JLG 1250AJP Illustrated Parts Manual 3121172 – PDF DOWNLOAD

Illustrated Parts Manual

Model 1250AJP

3121172 August 15, 2013

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REVISION LOG

GROUND MODULE MODULE IDENTIFICATION

MODULE ON MACHINES “WITH UGM” (UNIVERSAL GROUND MODULE)

MODULE ON MACHINES “WITHOUT UGM” (UNIVERSAL GROUND MODULE)

March 30, 2004 - Original Issue Of Manual (Edited to B/M 0010609 Revision 3) July 15, 2004 - Revised Manual (Edited to B/M 0010609 Revision 4) October 28, 2004 - Revised Manual (Edited to B/M 0010609 Revision 5) February 24, 2005 - Revised Manual (Edited to B/M 0010609 Revision 7) January 5, 2006 - Revised Manual (Edited to B/M 0010609 Revision 14) April 30, 2006 - Revised Manual (Edited to B/M 0010609 Revision 15) August 15, 2006 - Revised Manual (Edited to B/M 0010609 Revision 16) January 15, 2007 - Revised Manual (Edited to B/M 0010609 Revision 17) June 1, 2007 - Revised Manual (Edited to B/M 0010609 Revision 21) October 20, 2007 - Revised Manual (Edited to B/M 0010609 Revision 25) January 15, 2008 - Revised Manual (Edited to B/M 0010609 Revision 26) July 31, 2008 - Revised Manual (Edited to B/M 0010609 Revision 32) January 25, 2009 - Revised Manual (Edited to B/M 0010609 Revision 32) July 27, 2009 - Revised Manual (Edited to B/M 0010609 Revision 41) December 15, 2009 - Revised Manual (Edited to B/M 0010609 Revision 48) July 22, 2010 - Revised Manual (Edited to B/M 0010609 Revision 52) February 23, 2011 - Revised Manual (Edited to B/M 0010609 Revision 58) May 25, 2011 - Revised Manual (Edited to B/M 0010609 Revision 58) August 19, 2011 - Revised Manual (Edited to B/M 0010609 Revision 60) January 23, 2012 - Revised Manual (Edited to B/M 0010609 Revision E) June 22, 2012 - Revised Manual (Edited to B/M 0010609 Revision E) August 17, 2012 - Revised Manual (Edited to B/M 0010609 Revision E) December 20, 2012 - Revised Manual (Edited to B/M 0010609 Revision E) April 19, 2013 - Revised Manual (Edited to B/M 0010609 Revision E)

3121172

1250AJP

A

REVISION LOG August 15, 2013 - Revised Manual (Edited to B/M 0010609 Revision E)

B

1250AJP

3121172

TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

SECTION 1 - FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13

AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 DRIVE HUB ASSEMBLY (PRIOR TO S/N 0300079667) . . . . . . . . . . . . . . . . . . . . . . . 1-14 DRIVE MOTOR ASSEMBLY (PRIOR TO S/N 0300079667) . . . . . . . . . . . . . . . . . . . . 1-18 HUB AND MOTOR ASSEMBLY (S/N 0300079667 TO S/N 0300083556). . . . . . . . . . 1-20 HUB AND MOTOR ASSEMBLY (S/N 0300083556 TO S/N 0300103907). . . . . . . . . . 1-26 DRIVE HUB ASSEMBLY - BONFIGLIOLI (S/N 0300103907 TO PRESENT) . . . . . . . 1-32 DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI (S/N 0300103907 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 DRIVE MOTOR ASSEMBLY (S/N 0300103907 TO PRESENT) . . . . . . . . . . . . . . . . . 1-40 FRAME VALVES AND COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 TRACTION VALVE ASSEMBLY (PRIOR TO S/N 0300103907) . . . . . . . . . . . . . . . . . 1-46 TRACTION VALVE ASSEMBLY (S/N 0300103907 TO PRESENT) . . . . . . . . . . . . . . 1-48

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26

VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . 2-2 MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 TURNTABLE SWING DRIVE AND BEARING INSTALLATION . . . . . . . . . . . . . . . . . . 2-12 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 CATERPILLAR DIESEL ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 DEUTZ TIER II & TIER III ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 DEUTZ TIER IVi & TIER IVi-PRE ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . 2-38 PUMP ASSEMBLY (REXROTH) (CATERPILLAR ENGINE MACHINES) . . . . . . . . . 2-46 PUMP ASSEMBLY (REXROTH) (DEUTZ ENGINE MACHINES) . . . . . . . . . . . . . . . . 2-52 PUMP ASSEMBLY (SAUER TANDEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 PUMP ASSEMBLY (SAUER PISTON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 PUMP ASSEMBLY (SAUER GEAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 ROTARY COUPLING AND COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . 2-72 HYDRAULIC OIL COOLER INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 2-74 GROUND CONTROLS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . 2-76 GROUND CONTROLS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . 2-80 ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 ENGINE TRAY JACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-98 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-102 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 CLEARSKY TELEMATICS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . . . 2-118 CLEARSKY TELEMATICS INSTALLATION (WITH UGM) (OPTIONAL) . . . . . . . . . . . 2-122

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4

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BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 MAIN BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 ACTUATOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

1250AJP

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TABLE OF CONTENTS FIGURE NO.

