User Manuals: JLG 1230ES Vertical Mast Lift

User Manuals: JLG 1230ES Vertical Mast Lift

Manuals and User Guides for JLG 1230ES Vertical Mast Lift. We have 4 JLG 1230ES Vertical Mast Lift manuals available for free PDF download: Service Maintenance Manual, Service And Maintenance Manual, Operation And Safety Manual, Operation & Safety Manual

JLG 1230ES Service And Maintenance Manual

JLG 1230ES Service And Maintenance Manual (204 pages)

Vertical Mast Lift

Brand: JLG | Category: Lifting Systems | Size: 11 MB

Table of Contents

Table of Contents

5
- General
  3
- Hydraulic System Safety
  3
- Maintenance
  3
- Revision Log
  4
  - Table of Contents
    5
- Section 1 - Machine Specifications
  
  13
  - Operating Specifications
    13
    
    Batteries
    14
    
    Critical Stability Weights
    14
    
    Dimensional Data
    14
    
    Operating Specifications
    14
    
    Platform Capacities
    14
    
    Tires
    14
    
    Hydraulic Oil
    15
    
    Lubrication
    15
    
    Lubrication Capacities
    15
    
    Lubrication Specifications
    15
    
    Cylinder Specifications
    16
    
    Oil Check Procedure
    16
    
    Serial Number Locations
    16
    
    Torque Requirements
    16
  - Torque Chart (SAE Fasteners - Sheet 1 of 7)
    17
  - Torque Chart (SAE Fasteners - Sheet 2 of 7))
    18
  - Torque Chart (SAE Fasteners - Sheet 3 of 7)
    19
  - Torque Chart (SAE Fasteners - Sheet 4 of 7)
    20
  - Torque Chart (METRIC Fasteners - Sheet 5 of 7))
    21
  - Torque Chart (METRIC Fasteners - Sheet 6 of 7)
    22
  - Torque Chart (METRIC Fasteners - Sheet 7 of 7)
    23
- Section 2 - General Service Information
  
  25
  - 2.1 Machine Preparation, Inspection, and Maintenance
    25
    
    Annual Machine Inspection
    25
    
    General
    25
    
    Pre-Delivery Inspection and Frequent Inspection
    25
    
    Pre-Start Inspection
    25
    
    Preparation, Inspection, and Maintenance
    25
    
    Preventative Maintenance
    25
  - 2.2 Preventive Maintenance and Inspection Schedule
    26
    
    Preventive Maintenance & Inspection Schedule
    27
    
    Footnotes
    28
    
    Maintenance and Inspection Table Codes
    28
  - 2.3 Servicing and Maintenance Guidelines
    29
    
    Cleanliness
    29
    
    Component Disassembly and Reassembly
    29
    
    Components Removal and Installation
    29
    
    General
    29
    
    Pressure-Fit Parts
    29
    
    Safety and Workmanship
    29
    
    Batteries
    30
    
    Bearings
    30
    
    Bolt Usage and Torque Application
    30
    
    Gaskets
    30
    
    Hydraulic Lines and Electrical Wiring
    30
    
    Hydraulic System
    30
    
    Lubrication and Servicing
    30
  - 2.4 Lubrication Information
    31
    
    Changing Hydraulic Oil
    31
    
    Hydraulic Oil
    31
    
    Hydraulic System
    31
    
    Lubrication Specifications
    31
- Section 3 - Theory of Operation - 1230Es
  
  33
  - Overview
    33
  - Modes of Operation
    33
    
    Ground Mode
    33
    
    Platform Mode
    33
  - Can Communications
    33
  - Basic Electronic Module Connections
    34
    
    Controls & Sensors
    35
    
    Elevation
    35
    
    Joystick
    35
    
    Tilt
    35
    
    Traction
    35
    
    Interlocks
    36
    
    Personalities
    36
    
    Pump/Lift/Mast
    37
    
    Interlocks
    38
    
    Personalities
    38
    
    Steer
    38
- Section 4 - Base Components
  
  39
- Section 5 - Control Components
  
  79
- Section 6 - Mast Components
  
  105
  - Mast Components Overview
    105
  - Platform Tool Tray - Installation
    106
  - Mast Cover Plate - Installation
    106
  - Platform Ac Receptacle Box - Installation
    106
  - Mast Assembly - Components
    107
  - Platform Assembly
    108
    
