Jlg 1230ES Service Manual Manuel d'utilisateur Page 107
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- MARQUE LIVRES
Noté. / 5. Basé sur avis des utilisateurs
SECTION 6 - MAST COMPONENTS
3121222 – JLG Lift – 6-7
Mast Removal
NOTE: To ease removal and installation of the mast assem-
bly it is recommended that the complete machine be
elevated on suitable stands to allow easy access to
the mounting bolts on the base of the mast assem-
bly.
1. Lower the mast assembly completely before begin-
ning the mast removal process to ensure no residual
pressure remains in the lift cylinder.
2. Attach an overhead crane by strap through the cross
supports on the top of mast sections.
3. Remove the four (4) bolts, nuts, washers, and shims
from the base mount of the mast. Access the bolts
and nuts through the access holes in the bottom
and front of the base frame.
NOTE: Before removing the mast off the machine, you must
decide which way you want to disconnect the har-
ness cables to the AC receptacle box and platform
control box running through the power-trak in the
mast.
You can either disconnect the cables from their
source at the rear of the machine in the charger
compartment and free the cables through to the front
of the machine so the cables come out with the
mast.
Or disconnect the power-trak from the top of the
mast and allow it slide out through the bottom of the
mast as it is lifted off of the machine. This method
also requires the AC receptacle box and the platform
control box cable to be disconnected and feed down
through the mast with the power-trak.
4. If removing the power-trak from the mast use the fol-
lowing steps; (See illustration above)
a. Remove the attach screws from the power-trak
guide bracket.
b. Push the power track and cables down into the
mast past the hanger bracket slot in the side of
the mast.
5. At the top of the mast, carefully open the bleeder
valve on the top of the main hydraulic cylinder #1
attached to the base frame.
NOTE: While lifting the mast assembly out of the frame,
hydraulic cylinder #1 will still be attached to the base
frame, lift slowly straight up ONLY, do not attempt to
lift on an angle or the hydraulic cylinder may be dam-
aged.
NOTE: Also when lifting the mast assembly, if you detached
the power-trak from the top of the mast it will need to
be lowered out the bottom of the mast as the mast is
lifted upwards.
6. Carefully lift the mast assembly up out of the frame
far enough to gain access to the wire harness con-
nector for the lift down selenoid, and the hydraulic
lines connected to hydraulic cylinder #1, still
attached to the base frame.
Figure 6-7. Mast Base Mounting Hardware
(Front of frame shown cutaway for illustrative purposes only)
1. Mast Assembly
2. Fastening Hardware
3. 20 Ga. (.0359 in.)-
Mounting Shim
Figure 6-8. Power-Trak - Removal
1. Attach Screws
2. Power-Trak Hanger
Bracket (a)
3. Power-Trak Guide (b)
4. Hyd. Cyl. #1 Bleeder Valve
Note: (a) Remove hanger bracket from slot in mast and push
down into the mast.
(b) If platform has already been removed this will be
hanging loose.
1
2
3
- Model(s) 1
- A. GENERAL 3
- B. HYDRAULIC SYSTEM SAFETY 3
- C. MAINTENANCE 3
- REVISION LOG 4
- LIST OF FIGURES 10
- TABLE OF CONTENTS 11
- LIST OF TABLES 12
- 3121222 – JLG Lift – 1-1 13
- 1.1 OPERATING SPECIFICATIONS 14
- 1.2 LUBRICATION 14
- 1.3 CYLINDER SPECIFICATIONS 15
- 1.4 TORQUE REQUIREMENTS 15
- 1.5 SERIAL NUMBER LOCATIONS 15
- 1-4 – JLG Lift – 3121222 16
- 3121222 – JLG Lift – 1-5 17
- SOCKET HEAD CAP SCREWS 18
- 1-8 – JLG Lift – 3121222 20
- 3121222 – JLG Lift – 1-9 21
- Magni Coating (Ref 4150701)* 22
- AND MAINTENANCE 23
- INSPECTION SCHEDULE 24
- 3121222 – JLG Lift – 2-3 25
- Footnotes: 26
- GUIDELINES 27
- 2.4 LUBRICATION INFORMATION 28
- Lubrication Specifications 29
- Hydraulic Oil 29
- Changing Hydraulic Oil 29
- 2-8 – JLG Lift – 3121222 30
- 3.1 OVERVIEW 31
- 3.2 MODES OF OPERATION 31
- Ground Mode 31
- Platform mode 31
- 3.3 CAN COMMUNICATIONS 31
- 3-2 – JLG Lift – 3121222 32
- Line Contactor 33
- Right Field Winding 33
- Personalities 34
- Interlocks 34
- 3.6 PUMP/LIFT/MAST 35
- 3.7 STEER 36
- SECTION 4. BASE COMPONENTS 37
- 4.2 BASE FRAME COVERS 38
- Tire Wear and Damage 39
- Wheel and Tire Replacement 39
- Wheel Installation 39
