JLG 1230ES Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

ANSI

Original Instructions - Keep this manual with the machine at all times.

Model

1230ES

P/N - 3121221

May 20, 2016

NOTES:

SECTION - FOREWORD

3121221 – JLG Lift – A

FOREWORD

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD

PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS,

JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DIS-

TANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-

NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY

SATURATION.

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.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

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 possi-

ble 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.

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.

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 PROP-

ERTY OR THE JLG PRODUCT.

Contact :

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

or Your Local JLG Office

(See addresses on manual rear cover)

In USA:

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

Outside USA:

Phone: 240-420-2661

E-mail: ProductSafety@JLG.com

For :

• Accident Reporting

•ProductSafetyPub-

lications

•CurrentOwner

Updates

•QuestionsRegard-

ing Product Safety

• Standards and Regula-

tions Compliance

Information

• Questions Regarding

Special Product Appli-

cations

• Questions Regarding

Product Modifications

SECTION - REVISION LOG

D– JLG Lift – 3121221

REVISION LOG

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

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

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . July 13, 2006

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . January 23, 2007

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . March 19, 2007

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 16, 2007

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . June 11, 2007

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 6, 2008

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . June 22, 2010

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . August 15, 2013

Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 20, 2016

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 PREPARA-

TION 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 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . .2-5

2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . 3-10

3.3 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-12

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND

TABLE OF CONTENTS

ii – JLG Lift – 3121221

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

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

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

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

4.3 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.4 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

4.5 AC INVERTER OPERATION (OPTION) . . . . . . . . . . . . .4-4

4.6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Platform/Ground Select Switch . . . . . . . . . . . . . . .4-6

Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . .4-6

4.7 RAISING AND LOWERING PLATFORM . . . . . . . . . . . .4-7

Raising Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Lowering Platform. . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.8 STEERING AND TRAVELING. . . . . . . . . . . . . . . . . . . . 4-12

Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Driving Forward and Reverse . . . . . . . . . . . . . . . 4-13

4.9 PARKING AND STOWING MACHINE . . . . . . . . . . . . 4-15

4.10 TIE DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.11 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Electric Brake Release . . . . . . . . . . . . . . . . . . . . . . . 4-19

Mechanical Brake Release. . . . . . . . . . . . . . . . . . . 4-20

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

6.1 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 6-2

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

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

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

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

6.1 CRITICAL STABILITY WEIGHTS. . . . . . . . . . . . . . . . . . . 6-4

6.1 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

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

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

6.1 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 6-7

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

TABLE OF CONTENTS

3121221– JLG Lift – iii

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

6.1 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

6.1 TIRES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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

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

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

6.1 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . .6-10

6.1 DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . . . . . .6-11

6.1 DTC CHECK TABLE INDEX . . . . . . . . . . . . . . . . . . . . . .6-11

6.2 DIAGNOSTIC TROUBLE CODES (DTC)

CHECK TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

0-0 Help Comments . . . . . . . . . . . . . . . . . . . . . . . . .6-12

2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

2-2 Platform Controls. . . . . . . . . . . . . . . . . . . . . . . .6-14

2-3 Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . .6-16

2-5 Function Prevented. . . . . . . . . . . . . . . . . . . . . .6-16

3-1 Line Contactor Open Circuit. . . . . . . . . . . . . .6-18

3-2 Line Contactor Short Circuit. . . . . . . . . . . . . .6-19

3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . .6-19

4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . .6-21

4-4 Battery Supply. . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

8-2 Platform Load Sense . . . . . . . . . . . . . . . . . . . . .6-25

9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . .2-6

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 . . . . . . . . . . . . . . . . 3-10

3-10. 1230ES - Decal Installation.. . . . . . . . . . . . . . . . . . . . 3-12

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

4-2. Location of AC Inverter ON/OFF-Toggle Switch . .4-4

4-3. Platform/Ground Select Switch. . . . . . . . . . . . . . . . . .4-6

4-4. Ground Control - Emergency Stop Switch . . . . . . .4-6

4-5. Platform Control - Emergency Stop Switch . . . . . .4-7

4-6. Raising Platform From Ground Control. . . . . . . . . .4-8

4-7. Raising Platform From Platform Control. . . . . . . . .4-9

4-8. Lowering Platform From Ground Control . . . . . 4-10

TABLE OF CONTENTS

iv – JLG Lift – 3121221

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

4-9. Lowering Platform From Platform Control . . . . 4-11

4-10. Steering from Platform Control . . . . . . . . . . . . . . . 4-12

4-11. Driving Forward from Platform Control . . . . . . . 4-13

4-12. Grade and Side-Slope Definition . . . . . . . . . . . . . . 4-14

4-13. Securing Control Station to Platform.. . . . . . . . . . 4-15

4-14. Tie Down and Lift Lug Locations. . . . . . . . . . . . . . . 4-16

4-15. Lifting and Tie-Down Chart. . . . . . . . . . . . . . . . . . . . 4-17

4-16. Lifting Using Spreader Bar. . . . . . . . . . . . . . . . . . . . . 4-18

4-17. Electric Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-18. Brake - Manual Disengage. . . . . . . . . . . . . . . . . . . . . 4-20

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

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-6

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

2-2 Tilt Cutout Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3-1 1230ES - (ANSI and CE) Decal Installation Chart. 3-13

4-1 Battery Charger Fault Codes . . . . . . . . . . . . . . . . . . . . 4-3

6-1 Operating Specification . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . 6-6

6-10 Hydraulic Oil Specifications (OEM) . . . . . . . . . . . . . . 6-6

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

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

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Custom Equipment

Custom Equipment Hy-Brid Lifts 2 Series Programmierhandbuch

Hy-Brid Lifts

Hy-Brid Lifts HB-P3.6 Programmierhandbuch

BERG

BERG BeNomic EasyLeaf Bedienungsanleitung

Powermate

Powermate LiftGate LG-3 Bedienungsanleitung

Snorkel

Snorkel TM12 Series Bedienungsanleitung

Terberg

Terberg OMNIDEKA Bedienungsanleitung

Harmar Mobility

Harmar Mobility AL625 Betriebsanleitung

Rotary

Rotary SPO16 Bedienungsanleitung