3-5 3-6 3-7 3-8

TITLE

PAGE NO.

POWER TRACK & BOOM CLAMPS INSTALLATION (TOWER BOOM) . . . . . . . . . . .3-20 POWER TRACK & BOOM CLAMPS INSTALLATION (MAIN BOOM & JIB) . . . . . . . .3-22 BOOM SENSORS AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .3-26 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS. . . . . . . . . . . . . . . .3-30

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5 4-6

PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM) . . . . . . .4-8 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 CONTROLLER ASSEMBLY (LIFT & SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . .4-22

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10

AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 PLATFORM LEVEL CYLINDER ASSEMBLY (PRIOR TO S/N 0300080030). . . . . . . .5-6 PLATFORM LEVEL CYLINDER ASSEMBLY (S/N 0300080030 TO PRESENT) . . . . .5-8 LIFT CYLINDER ASSEMBLY (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 LIFT CYLINDER ASSEMBLY (TOWER BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 JIB CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 TELESCOPE CYLINDER ASSEMBLY (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . .5-20 TELESCOPE CYLINDER ASSEMBLY (TOWER BOOM). . . . . . . . . . . . . . . . . . . . . . .5-22

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7

HYDRAULIC DIAGRAM - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 HYDRAULIC DIAGRAM - DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 HYDRAULIC DIAGRAM - OSCILLATING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 HYDRAULIC DIAGRAM - STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 HYDRAULIC DIAGRAM - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 HYDRAULIC DIAGRAM - AUXILIARY POWER MOTOR . . . . . . . . . . . . . . . . . . . . . . .6-18 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-1 7-2 7-3 7-4

ii

ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO S/N 0300087575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (S/N 0300087575 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22 HARNESS COMPONENTS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . .7-46

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TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 8-1 8-2 8-3 8-4 8-5 8-6

DECAL INSTALLATION - ANSI SPEC (PRIOR TO S/N 0300089066) . . . . . . . . . . . . 8-2 DECAL INSTALLATION - ANSI SPEC (S/N 0300089066 TO PRESENT). . . . . . . . . . 8-6 DECAL INSTALLATION - ANSI EXPORT SPEC (PRIOR TO S/N 0300089066) . . . . 8-10 DECAL INSTALLATION - ANSI EXPORT SPEC (S/N 0300089066 TO PRESENT) . . 8-16 DECAL INSTALLATION - AUSTRALIAN & CE SPEC (PRIOR TO S/N 0300089066). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 DECAL INSTALLATION - AUSTRALIAN & CE SPEC (S/N 0300089066 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

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TABLE OF CONTENTS FIGURE NO.

iv

TITLE

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PAGE NO.

3121172

SECTION 1 FRAME

3121172

1250AJP

1-1

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS

47 57

22

27

19

30

47 6 1

20 47 3 13 1

115 254 105 144 145 46

18 1 6

29

1 6 47

49 46

28

34

220 217

17 48

246 231 212

1 11 37 38

26

23 47 8 1

301 302 303 47

26

47 8 1

1 33

29

2 14

51 41 42 47 1 8 41 42 47 1 8

26 41 42

47 1 7 1 47 7

26 41 42 43

21 31

39 40

43 47 7 1 1-2

16 2

4

2 53 54 55 39 56 40 25

24 1 9 47

32

50

225 220 246 231 212 226

41 42 1 9 47 41 42

18

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50

2 52 53 56

1 41 42 7 47 26

7 1 47 41 42

26

25

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SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS ITEM #

1 2 3 4 5 6 7 8 9 10 11 12 13

PART NUMBER

QTY.

0271934 0271521

Ref. Ref. Ref.

