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JLG 1230ES Operation & Safety Manual
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JLG 1230ES Operation & Safety Manual

JLG 1230ES Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
Model
1230ES
PVC 2202
31219982
February 14, 2022 - Rev A
Copyright ©
ANSI
AZ/NZS MOL70

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Summary of Contents for JLG 1230ES

  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. Model 1230ES PVC 2202 31219982 February 14, 2022 - Rev A Copyright © ANSI AZ/NZS MOL70...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other re- productive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 3 Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 Indicates a potentially hazardous situation. If not avoided, may result in minor or moderate injury. It may also alert against unsafe practices. This decal will have a yellow background. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 31219982 1230ES...
  • Page 5 NOTICE JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...
  • Page 7 REVISION LOG DATE REVISION DESCRIPTION February 14, 2022 Original Issue 1230ES 31219982...
  • Page 8 This Page is intentionally left blank...
  • Page 9 MACHINE CONTROLS AND INDICATORS........31 General................31 Controls and Indicators ............31 Decal Installation ............... 40 SECTION 4 MACHINE OPERATION..............43 Description ............... 43 Operating Characteristics and Limitations......43 Platform Loading ............... 43 Battery Charging..............44 AC Inverter Operation (Option) ..........45 1230ES 31219982...
  • Page 10 Tires and Wheels..............70 Diagnostic Trouble Codes (DTC) ........... 72 Diagnostic Trouble Codes (DTC) Check Tables ......72 6.10 Supplemental Information Only Applicable to CE/UKCA Machines ................86 6.11 EC Declaration of Conformity..........87 6.12 UKCA Declaration of Conformity .......... 88 31219982 1230ES...
  • Page 11 Read, understand, and study the Operation and Safety Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including recognition and avoiding hazards associated with their operation) shall be authorized to operate a MEWP.
  • Page 12 Do not travel on unsupported surfaces. • This machine can be operated in nominal ambient temperatures of 0° F to 104° F (-20° C to 40° C). Consult JLG to optimize operation outside of this temperature range. 1.2.3 Machine Inspection •...
  • Page 13 Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.
  • Page 14 Trip and Fall Hazards • JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc.
  • Page 15 Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11) Over 750 KV to 1000 KV 45 (14) Note: This requirement shall apply except where employer, local or govern- mental regulations are more stringent. 1230ES 31219982...
  • Page 16 Do not travel on unsupported surfaces. • The user should be familiar with the operating surface before driving. Do not exceed the allowable side slope and grade while driving. 31219982 1230ES...
  • Page 17 • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Keep the chassis of the machine a minimum of 2 ft (0.6 m) from holes, bumps, drop- offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
  • Page 18 Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only. • Do not use high speed drive in restricted or close quarters or when driving in reverse. 31219982 1230ES...
  • Page 19 Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components. • DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure. 1230ES 31219982...
  • Page 20 Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.
  • Page 21 Immediately rinse any contacted area with clean water and seek medical attention. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 1230ES 31219982...
  • Page 22 This Page is intentionally left blank...
  • Page 23 10. The requirement for familiarization in addition to training. 2.1.2 Training Supervision Training must be delivered by a qualified person in an open area, free of hazards until the trainee has demonstrated the ability to safely control and operate the machine. 1230ES 31219982...
  • Page 24 2. Purpose and function of the machine controls and indicators at the platform and ground control stations; 3. Purpose, location, and function of the emergency controls; 4. Operating characteristics and limitations; 5. Features and devices; 6. Accessories and optional equipment. 31219982 1230ES...
  • Page 25 Note: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG service training school for the specific JLG product model. PRE-START INSPECTION...
  • Page 26 9. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section — Machine Operation for more specific instructions on the operation of each function. 31219982 1230ES...
  • Page 27 1. Platform Control Console - Placard secure and legible, control lever and switches return to neutral, and emergency stop switch function properly, manual in storage box. 2. Front Wheel - Drive motor, steer linkage, and steer cylinder - (open side access door) - Refer to Inspection Note. 1230ES 31219982...
  • Page 28 Ensure that all machine functions are disabled when the Emergency Stop Button is depressed. d. With platform raised a few feet (meters), check if the manual descent valve (located at the base of the mast on the front of the machine), lowers the platform properly. 31219982 1230ES...
  • Page 29 Table — Tilt Cutout Settings, page Table 4. Tilt Cutout Settings Tilt Setting (front to back) Tilt Setting (side to side) 1230ES ANSI/CSA 3° 1.5° 3° 1.5° CE/UKCA 3.4°...
  • Page 30 This Page is intentionally left blank...