    Platform - Extending Mast Unpowered
    108
    
    Platform Removal
    108
    
    Platform Installation
    109
  - Mast Assembly
    110
    
    Mast Removal
    111
    
    Mast Disassembly
    112
    
    Mast - Reassembly
    113
    
    Mast Installation
    114
    
    Mast Installation Completion
    116
    
    Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure
    116
  - Multi-Stage Hydraulic Cylinder - Servicing
    117
    
    Overview
    117
    
    Hydaulic Cylinder - Disassembly
    119
  - Valve Block - Removal
    119
  - Cylinder Rod/Gland - Removal
    120
    
    Hydraulic Cylinder - Assembly
    121
    
    Hydraulic Cylinder Component Inspection
    121
    
    Hydraulic Cylinder Assembly Testing
    122
- Section 7 - Jlg Control System
  
  123
  - Electronic Control System
    123
    
    To Connect the Hand Held Analyzer
    123
    
    Using the Analyzer
    123
    
    Changing the Access Level of the Hand Held Analyzer
    124
    
    Diagnostic Trouble Codes (DTC)
    125
    
    Machine Setup
    125
  - Machine Configuration Programming Information
    131
  - ZAPI - 1001092456 Power Module Only
    132
    
    Machine Personality - Adjustment Settings
    133
    
    7.4 Tilt Sensor Calibration
    134
    
    Calibration Failures
    134
    
    Ground Module Software Version 1.4
    134
    
    Ground Module Software Version 1.5
    134
    
    7.5 Tilt Sensor Electrical Evaluation
    135
    
    Elevation Angle Sensor Electrical Evaluation
    135
    
    Tilt Vs. Allowed Height Evaluation
    135
    
    7.7 Elevation Sensor Calibration
    136
Section 8 - Diagnostic Trouble Codes/Introduction

137
- Section 8 - Diagnostic Trouble Codes
  
  137
  - Introduction
    137
  - X-Connector References
    137
  - Dtc Index
    137
  - Dtc Check Tables
    141
    
    0-0 Help Comments
    141
  - Everything Ok
    141
  - Ground Mode Ok
    141
  - Alarm Sounding - Tilted & above Elevation
    141
  - Driving at Cutback - above Elevation
    141
  - Drive & Lift up Prevented - Tilted & Elevated
    141
    
    2-1 Power-Up
    142
    
    2-2 Platform Controls
    142
  - Lift up Prevented - Max Height Zone a
    142
  - Driving at Cutback - Pothole Still Engaged
    142
  - Functions Locked out - System Powered down
    142
  - Drive Prevented - Elevated above Drive Cutout Height
    142
  - Power Cycle
    142
  - Keyswitch Faulty
    142
  - Function Problem - Horn Permanently Selected
    142
  - Function Problem - Indoor / Outdoor Permanently Selected
    143
  - Function Problem - Drive & Lift Active Together
    143
  - Function Problem - Steer Left Permanently Selected
    143
  - Function Problem - Steer Right Permanently Selected
    143
  - Accelerator Faulty - Wiper out of Range
    143
  - Steer Switches Faulty
    143
  - Function Locked out - Accelerator Not Centered
    143
  - Function Problem - Trigger Permanently Closed
    143
    
    2-3 Ground Controls
    144
    
    2-5 Function Prevented
    144
    
    Elev Angle Sensor Faulty - Voltage out of Range
    144
    
    Elev Angle Sensor Has Not Been Calibrated
    144
    
    Function Problem - Brake Release Permanently Selected
    144
    
    Function Problem - Lift Permanently Selected
    144
    
    Ground Lift up / down Active Together
    144
  - Drive Prevented - Charger Connected
    145
  - Drive & Lift up Prevented - Charger Connected
    145
  - Platform Overloaded
    145
  - Drive Prevented - Pothole Not Engaged
    145
  - Elev Prox Permanently Closed - Check Prox and Angle Adjustment
    145
  - Model Changed - Hydraulics Suspended - Cycle Ems
    145
    
