JLG 1230ES Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

ANSI

Keep this manual with the machine at all times.

Model - 1230ES

P/N - 3121221

May 8, 2006

SECTION - FOREWORD

3121221 – JLG Lift – a

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and

operating procedures essential for the safe and proper machine operation for its intended purpose.

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.

SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

b– JLG Lift – 3121221

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALITY 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.

This is the Safety Alert Symbol. It is used to alert you to the potential personal

injury hazards. Obey all safety messages that follow this symbol to avoid possible

injury or death

SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

3121221 – JLG Lift – c

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

IMPORTANT

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.

IMPORTANT

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL

OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL

PROPERTY OR THE JLG PRODUCT.

Contact :

Product Safety and Reliability Department

JLG Industries, Inc.

1 JLG Drive

McConnellsburg, PA 17233

or Your Local JLG Office

(See addresses on manual rear cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 717-485-5161

E-mail: [email protected]

For :

• Accident Reporting

• Product Safety Publica-

tions

• Current Owner Updates

• Questions Regarding

Product Safety

• Standards and Regulations

Compliance Information

• Questions Regarding Spe-

cial Product Applications

• Questions Regarding Prod-

uct Modifications

SECTION - REVISION LOG

d– JLG Lift – 3121221

REVISION LOG

Original Issue of Manual . . . . . . . . . . . . . . November 4, 2005

Manual Revised . . . . . . . . . . . . . . . . . . . . . May 8, 2006

TABLE OF CONTENTS

3121221 – JLG Lift – i

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . B

Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operator Training and Knowledge . . . . . . . . . . . . . . 1-2

Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-6

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Crushing and Collision Hazards. . . . . . . . . . . . . . . . 1-9

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . 1-10

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-

RATION AND INSPECTION

2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . 2-2

2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . 2-7

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . 3-2

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . 3-3

Battery Charger/Hour Meter Indicators . . . . . . . . . . . 3-5

Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-8

Platform Control and Indicator Panel . . . . . . . . . . . . 3-9

Drive/Lift/Steer Joystick Control . . . . . . . . . . . . . 3-11

3.3 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 3-13

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

TABLE OF CONTENTS

ii – JLG Lift – 3121221

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Battery Charger Fault Codes. . . . . . . . . . . . . . . . . . . 4-3

4.5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Platform/Ground Select Switch . . . . . . . . . . . . . . . . . 4-4

Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . 4-4

4.6 RAISING AND LOWERING PLATFORM. . . . . . . . . . . . 4-5

Raising Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Lowering Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.7 STEERING AND TRAVELING. . . . . . . . . . . . . . . . . . . 4-10

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Driving Forward and Reverse . . . . . . . . . . . . . . . . 4-11

4.8 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.9 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . . 4-13

4.10 AC INVERTER OPERATION (OPTION) . . . . . . . . . . 4-14

4.11 TIE DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.12 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Electric Brake Release. . . . . . . . . . . . . . . . . . . . . . . 4-17

Mechanical Brake Release . . . . . . . . . . . . . . . . . . . 4-17

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine. . . . . . . . . . . . 5-1

Platform Caught Overhead . . . . . . . . . . . . . . . . . . . 5-1

5.3 PLATFORM MANUAL DESCENT . . . . . . . . . . . . . . . . . 5-1

5.4 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . 5-2

SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR

MAINTENANCE

6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Other Publications Available

Specific to this Machine: . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . 6-2

Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . . . . . 6-4

6.4 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Lubrication Capacities . . . . . . . . . . . . . . . . . . . . . . . 6-5

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 6-5

TABLE OF CONTENTS

3121221 – JLG Lift – iii

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

6.5 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-7

Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.6 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . 6-8

Battery Maintenance and Safety Practices. . . . . . . . 6-8

6.7 TIRES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Tire Wear and Damage. . . . . . . . . . . . . . . . . . . . . . . 6-9

Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . 6-9

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . 2-8

3-1. Location of Machine Controls. . . . . . . . . . . . . . . . . 3-2

3-2. Ground Control Station . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-4. Battery Charger and Hour Meter Indicators. . . . . . 3-5

3-5. Location of Manual Descent Valve. . . . . . . . . . . . . 3-6

3-6. Location of Brake Release Switch . . . . . . . . . . . . . 3-7

3-7. Platform Control Station. . . . . . . . . . . . . . . . . . . . . 3-8

3-8. Platform Control/Indicator Panel . . . . . . . . . . . . . . 3-9

3-9. Platform Control Components . . . . . . . . . . . . . . . 3-11

3-10. 1230ES - Decal Installation. . . . . . . . . . . . . . . . . . 3-13

4-1. Location of Battery Charger AC Input Plug . . . . . . 4-2

4-2. Platform/Ground Select Switch. . . . . . . . . . . . . . . . 4-4

4-3. Ground Control - Emergency Stop Switch . . . . . . . 4-4

4-4. Platform Control - Emergency Stop Switch . . . . . . 4-5

4-5. Raising Platform From Ground Control . . . . . . . . . 4-6

4-6. Raising Platform From Platform Control . . . . . . . . . 4-7

4-7. Lowering Platform From Ground Control . . . . . . . . 4-8

4-8. Lowering Platform From Platform Control . . . . . . . 4-9

4-9. Steering from Platform Control . . . . . . . . . . . . . . . 4-10

4-10. Driving Forward from Platform Control. . . . . . . . . 4-11

4-11. Grade and Slideslope Definition . . . . . . . . . . . . . . 4-12

4-12. Location of AC Inverter ON/OFF Toggle Switch. . 4-14

4-13. Tie Down and Lift Lug Locations. . . . . . . . . . . . . . 4-16

4-14. Electric Brake Release. . . . . . . . . . . . . . . . . . . . . . 4-17

4-15. Brake - Manual Disengage.. . . . . . . . . . . . . . . . . . 4-18

5-1. Location of Manual Descent Valve . . . . . . . . . . . . . 5-2

6-1. Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . 6-7

6-2. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-3. Wheel Lug Nut Tightening Sequence. . . . . . . . . . . 6-9

TABLE OF CONTENTS

iv – JLG Lift – 3121221

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

LIST OF TABLES

1-1 Minimum Safe Approach Distance (M.S.A.D.) . . . . 1-6

2-1 Inspection and Maintenance Table. . . . . . . . . . . . . 2-3

2-2 Tilt Cutout Settings . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3-1 1230ES - (ANSI and CE) Decal Installation Chart. 3-14

4-4 Battery Charger Fault Codes . . . . . . . . . . . . . . . . . 4-3

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-4

6-7 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 6-5

6-10 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . 6-6

6-11 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-10

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

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