  • Page 31 * When equipped with the inverter/charger option, the AC plug (4) to the platform AC receptacle box outlet will be eliminated from the rear panel. The platform AC receptacle box outlet will be plugged directly into the inverter/charger internally. Also an inverter ON/STANDBY toggle switch will be mounted on the rear panel. 1230ES 31219982...
  • Page 32 When the machine is shut down for overnight parking or battery charging, the emergency stop and power select switches must be positioned to off to prevent draining the batteries. Figure 2. Ground Control Station 1. Ground Controls 2. Battery Charging - Status Indica- 3. Hour Meter tors and Circuit Breaker 31219982 1230ES...
  • Page 33 1. Battery Charger Status - This panel, located to the right of the ground control box, is designed to give the operator an accurate read on the status of the battery charger. GREEN - Charge Complete YELLOW - Charging in Process RED - Charging Abnormal 1230ES 31219982...
  • Page 34 1. Locate the manual descent valve (1) on the front of the machine at the base of the mast. Figure 5. Location of Manual Descent Valve (Front of Machine) WARNING Keep hands and arms out of the path of the mast and platform while lowering. 31219982 1230ES...
  • Page 35 2. The machine must be powered ON to GROUND CONTROL MODE at the Platform/ Off/Ground Selector Switch on the Ground Control Station (3) to operate the brake release switch. Figure 6. Location of Brake Release Switch (Rear of Machine) 1230ES 31219982...
  • Page 36 Note: * This lamp when activated is flashing a DTC (Diagnostic Troubleshooting Code). For an explanation of these codes and items the Operator can or cannot correct, Section — General Specifications And Operator Maintenance; Sub - Section — Diagnostic Trouble Codes (DTC). 31219982 1230ES...
  • Page 37 3. Tilt Indicator Warning Light 6. Drive Mode Indicator Note: The button and indicators shown shaded on the indicator panel are currently not used on the 1230ES machine. WARNING To avoid serious injury, do not operate machine if any control levers or toggle switches controlling any machine functions do not return to the off or neutral position when released.
  • Page 38 1. Trigger Switch - This switch is located on the front of the joystick controller. The trigger switch acts as an enable and must be depressed before operating the drive, steer and lift functions. When released, the function being operated will stop. 31219982 1230ES...
  • Page 39 With the Power selector switch positioned to platform, power is turned on by pulling the switch out (on), and is turned off by pushing the switch in (off ). 1230ES 31219982...
  • Page 40 Machine Controls and Indicators DECAL INSTALLATION Figure 10. 1230ES - Decal Installation. 31219982 1230ES...
  • Page 41 Machine Controls and Indicators 1230ES 31219982...
  • Page 42 Machine Controls and Indicators 31219982 1230ES...
  • Page 43 The machine can be used to reach work areas located above machinery or equipment positioned at ground level. This JLG Lift has a primary operator Control Station in the platform. From this Control Station, the operator can drive and steer the machine in both forward and reverse directions, raise and lower the platform.
  • Page 44 4. The batteries are fully charged when the green light on the battery charger status panel (Ground Control Station) is illuminated. Note: If the charger is left plugged in, the charger will automatically restart a complete charge cycle if the batteries voltage drops below a minimum voltage or 30 days has elapsed. 31219982 1230ES...
  • Page 45 To continue inverter operation after an automatic shut-down, cycle the inverter ON/OFF toggle switch to OFF then back to ON. 1. The AC inverter ON/OFF toggle switch (1) is located on the lower rear panel (2) of the machine. 1230ES 31219982...
  • Page 46 This emergency stop switch (1), when in the on (out) position, provides electrical power to the ground controls or platform controls, as applicable. In addition, the switch can be used to turn off power (push the switch IN) to the function controls in the event of an emergency. 31219982 1230ES...
  • Page 47 1. If the machine is shut down, place the platform/ ground select switch to the desired position (platform or ground). 2. Position both the ground control station and platform control station emergency stop switches to the on position. From Ground Control Station 1230ES 31219982...
  • Page 48 Note: To ensure proper orientation of the desired platform function, match the color (black/white) of the directional arrow (4), to the lift/lower arrow (5) on the plat- form control indicator panel. 31219982 1230ES...
  • Page 49 Position the lift switch (1) to down and hold until desired elevation is achieved or until platform is fully lowered. WARNING Do not operate from ground control station with personnel in the platform except in an emergency. From Platform Control Station Figure 19. Lowering Platform From Platform Control 1230ES 31219982...
  • Page 50 When released, the switch will return to the center-off position and the wheels will remain in the previously selected position. To return the wheels to the straightened position, the switch must be activated in the opposite direction until the wheels are centered. 31219982 1230ES...
