

9.5.3 Engine Replacement​

9.5.4 Surge Tank​

9.5.5 Pump Coupling Kit​

9.5.6 Air Filter Assembly​

9.5.7 Radiator Assembly​

9.5.8 Thermostat​

9.5.9 Coolant Temperature Sensor​

9.5.10 Relay Assembly​

9.5.11 Starter​

9.5.12 Alternator​

9.5.13 Fuel Tank​

9.5.14 Pre-Fuel Filter and Fuel Pump​

Transmission​

Hydraulic Cylinders​

9.7.1 Tower Telescopic Cylinder​

9.7.2 Tower Lift Cylinder​

9.7.3 Main Lift Cylinder​

9.7.4 Main Boom Telescope Cylinder​

9.7.5 Platform Level Cylinder​

9.7.6 Jib Lift Cylinder​

9.7.7 Steer Cylinder​

9.7.8 Axle Extend Cylinder​

9.7.9 Axle Lockout Cylinder​

Hydraulic Valves​

9.8.1 Platform Valve​

9.8.2 Main Control Valve​

9.8.3 Traction Valve​

9.8.4 Axle Extend and Steer Valve​

9.8.5 Enable Valves​

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 Drive Hub​

9.11.2 Swing Brake​

9.11.3 Procedure For Setting Gear Backlash​

9.11.4 Swing Drive Lubrication​

9.11.5 Rotary Coupling​

9.11.6 Swing Bearing​

9.11.7 Counterweight​

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​

Boom and Jib Assembly​

10.2.1 Main Boom​

10.2.2 Tower Boom​

10.2.3 Rotary Actuator​

Pumps​

10.3.1 Drive Pumps​

10.3.2 Function Pump​

Hydraulic Cylinders​

10.4.1 Disassembly​

10.4.2 Cleaning and Inspection​

10.4.3 Assembly​

Turntable​

10.5.1 Swing Drive Hub​

10.5.2 Swing Drive​

10.5.3 Swing Brake​

10.5.4 Rotary Coupling Seal​

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 Schematic​