    3-1 Line Contactor Open Circuit
    146
    
    3-2 Line Contactor Short Circuit
    146
    
    Contactor Driver Permanently off
    146
    
    Line Contactor Miswired on or Welded
    146
    
    Open Circuit Line Contactor
    146
    
    3-3 Ground Output Driver
    147
    
    Brake Open Circuit
    147
    
    Brake Short to Battery
    147
    
    Contactor Driver Permanently on
    147
    
    Lift Dn Open Circuit
    147
    
    Lift Dn Short to Battery
    147
    
    Lift up Open Circuit
    147
    
    Lift up Short to Battery
    147
    
    Steer Left Open Circuit
    147
    
    Steer Left Short to Battery
    147
  - Steer Right Short to Battery
    148
  - 33298 Steer Left Valve - Short to Ground
    148
  - 33299 Line Contactor Coil - Short to Battery
    148
    
    33304 Right Brake - Short to Ground
    149
    
    33305 Steer Right Valve - Short to Ground
    149
    
    33407 Lift Dn Valve - Short to Ground
    149
    
    Driving at Cutback - Power Module Current Limit
    149
    
    Lift up at Cutback - Power Module Current Limit
    149
    
    Power Module too Hot - Please Wait
    149
    
    Thermal Limit (SOA)
    149
    
    4-4 Battery Supply
    150
    
    6-6 Communication
    150
    
    Battery Voltage too High - System Shutdown
    150
    
    Battery Voltage too Low - System Shutdown
    150
    
    Canbus Failure - Power Module
    150
    
    Logic Supply Voltage out of Range
    150
    
    Lss Battery Voltage too High
    150
    
    Lss Battery Voltage too Low
    150
    
    6-7 Accessory
    152
    
    7-7 Electric Motor
    152
    
    8-1 Tilt Sensor
    153
    
    8-2 Platform Load Sense
    154
    
    9-9 Hardware
    154
- Section 9 - General Electrical Information & Schematics
  
  159
  - General
    159
  - Multimeter Basics
    159
    
    Backprobing
    159
    
    Grounding
    159
    
    Min/Max
    159
    
    Polarity
    159
    
    Scale
    159
  - Voltage Measurement (DC)
    160
  - Continuity Measurement
    161
    
    Continuity Measurement over Long Distances
    162
    
    Procedure
    162
    
    Requirements
    162
    
    Basic Check
    163
    
    Electrical Switch Testing
    163
    
    Limit Switches
    163
    
    Automatic Switches
    164
    
    Switch Wiring - Low Side, High Side
    164
    
    Applying Silicone Dielectric Compound to Amp Connectors
    165
    
    Assembly
    166
    
    Disassembly
    168
    
    Service - Voltage Reading
    168
    
    Wedge Lock
    168
  - Connector Installation
    169
    
    DT/DTP Series Assembly
    170
    
    DT/DTP Series Disassembly
    170
    
    HD30/HDP20 Series Assembly
    170
    
    Working with Deutsch Connectors
    170
    
    HD30/HDP20 Series Disassembly
    171
    
    X-Connector References
    171
    
    Connector Loading Diagrams
    172
    
    X-Connector ID Index
    175
    
    Machine Location of Component X-Connectors
    178
  - ES -Location of Component X-Connectors on Ground Control Module
    179
    
    9.10 Electrical Layout and Schematics
    180
  - ES - Overview of Electrical System Components. (1001092456 Drive Module)
    182
  - Electrical Schematic. (Machines with 1600346 Drive Module)
    184
  - Electrical Schematic. (Machines with 1001092546 Drive Module)
    186
  - Electrical Schematic. (Machines with 1001092546 Drive Module)
    188
  - Electrical Schematic (Ground Control Module) - (Machines with 1001092546 Drive Module)
    190
    
    9.11 Pin Input/Output Types
    191
  - Ground Board J3 - Connector X003
    192
  - Power Module - Connector X027 (1600346 Power Module)
    193
  - Power Module - J1 (1001092456 Power Module ONLY)
    194
  - Power Module - J2 (1001092456 Power Module ONLY)
    195
  - Battery Charger/Inverter Electrical Connection Schematic
    196
    
    9.12 Ac Power Receptacles and Wiring (Platform) - Ce Spec Machines Only
    197
    
    9.13 Hydraulic Schematic
    201

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JLG 1230ES Operation And Safety Manual

JLG 1230ES Operation And Safety Manual (96 pages)

Vertical Mast Lift

Brand: JLG | Category: Lifting Systems | Size: 4 MB

Table of Contents

Foreword
3
Safety Alert Symbols and Safety Signal Words
4
- Contact
  5
- In USA
  5
- Outside USA
  5
- Revision Log
  6
- Table of Contents
  7
Section 1 - Safety Precautions