  • Page 51 (black/white) of the directional arrow (5), to the lift/lower arrow (6) on the plat- form control indicator panel. WARNING If the tilt indicator warning light/alarm is activated while driving with platform raised, lower platform completely and drive to a firm level surface. 1230ES 31219982...
  • Page 52 The machine may also be lifted using a fork truck. Lift only with the platform in the stowed position (pot hole protection bars in the up position). Adjust the spread of the fork truck lifting tines (1) to just inside the machines front and rear wheels, see below. 31219982 1230ES...
  • Page 53 Machine Operation Figure 23. Tie Down and Lift Lug Locations Figure 24. Lifting and Tie-Down Chart. 1230ES 31219982...
  • Page 54 Note: Any action to remove electrical power from the brakes such as, depressing the ground control emergency stop switch, or switching the key switch to OFF or PLATFORM MODE will re-engage the brakes. 31219982 1230ES...
  • Page 55 After the machine is towed the disengage bolts must be removed from the brake disengage holes. The brakes cannot be engaged if the disengage bolts are left in the disengage holes. This will cause the machine to roll when parked on an incline. 1230ES 31219982...
  • Page 56 Machine Power Up Note: When entering the Operator’s Code on the keypad, a short beep indicates a properly depressed key. A long beep indicates an error in depressing key. If an error occurs, restart the code entry process again. 31219982 1230ES...
  • Page 57 3. Press the OFF button on the keypad to activate the new Operator’s Code. Note: The new Operator’s Code will remain in the PSL™ even when power is removed from the equipment, or until that code is changed again using the Permanent Code. 1230ES 31219982...
  • Page 58 This Page is intentionally left blank...
  • Page 59 6. Inspect the machine for damage. If the machine is damaged or does not operate properly, turn off the machine immediately. Report the problem to the proper maintenance personnel. Do not operate the machine until it is declared safe for operation. 1230ES 31219982...
  • Page 60 Keep hands and arms out of the path of the mast and platform while lowering. 2. Press and hold the RED button on the manual descent valve, release the button when the platform is lowered to desired level. Figure 29. Location of Manual Descent Valve (Front of Machine) 31219982 1230ES...
  • Page 61 Emergency Procedures INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
  • Page 62 This Page is intentionally left blank...
  • Page 63 GLOBAL ..............31219984 OPERATING SPECIFICATIONS Table 7. Operating Specification DESCRIPTION MODEL 1230ES PLATFORM Maximum Platform Height 12 ft. (3.66 m)
  • Page 64 General Specifications and Operator Maintenance Table 7. Operating Specification (continued) DESCRIPTION MODEL 1230ES Inside Turning Radius 4.4 in. (11.2 cm) Outside Turning Radius 57.6 in. (1.46 m) CHASSIS Approximate Gross Machine Weight- 1765lb. (800.6 kg) ANSI/CSA/CE/UKCA/AUS 2360 lb. (1070 kg) - AUS w/CWT Maximum Tire Load (per wheel) 880 lb.
  • Page 65 General Specifications and Operator Maintenance 6.3.1 Dimensional Data Table 8. Dimensions DESCRIPTION MODEL 1230ES Platform Height - Elevated 3.66 m 12 ft. Platform Height - Stowed 22 in. 56 cm Working Height 5.48 m 18 ft. 65.39 in. 166 cm Overall Stowed Machine Height 68.6 in.
  • Page 66 50° F to 210° F (+10° C to +210° C) 20W-20 Note: Hydraulic oils require anti-wear qualities at least API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Indus- tries recommends the use of standard UTTO. 31219982...
  • Page 67 Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 68 Lube Point(s) - Hydraulic Reservoir • Reservoir Capacity: 0.80 Gal. (3 L) • Lube - Hydraulic Oil • Interval - Check Daily Note: Be certain the hydraulic oil has warmed to operating temperature before check- ing the oil level in the reservoir. 31219982 1230ES...
  • Page 69 Figure 30. Hydraulic Oil Check Procedure Note: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be in- creased accordingly. 1230ES 31219982...
  • Page 70 Tire Wear and Damage Inspect tires periodically for wear or damage. Tires with worn edges or distorted profiles require replacement. Tires with significant damage in the tread area or side wall, require immediate evaluation before replacing the machine into service. 31219982 1230ES...
  • Page 71 (28 - 42 Nm) (91 - 112 Nm) (142 - 163 Nm) 4. Wheel lug nuts should be torqued after the first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation. 1230ES 31219982...