- SECTION 4 - BASE COMPONENTS 40
- 3121222 – JLG Lift – 4-5 41
- 4-6 – JLG Lift – 3121222 42
- Steer Cylinder Disassembly 43
- Steer Cylinder - Assembly 44
- Roll And Leak Testing 48
- Oil Type & Capacity 48
- Drive Motor Disassembly 51
- Drive Motor - Reassembly 53
- Main Gear Box Disassembly 54
- Input Carrier Disassembly 55
- Hub - Disassembly 56
- Spindle Disassembly 57
- Spindle Sub-Assembly 58
- Hub Sub-Assembly 60
- Input Carrier Sub-Assembly 61
- Main Gear Box Sub-Assembly 62
- Motor Assembly 64
- Common Difficulties 65
- 3121222 – JLG Lift – 4-31 67
- Pump Components 68
- Removal Procedure 72
- Motor Brush Installation 72
- 4-38 – JLG Lift – 3121222 74
- 3121222 – JLG Lift – 4-39 75
- 3121222 – JLG Lift – 5-1 77
- Main Power Contactor Relay 78
- Elevation Limit Switch 78
- Ground Alarm 78
- 3121222 – JLG Lift – 5-3 79
- 5.3 TRACTION SYSTEM 80
- 3121222 – JLG Lift – 5-5 81
- 5-6 – JLG Lift – 3121222 82
- Installation 83
- 5-8 – JLG Lift – 3121222 84
- Power Module Diagnostics 85
- 5-10 – JLG Lift – 3121222 86
- ZAPI POWER MODULE 87
- P/N - 1001092456 87
- "HEALTH" 88
- (STATUS LED) 88
- PROCEDURE 89
- 5-14 – JLG Lift – 3121222 90
- 3121222 – JLG Lift – 5-15 91
- 5-16 – JLG Lift – 3121222 92
- 3121222 – JLG Lift – 5-17 93
- 5-18 – JLG Lift – 3121222 94
- 5.8 BATTERY/BATTERY CHARGER 95
- 5-20 – JLG Lift – 3121222 96
- FAULT LED Flashing 97
- 5-22 – JLG Lift – 3121222 98
- 3121222 – JLG Lift – 5-23 99
- - INSTALLATION 100
- SECTION 6. MAST COMPONENTS 101
- INSTALLATION 102
- SECTION 6 - MAST COMPONENTS 103
- 6.6 PLATFORM ASSEMBLY 104
- Platform Installation 105
- 6.7 MAST ASSEMBLY 106
- Mast Removal 107
- Mast Disassembly 108
- Mast - Reassembly 109
- Mast Installation 110
- Procedure 112
- Mast Installation Completion 112
- Overview 113
- Hydraulic Cylinder - Assembly 117
- 7.1 ELECTRONIC CONTROL SYSTEM 119
- Using the Analyzer: 119
- Analyzer: 120
- Machine Setup 121
- ANALYZER SCREEN LAYOUT 122
- 123
- 7-6 – JLG Lift – 3121222 124
- 3121222 – JLG Lift – 7-7 125
- 7-8 – JLG Lift – 3121222 126
- 7.2 MACHINE CONFIGURATION 127
- PROGRAMMING INFORMATION 127
- 7-10 – JLG Lift – 3121222 128
- SETTINGS 129
- 7.4 TILT SENSOR CALIBRATION 130
- Calibration Failures 130
- EVALUATION 131
- 7-14 – JLG Lift – 3121222 132
- 8.1 INTRODUCTION 133
- 8.2 X-CONNECTOR REFERENCES 133
- 8.3 DTC INDEX 133
- 8-4 – JLG Lift – 3121222 136
- 8.4 DTC CHECK TABLES 137
- 0-0 Help Comments 137
- 2-1 Power-Up 138
- 2-2 Platform Controls 138
- 2-3 Ground Controls 140
- 2-5 Function Prevented 140
- 3-3 Ground Output Driver 143
- 4-2 Thermal Limit (SOA) 145
- 4-4 Battery Supply 146
- 6-6 Communication 146
- 6-7 Accessory 148
- 7-7 Electric Motor 148
- 8-1 Tilt Sensor 150
- 8-2 Platform Load Sense 150
- 9-9 Hardware 150
- 8-22 – JLG Lift – 3121222 154
- 3121222 – JLG Lift – 9-1 155
- 9-2 – JLG Lift – 3121222 156
- 3121222 – JLG Lift – 9-3 157
- Requirements: 158
- 9.3 ELECTRICAL SWITCH TESTING 159
- Basic Check 159
- Limit Switches 159
- Automatic Switches 160
- 3121222 – JLG Lift – 9-7 161
- Assembly 162
- 3121222 – JLG Lift – 9-9 163
- Disassembly 164
- Wedge Lock 164
- Service - Voltage Reading 164
- 3121222 – JLG Lift – 9-11 165
- DT/DTP Series Assembly 166
- DT/DTP Series Disassembly 166
- HD30/HDP20 Series Assembly 166
- HD30/HDP20 Series Disassembly 167
- 9.6 X-CONNECTOR REFERENCES 167
- REAR VIEW 169
- 9-16 – JLG Lift – 3121222 170
- 9.8 X-CONNECTOR ID INDEX 171
- 9-18 – JLG Lift – 3121222 172
- 3121222 – JLG Lift – 9-19 173
- 9-20 – JLG Lift – 3121222 174
- 3121222 – JLG Lift – 9-21 175
- 9-22 – JLG Lift – 3121222 176
- 3121222 – JLG Lift – 9-23 177
- 9-24 – JLG Lift – 3121222 178
- 3121222 – JLG Lift – 9-25 179
- 9-26 – JLG Lift – 3121222 180
- 3121222 – JLG Lift – 9-27 181
- 9-28 – JLG Lift – 3121222 182
- 1001114879_F-1 183
- 9-30 – JLG Lift – 3121222 184
- 1001114879_F-2 185
- 1001114879_F-3 186
- 9.11 PIN INPUT/OUTPUT TYPES 187
- 9-34 – JLG Lift – 3121222 188
- 3121222 – JLG Lift – 9-35 189
- 9-36 – JLG Lift – 3121222 190
- 3121222 – JLG Lift – 9-37 191
- 9-38 – JLG Lift – 3121222 192
- 3121222 – JLG Lift – 9-39 193
- 9-40 – JLG Lift – 3121222 194
- 3121222 – JLG Lift – 9-41 195
- 9.12 HYDRAULIC SCHEMATIC 196
- BATTERY WARNING 197
- JLG Worldwide Locations 198
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