Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
NOTES:
SECTION - FOREWORD 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 SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS 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 INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALIT Y HA ZARDOUS SITUATION.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS For : THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFET Y RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates • Questions Regarding Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE.
SECTION - REVISION LOG 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. . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . . . . . . . B Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 4 - MACHINE OPERATION 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4.3 PLATFORM LOADING . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE 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 . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 5-1. 6-1. 6-2. 6-3. iv PAGE Ground Control - Emergency Stop Switch . . . . . . .4-6 Platform Control - Emergency Stop Switch . . . . . .4-7 Raising Platform From Ground Control . . . . . . . . . .4-8 Raising Platform From Platform Control . . . . . . . . .4-9 Lowering Platform From Ground Control . . . . . . 4-10 Lowering Platform From Platform Control . . . . .
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 These sections contain the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation.If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”). GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance.
SECTION 1 - SAFETY PRECAUTIONS 1.2 • Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG. PRE-OPERATION Operator Training and Knowledge • The Operators and Safety Manual must be read in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.
SECTION 1 - SAFETY PRECAUTIONS • Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. • Do not operate the machine when wind conditions exceed 28 mph (ANSI/CSA SPEC) /(CE/AUST SPEC) - Indoor Use Only. • This machine can be operated in nominal ambient temperatures of 0o F to 104o F (-20o C to 40o C). Consult JLG to optimize operation outside of this temperature range.
SECTION 1 - SAFETY PRECAUTIONS 1.3 • Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. OPERATION General • Do not use the machine for any purpose other than positioning personnel, their tools, and equipment. • Do not carry materials directly on platform railing unless approved by JLG. • Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.
SECTION 1 - SAFETY PRECAUTIONS Trip and Fall Hazards . • JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc. • Prior to operation, ensure all gates and rails are fastened and secured in their proper position.
SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards • This machine is not insulated and does not provide protection from contact or proximity to electrical current. • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1. • Allow for machine movement and electrical line swaying. Table 1-1. Minimum Approach Distances (M.A.D.
SECTION 1 - SAFETY PRECAUTIONS to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.
SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces. • The user should be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving. • Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface.
SECTION 1 - SAFETY PRECAUTIONS • Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine. Crushing and Collision Hazards • Do not increase the platform size with unauthorized deck extensions or attachments. • If mast assembly or platform is caught so that one or more wheels are off the ground, all persons must be removed before attempting to free the machine.
SECTION 1 - SAFETY PRECAUTIONS • During operation, keep all body parts inside platform railing. • Always post a lookout when driving in areas where vision is obstructed. • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving operations. • Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.1 PERSONNEL TRAINING Operator Training The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel. Operator training must cover: Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Training Supervision 2.2 Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine. Table 2-1 covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Table 2-1. Inspection and Maintenance Table Type Pre-Start Inspection Pre-Delivery Inspection (see note below) Frequent Inspection Annual Machine Inspection (see note below) Preventative Maintenance Frequency Before using each day; or whenever there’s an Operator change. Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.3 PRE-START INSPECTION The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. . Parent Metal Crack 2-4 Weld Crack – JLG Lift – 3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.4 FUNCTION CHECK Perform the Function Check as follows: 1. From the Ground Control Panel with no load in the platform: a. Check if the platform/off/ground selector switch and the platform lift-up/lift-down switch operate properly. b. Check that Pot-Hole-Protection system operates properly, platform raised - bars down, platform down - bars up. 2. From the Platform Control Console: a.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 3. With the platform in the transport (stowed) position. a. Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the brakes hold. b. Check the tilt indicator light/alarm to ensure proper operation. The light/alarm should be activated when tilted at or beyond the values in Table 2-2. NOTE: When the tilt indicator warning is activated the following functions are affected; ANSI/CSA/AUS Spec.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.5 DAILY WALK-AROUND INSPECTION Begin the “Walk-Around Inspection” at Item 1, see Figure 2-1. on page 2-8. Continue checking each item in sequence for the conditions listed in the following checklist. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF”. DO NOT OPERATE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection (Shown Top View Cutaway).