11
- General
  11
- Pre-Operation
  12
  - Operator Training and Knowledge
    12
  - Workplace Inspection
    12
  - Machine Inspection
    13
  - Operation
    14
    
    General
    14
    
    Trip and Fall Hazards
    15
    
    Electrocution Hazards
    16
- Minimum Approach Distances (M.A.D.)
  16
  - Tipping Hazards
    18
  - Crushing and Collision Hazards
    19
  - Towing, Lifting, and Hauling
    20
Section 2 - User Responsibilities, Machine Preparation and Inspection

21
- Personnel Training
  21
  - Operator Training
    21
  - Training Supervision
    22
  - Operator Responsibility
    22
- Preparation, Inspection, and
  22
- Inspection and Maintenance Table
  23
  - Pre-Start Inspection
    24
  - Daily Walk-Around Inspection
    25
  - Daily Walk-Around Inspection
    26
  - Function Check
    27
- Tilt Cutout Settings
  28
Section 3 - Machine Controls and Indicators

29
Section 4 - Machine Operation

43
- Description
  43
- Operating Characteristics and
  43
- JLG Lift
  43
- Limitations
  43
- General
  43
- Placards
  43
- Platform Loading
  43
- Battery Charging
  44
  - Battery Charger Fault Codes
    45
- Ac Inverter Operation (Option)
  46
- Operation
  48
  - Platform/Ground Select Switch
    48
  - Emergency Stop Switch
    48
- Raising and Lowering Platform
  49
- Lowering Platform from Platform Control
  53
- Steering and Traveling
  54
  - Steering
    54
  - Driving Forward and Reverse
    55
- Driving Forward from Platform Control
  55
- Grade and Side-Slope Definition
  56
- Parking and Stowing Machine
  57
- Tie Down/Lift Lugs
  58
  - Tie down
    58
  - Lifting
    58
- Lifting and Tie-Down Chart
  59
- Lifting Using Spreader Bar
  60
- Towing
  61
  - Electric Brake Release
    61
  - Mechanical Brake Release
    62
- Brake - Manual Disengage
  62
Section 5 - Emergency Procedures

63
- General Information
  63
- Emergency Operation
  63
  - Operator Unable to Control Machine
    63
  - Platform Caught Overhead
    63
- Platform Manual Descent
  63
- Incident Notification
  64
Section 6 - General Specifications and Operator Maintenance

65
- Introduction
  65
  - Other Publications Available Specific to
    65
- Operating Specifications
  66
- Operating Specification
  66
  - Platform Capacities
    67
  - Dimensional Data
    67
  - Tires
    68
  - Batteries
    68
  - Critical Stability Weights
    68
- Tire Specifications
  68
- Battery Specifications
  68
  - Lubrication
    69
    
    Lubrication Capacities
    69
    
    Hydraulic Oil
    69
    
    Lubrication Specifications
    70
  - Operator Maintenance
    71
    
    Oil Check Procedure
    71
- Hydraulic Oil Check Procedure
  71
- Battery Maintenance
  72
  - Battery Maintenance and Safety Practices
    72
- Battery Fluid Level
  72
- Tires and Wheels
  73
  - Tire Wear and Damage
    73
  - Wheel and Tire Replacement
    73
  - Wheel Installation
    73
- Wheel Lug Nut Tightening Sequence
  73
- Supplemental Information
  74
- Diagnostic Trouble Codes (Dtc)
  75
- Dtc Check Table Index
  75
  - Help Comments
    76
  - Check Tables
    76
  - Power-Up
    78
  - Platform Controls
    78
  - Ground Controls
    80
  - Function Prevented
    80
  - Line Contactor Open Circuit
    82
  - Line Contactor Short Circuit
    83
  - Ground Output Driver
    83
  - Thermal Limit (SOA)
    85
  - Battery Supply
    85
  - Communication
    86
  - Accessory
    87
  - Electric Motor
    87
  - Tilt Sensor
    88
  - Platform Load Sense
    89
    
    Hardware
    90
Section 7. Inspection and Repair Log

93
- Inspection and Repair Log
  93

JLG 1230ES Service Maintenance Manual

JLG 1230ES Service Maintenance Manual (238 pages)

Brand: JLG | Category: Scissor Lifts | Size: 18 MB

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JLG 1230ES Operation & Safety Manual

JLG 1230ES Operation & Safety Manual (92 pages)

Brand: JLG | Category: Boom Lifts | Size: 10 MB

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