Jlg 1230ES Service Manual Manuel d'utilisateur Page 4
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INTRODUCTION - REVISION LOG
b – JLG Lift – 3121222
REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . . . June 8, 2006
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . July 13, 2006
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . January 23, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . February 26, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . March 22, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . March 30, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . April 11, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 15, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . November 30, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . June 4, 2008
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . November 11, 2008
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . August 18, 2010
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . August 31, 2011
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . February 22, 2012
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . April 22, 2013
- 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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