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 This section provides the necessary information needed to understand controls and their functions. GENERAL NOTICE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3.2 CONTROLS AND INDICATORS 1. 2. 3. 4. Ground Control Station Platform Control Station Platform Manual Descent Valve *AC Plug - To Platform AC Receptacle Outlet Box 5. AC Plug - Battery Charger Input Plug 6. Brake Release Button 2 * When equipped with the inverter/charger option, the AC plug (4) to the platform AC receptacle box outlet will be eliminated from the rear panel.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Station 1 2 3 DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF PLATFORM LIFT/ LOWER SWITCH DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. 000000 PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION AS POSSIBLE.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform/Off/Ground Selector Switch - A three position, key-operated power select switch supplies operating power to the platform or ground controls and powers machine down in the off position. 2. Platform Lift/Lower Switch - A three position, momentary contact lift control switch provides raising and lowering of the platform when positioned to up or down. 3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Battery Charger/Hour Meter Indicators 1. Battery Charger Status - This panel, located to the right of the ground control box, is designed to give the operator an accurate read on the status of the battery charger. 1 2 3 000000 GREEN - Charge Complete YELLOW - Charging in Process RED - Charging Abnormal 2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Manual Descent Valve The platform manual descent valve is used in the event of total power failure to retract and lower the platform using gravity. The manual descent valve is located at the bottom of the mast assembly on the front of the machine inside an access hole. Look for the instruction decal located just above the access hole. The procedure is as follows: 1. Locate the manual descent valve (1) on the front of the machine at the base of the mast.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Brake Release Switch NOTE: If the machine’s batteries are completely depleted of electrical charge the brakes cannot be released electrically. The brakes must be released mechanically, see “Mechanical Brake Release” on page 4-19. 3 DO NOT MANUALLY DISENGAGE THE BRAKES UNLESS THE MACHINE IS SETTING ON A LEVEL SURFACE OR THE MACHINE IS FULLY RESTRAINED. 1. The brake release switch (1) is located on the lower rear panel (2) on the machine. 2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Station 1. Platform Control and Indicator Panel 2. Drive/Lift/Steer Joystick Control 3. Emergency Stop Switch 1 2 3 Figure 3-7. Platform Control Station.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control and Indicator Panel 1 2 3 NOTE: The platform control and indicator panel uses different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below. Tilt Indicator Warning Light - Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. System Distress Indicator - This indicator will light up with a fault flash code that indicate where a problem within the system exists. 2. Battery Discharge Indicator (BDI) - This set of lights is designed to let the operator know the condition of the batteries. 3. Tilt Indicator Warning Light and Alarm - A red warning light on the control panel illuminates and an audible alarm sounds when the chassis is at or beyond the permitted amount of slope.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Trigger Switch - This switch is located on the front of the joystick controller. The trigger switch acts as an enable and must be depressed before operating the drive, steer and lift functions. When released, the function being operated will stop. 2. Joystick Controller - The control handle controls three functions: drive, lift, and steer.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3.3 DECAL INSTALLATION 14 2 1 3 4 5 6 13 7 8 9 15 10 7 8 11 12 Figure 3-10. 1230ES - Decal Installation.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Table 3-1. 1230ES - (ANSI and CE) Decal Installation Chart (See Figure 3-10.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-14 – JLG Lift – 3121221
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION Placards This machine is a self-propelled aerial work platform on top of an elevating mast mechanism. The Lift’s intended purpose is to position personnel with their tools and supplies at positions above ground level. The machine can be used to reach work areas located above machinery or equipment positioned at ground level. This JLG Lift has a primary operator Control Station in the platform.
SECTION 4 - MACHINE OPERATION 4.4 BATTERY CHARGING NOTE: Be sure that machine is parked in a well ventilated area before charging begins. ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED BATTERY TERMINAL. DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY WAY. 2 Figure 4-1.
SECTION 4 - MACHINE OPERATION Battery Charger Fault Codes If a fault occurred during charging, the red "Fault" LED (located on the Ground Control Station panel) will flash with a code corresponding to the error. Refer to the table following for the flash codes and their removal. If required, further general and troubleshooting information about the battery charger can be found in the charger manufacturers Owner’s Guide included in the manual storage box mounted on the machine. Table 4-1.
SECTION 4 - MACHINE OPERATION 4.5 1. The AC inverter ON/OFF toggle switch (1) is located on the lower rear panel (2) of the machine. 2. When the toggle switch is set to the ON position this will allow AC current from the inverter to flow to the AC receptacle box in the platform. AC INVERTER OPERATION (OPTION) NOTE: Connect devices one at a time to the AC receptacle box. Do not connect to many high-surge devices at once. ON OFF 3.