  • Page 72 NOTICE Should a fault occur which cannot be corrected at the operator’s level, the problem must be referred to a mechanic qualified to repair this model of JLG lift. DIAGNOSTIC TROUBLE CODES (DTC) CHECK TABLES 6.9.1...
  • Page 73 Check that the pothole protection switches are securely mounted. • Check that the elevation angle sen- sor is securely mounted. Refer problem to a qualified JLG mechanic. DRIVING AT CUTBACK - The platform is elevated • Fully stow the platform.
  • Page 74 • If there are any elevation sensor faults (DTC 251, 252, 2511, or 2512), troubleshoot those first. Refer problem to a qualified JLG mechanic. DRIVING AT CUTBACK - While stowed, drive speed • Check for obstructions around the...
  • Page 75 Normal operation. No check necessary. sued at each power cycle. Displays on the analyzer only. KEYSWITCH FAULTY Both platform and ground Refer problem to a qualified JLG modes are selected simul- mechanic. taneously. Defaults to ground mode. 6.9.3 2-2 Platform Controls...
  • Page 76 • Check if the steer switches are dam- right inputs were closed aged, obstructed or jammed. simultaneously. Refer problem to a qualified JLG mechanic. FUNCTION LOCKED OUT - The joystick was not cen- • Release joystick and allow to center.
  • Page 77 PERMANENTLY SELECTED lift switch was closed up or jammed. or down, during power- up in ground mode. Refer problem to a qualified JLG mechanic. GROUND LIFT UP / DOWN The lift up / down inputs • Check if the lift switch is obstructed ACTIVE TOGETHER are closed simultaneously.
  • Page 78 • Check that the platform is not caught on something, preventing up or down movement. Refer problem to a qualified JLG mechanic. DRIVE PREVENTED- POT- Driving is not possible • Check for obstructions or mechanical HOLE NOT ENGAGED...
  • Page 79 Check that the elevation angle sen- FAULTY - NOT MOUNTED the elevation angle sensor sor is securely mounted. indicates the elevation an- gle sensor is not Refer problem to a qualified JLG mounted. mechanic. 2512 ELEV ANGLE SENSOR NOT The input voltage from •...
  • Page 80 General Specifications and Operator Maintenance FAULT MESSAGE DESCRIPTION CHECK LIFT DN SHORT TO A problem has been de- Refer problem to a qualified JLG BATTERY tected in this function. mechanic. LIFT DN OPEN CIRCUIT A problem has been de- Refer problem to a qualified JLG tected in this function.
  • Page 81 - PLEASE WAIT reached thermal cutout. • Do not operate in ambients over 140° F (60° C). Refer problem to a qualified JLG mechanic. DRIVING AT CUTBACK - The drive portion of the Refer problem to a qualified JLG POWER MODULE CURRENT power module has mechanic.
  • Page 82 4421 ured to be out of normal bat- tery; otherwise; operating range. 4422 • Refer problem to a qualified JLG mechanic. 6.9.11 6-6 Communication FAULT MESSAGE DESCRIPTION CHECK CANBUS FAILURE- POWER...
  • Page 83 6.9.13 7-7 Electric Motor FAULT MESSAGE DESCRIPTION CHECK OPEN CIRCUIT DRIVE MO- The power module de- Refer problem to a qualified JLG TOR WIRING tected a problem in the mechanic. drive motors' power cir- cuit wiring. STALLED TRACTION MO- The power module de-...
  • Page 84 General Specifications and Operator Maintenance FAULT MESSAGE DESCRIPTION CHECK 7711 PUMP P LOW - CHECK The power module de- Refer problem to a qualified JLG POWER CIRCUITS tected a problem in the mechanic. drive motors' power cir- cuit wiring. 7741...
  • Page 85 General Specifications and Operator Maintenance FAULT MESSAGE DESCRIPTION CHECK 9910 FUNCTION LOCKED OUT - The platform board soft- Refer problem to a qualified JLG PLATFORM MODULE SOFT- ware version is not com- mechanic. WARE VERSION IMPROPER patible with the rest of the system.
  • Page 86 A problem has been de- Cycle machine power on /off a few times INTERNAL ERROR tected with the power if this doesn’t clear the DTC, refer prob- 9951 module lem to a qualified JLG mechanic. 9952 9953 9954 9955 9956 9957...
  • Page 87 EN 61000-6-2:2005 • EN 60204-1:2018 • EN 280:2013+ A1:2015 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) Note: This declaration conforms with the requirements of annex II-A of the council di- rective 2006/42/EC.
  • Page 88 EN 60204-1:2018 • EN 280:2013+ A1:2015 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 20165 •...
  • Page 89 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 90 Inspection, Maintenance and Repair Log...
  • Page 92 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...