0100011 0100019 0100081 0363037 Not Used 0641606 0641608 0641609 0641611 Not Used 0641613 Not Used

DESCRIPTION AXLE INSTALLATIONS - COMMON PARTS Fixed Axle Oscillating Axle

A/R A/R A/R 4

Compound, Locking Compound, Locking Adhesive #454 Bar, Stop

40 48 32 16

Bolt 3/8"-16NC x 3/4" Bolt 3/8"-16NC x 1" Bolt 3/8"-16NC x 1 1/8" Bolt 3/8"-16NC x 1 3/8"

8

Bolt 3/8"-16NC x 1 5/8”"

4

Bolt Options: Fixed Axle - Bolt 3/8”-16NC x 2 1/2” Oscillating Axle - Bolt 3/8”-16NC x 3" Bolt 1/2”-13NC x 1”

0641620 0641624 0641808 Not Used 0642214 0962033 1180358 7024365

1 2 4 A/R

7024366

1

19 20 21

1320263 1320298 1684102

4 4 4

22 23 24 25 26 27 28 29 30 31 32 33 34 35 to 36 37 38 39

3310805 3340881 3340907 3340946 3340932 3340939 3422918 3422960 3573294 3573335 3841287 3900270 3930820 Not Used 4071035 4071036 4071054

8 8 2 8 32 8 1 4 4 8 1 4 8

Bolt 3/4”-10NC x 1 3/4” Bushing Carrier 24 in Section Repair Kit (Includes Inner & Outer Links, Joining Bars & Rollers, and Assembling Hardware) Mounting Bracket Kit (Includes Mounting Brackets for Both Ends, 1 Roller Assembly and Assembling Hardware) Clamp, Cable Clamp, Hose Axle Extension Cylinder Assembly (See Section 7 for Breakdown) Locknut #8-32NC Pad, Wear Pad, Axle Pad, Wear Pad, Wear Pad, Rubber Pin Pin Plate Plate Keeper, Pin Bolt, Shoulder 1/2” -13NC x 1 1/2” Capscrew #8-32NC x 1 1/4”

2 4 8

Shim #18 Gauge Shim #11 Gauge Shim #18 Gauge

14 15 16 17 18

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8

1250AJP

REV. J J

1-3

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED) ITEM #

PART NUMBER

QTY.

40 41 42 43 44 to 45 46

4071055 4071039 4071040 4071042 Not Used

12 24 36 24

Shim #11 Gauge Shim #18 Gauge Shim #11 Gauge Shim #16 Gauge

4

Switch, Limit Options: Prior to S/N 0300074420 (was p/n 4360322) S/N 0300074420 to S/N 0300080869 (was p/n 4360549) S/N 0300080869 to Present Flatwasher 3/8” Thin Thrustwasher Flatwasher #8 Regular Extension, Axle Box, Axle Pivot Bolt 1/2”-13NC x 1 5/8” (Grade 8) Bolt 1/2”-13NC x 1 3/4” (Grade 8) Bolt 1/2”-13NC x 1 7/8” (Grade 8) Bolt 1/2”-13NC x 2” (Grade 8) Flatwasher 1/2” Thin Connector, Strain Relief (Not Shown)

47 48 49 50 51 52 53 54 55 56 57

Use 4360578 Use 4360578 4360578 4711600 4740461 4750800 4846637 4846383 0681813 0681814 0681815 0681816 4711800 4460968

140 1 8 4 1 12 18 12 6 48 4 Ref.

101 to 104 105 106 to 114 115 116 to 143 144 145

DESCRIPTION

REV.

AXLE INSTALLATION - OPTIONAL PARTS

0271934 Not Used 0363076 Not Used 0641814 Not used 4071049 4071050

Ref.

Fixed Axle

2

Bar, Stop

4

Bolt 1/2”-13NC x 1 3/4”

6 4

Shim 11 Gauge Shim 16 Gauge Oscillating Axle

J

0271521

Ref.

201 to 211 212 213 to 216 217

0642020 Not Used 1684081

4

Bolt 5/8”-11NC x 2 1/2”

2

Oscillating Axle Cylinder Assembly (See Section 5 for Breakdown)

218 to 219 220 221 to 224 225 226 227 to 230 231 232 to 245 246 247 to 253 254

Not Used 3312005 Not Used 3422833 3422915 Not Used 3841258 Not Used 4712000 Not Used 3520054

4

Locknut 5/8”-11NC

2 2

Pin Pin

4

Keeper, Pin

4

Flatwasher 5/8” Thin

4

Plug

1-4

1250AJP

J

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SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED) ITEM #

301 302 303

3121172

PART NUMBER

QTY.

DESCRIPTION

REV.

0274106

Ref.

AXLE STOP BLOCKS INSTALLATION

A

0100019 3931816 4220235

A/R 4 2

Compound, Locking Capscrew, Socket Head 1/2”-13NC x 1” Block, Stop

1250AJP

1-5

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