JLG Boom Lift 1230ES Service & Maintenance Manual 3122346200

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JLG Boom Lift 1230ES Service & Maintenance Manual 3122346200
Size: 23.48 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 1230ES Boom Lift
Serial Number: P130000001 to Present
Part Number: 3122346200
Publication Date: 2024
Number of Pages: 296 Pages

Contents:
Coverpage
Effectivity Page
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 Informations and Specifications

Specifications​

2.1.1 Operating Specifications​

2.1.2 Platform Capacities​

2.1.3 Dimensional Data​

2.1.4 Tires Specifications​

2.1.5 Battery Specifications​

2.1.6 Critical Stability Weights​

2.1.7 Cylinder Specifications​

Serial Number Locations​

Lubrication​

2.3.1 Hydraulic System​

2.3.2 Lubrication Capacities​

2.3.3 Lubrication Specifications​

2.3.4 Hydraulic Oil​

2.3.5 Changing Hydraulic Oil​

2.3.6 Hydraulic Oil Specifications​

2.3.7 Oil Check Procedure​

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 Preventative Maintenance​

Preventive Maintenance and Inspection Schedule​

Servicing and Maintenance Guidelines​

3.3.1 General​

3.3.2 Safety and Workmanship​

3.3.3 Cleanliness​

3.3.4 Components Removal and Installation​

3.3.5 Component Disassembly and Reassembly​

3.3.6 Pressure-Fit Parts​

3.3.7 Bearings​

3.3.8 Gaskets​

3.3.9 Bolt Usage and Torque Application​

3.3.10 Hydraulic Lines and Electrical Wiring​

3.3.11 Hydraulic System​

3.3.12 Lubrication and Servicing​

3.3.13 Batteries​

Wheels and Tires - Drive and Rear​

3.4.1 Tire Wear and Damage​

3.4.2 Wheel and Tire Replacement​

Battery/Battery Charger​

3.5.1 Battery Maintenance and Safety Practices​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter Basics​

4.1.2 Threadlocking Compound​

Wheel Drive Assembly - Servicing​

4.2.1 Drive Motor Electrical Evaluation​

4.2.2 Roll and Leak Testing​

4.2.3 Oil Type and Capacity​

4.2.4 Drive Motor Power Harness Routing​

Tilt Sensor Calibration​

Tilt Sensor Electrical Evaluation​

Elevation Angle Sensor Electrical Evaluation​

4.5.1 Tilt vs. Allowed Height Evaluation​

Elevation Sensor Calibration​

Wheel Drive Brake - Manual Disengage Procedure​

Hydraulic System Pressure Settings​

Hydraulic Cylinder Component Inspection​

Hydraulic Cylinder Assembly Testing​

System Software

Overview​

Modes Of Operation​

5.2.1 Ground Mode​

5.2.2 Platform mode​

CAN Communications​

Controls and Sensors​

5.4.1 Elevation​

5.4.2 Joystick​

5.4.3 Tilt​

Traction​

5.5.1 Personalities​

5.5.2 Interlocks​

Pump/Lift/Mast​

5.6.1 Personalities​

5.6.2 Interlocks​

Steer​

5.7.1 Personalities​

5.7.2 Interlocks​

Electronic Control System​

5.8.1 To Connect the Hand Held Analyzer​

5.8.2 Using the Analyzer​

5.8.3 Changing the Access Level of the Hand Held Analyzer​

5.8.4 Machine Setup​

5.8.5 Diagnostic Trouble Codes (DTC)​

Machine Configuration Programming Information​

Machine Personality - Adjustment Settings​

Fault Codes

Introduction​

DTC Index​

DTC Check Tables​

Troubleshooting​

6.4.1 Battery Charger Troubleshooting​

6.4.2 Battery Charger Fault Codes​

6.4.3 Trackunit Troubleshooting​

Hydraulics

Hydraulic Pump/Motor/Valve Components​

7.1.1 Common Difficulties​

7.1.2 Pump Components​

7.1.3 Hydraulic System Pressure Check Port​

Multi-Stage Hydraulic Cylinder​

7.2.1 Overview​

7.2.2 Hydraulic Cylinder - Disassembly​

7.2.3 Hydraulic Cylinder - Assembly​

7.2.4 Hydraulic Cylinder Assembly Testing​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Amp Connectors​

8.1.2 Dielectric Grease Application​

8.1.3 Installation​

8.1.4 AMP Mate-N-Lok​

8.1.5 AMP Faston​

8.1.6 AMP Micro-Fit​

8.1.7 AMP Mini Fit Jr​

8.1.8 Mini Fit Sr​

8.1.9 DIN Connectors​

8.1.10 Exceptions​

8.1.11 Scissor Platform Cable at the Platform Control​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Layout​

Amp Connector​

8.4.1 Assembly​

8.4.2 Disassembly​

8.4.3 Wedge Lock​

8.4.4 Service - Voltage Reading​

Electrical Switches​

8.5.1 Basic check​

8.5.2 Limit Switches​

8.5.3 Automatic Switches​

8.5.4 Switch Wiring - Low Side, High Side​

Control Components​

8.6.1 Control Components Overview​

8.6.2 Control Components - Service​

Traction System​

8.7.1 Common Traction System Difficulties​

Power Module​

8.8.1 ZAPI Power Module Electrical Evaluation​

X-Connector​

8.9.1 Machine Location Of Component X-Connectors​

8.9.2 X-Connector References​

8.9.3 X-Connector Id Index​

Connector Loading Diagrams​

Pin Input /Output Types​

AC Power Receptacles And Wiring (Platform)​

Removal and Installation

Mast Components​

9.1.1 Mast Components Overview​

9.1.2 Mast Removal​

9.1.3 Mast Installation​

9.1.4 Mast Cover Plate - Installation​

Platform Tool Tray - Installation​

Pot Hole Protection System​

Base Frame Covers​

9.4.1 Base Top Cover - Installation​

9.4.2 Step Plate/Battery Charger Cover - Installation​

9.4.3 Battery Tray/Side Door - Installation​

Wheel Installation​

Rear Wheel Hub - Installation​

Steering Linkage Assembly - Installation​

Drive Motor/Spindle Assembly - Installation​

Wheel Drive Motor Assembly - Removal From Machine​

Pump/Motor/Valve Assembly - Removal/Installation​

Motor Cover/Motor Installation​

Preventative Maintenance - Brush Wear - Dust Removal Procedu​

Motor Brush Installation​

Ground Control Module​

9.14.1 Ground Control Station​

9.14.2 Printed Circuit Board (PCB) Replacement​

Tilt Sensor​

Battery Installation​

Battery Charger - Installation​

Battery Inverter Installation​

Platform Assembly​

9.19.1 Platform - Extending Mast Unpowered​

9.19.2 Platform Removal​

9.19.3 Platform Installation​

Platform AC Receptacle Box - Installation​

Disassembly and Assembly

Base Assembly Components​

Mast Disassembly​

Mast Assembly - Components​

Mast - Reassembly​

Mast Installation Completion​

Steer Cylinder​

10.6.1 Steer Cylinder Disassembly​

10.6.2 Steer Cylinder - Assembly​

Drive Motor​

10.7.1 Drive Motor Disassembly​

10.7.2 Drive Motor Inspection and Servicing​

10.7.3 Drive Motor Reassembly​

10.7.4 Motor Assembly​

Main Gear Box​

10.8.1 Main Gear Box Disassembly​

10.8.2 Main Gear Box Sub-Assembly​

Input Carrier​

10.9.1 Input Carrier Disassembly​

10.9.2 Input Carrier Sub-Assembly​

Hub​

10.10.1 Hub - Disassembly​

10.10.2 Hub Sub-Assembly​

Spindle​

10.11.1 Spindle Disassembly​

10.11.2 Spindle Sub-Assembly​

Platform Control Station​

10.12.1 Platform Control Station Assembly​

10.12.2 Upper Control Box - Component Replacement​

10.12.3 Lower Control Box - Component Replacement​

Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure​

Hydraulic Cylinder​

10.14.1 Hydraulic Cylinder - Disassembly​

10.14.2 Hydraulic Cylinder - Assembly​

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

General​

Hydraulic Schematic​

Electrical Schematic​