SECTION 4 - MACHINE OPERATION NOTES: 3121221 – JLG Lift – 4-5
SECTION 4 - MACHINE OPERATION 4.6 OPERATION Emergency Stop Switch Platform/Ground Select Switch 3 1 4 1 2 Figure 4-4. Ground Control - Emergency Stop Switch Figure 4-3. Platform/Ground Select Switch The power selector switch (1) on the Ground Control Station functions to direct electrical power to the desired control station. With the switch in the ground position (2), power is supplied to the emergency stop switch at the ground control station.
SECTION 4 - MACHINE OPERATION 4.7 RAISING AND LOWERING PLATFORM DO NOT RAISE PLATFORM EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES. 1 TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, USE THE EMERGENCY STOP SWITCH TO STOP THE MACHINE. Figure 4-5.
SECTION 4 - MACHINE OPERATION From Ground Control Station Raising Platform 1. If the machine is shut down, place the platform/ ground select switch to the desired position (platform or ground). 2. Position both the ground control station and platform control station emergency stop switches to the on position. 1 Figure 4-6. Raising Platform From Ground Control 1. If operating from the ground controls Position the lift switch (1) to up and hold until desired elevation is achieved.
SECTION 4 - MACHINE OPERATION From Platform Control Station 1. If operating from the platform controls Set the lift/drive select switch to lift (1), squeeze and hold the red trigger switch (2), move the joystick backward (3) (platform up) and hold until desired elevation is reached. Releasing the red trigger switch or moving the joystick back to it’s centered position will stop the function being operated.
SECTION 4 - MACHINE OPERATION From Ground Control Station Lowering Platform ENSURE THE AREA BENEATH THE PLATFORM IS FREE OF PERSONNEL PRIOR TO LOWERING. NOTE: The machine is equipped with a descent alarm which will sound as the platform is being lowered (optional on CE units). 1 Figure 4-8. Lowering Platform From Ground Control 1. If operating from the ground controls Position the lift switch (1) to down and hold until desired elevation is achieved or until platform is fully lowered.
SECTION 4 - MACHINE OPERATION From Platform Control Station 1. If operating from the platform controls Set the lift/drive select switch to lift (1) squeeze the red trigger switch (2) and push the joystick forward (3) (platform down) and hold until desired elevation is reached or until platform is fully lowered. Releasing the red trigger switch or moving the joystick back to it’s centered position will stop the function being operated.
SECTION 4 - MACHINE OPERATION 4.8 STEERING AND TRAVELING DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES. DO NOT ATTEMPT TO DRIVE THE MACHINE WITH THE PLATFORM RAISED UNLESS THE POT HOLE PROTECTION SYSTEM BARS HAVE BEEN FULLY LOWERED. TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED. REFERENCE FIGURE 4-12. AND TABLE 6-1. 1.
SECTION 4 - MACHINE OPERATION drive in reverse. The drive system is proportional so for additional drive speed, push the joystick further in the direction of travel. Releasing the red trigger switch or returning the joystick to center will stop the function being operated. Driving Forward and Reverse NOTE: To ensure proper orientation of the desired platform function, match the color (black/white) of the directional arrow (5), to the lift/lower arrow (6) on the platform control indicator panel.
SECTION 4 - MACHINE OPERATION GR A DE SIDE-SLOPE HORIZONTAL (LEVEL) Figure 4-12.
SECTION 4 - MACHINE OPERATION 4.9 PARKING AND STOWING MACHINE 1. Drive the machine to a reasonably well-protected and well-ventilated area. 2. Ensure the platform is fully lowered. 3. At the platform control station, turn the platform ground selector switch to off and remove the key to disable the machine and prevent unauthorized use. NOTE: For added protection, the platform control station can be secured to it’s mounting plate see Figure 4-13. 4.
SECTION 4 - MACHINE OPERATION 4.10 TIE DOWN/LIFT LUGS See Figure 4-15. on page 4-17 Tie Down When transporting the machine, the platform must be fully lowered in the stowed position with the machine securely tied down to the truck or trailer deck. There are two tie-down/lift lugs located at the front and rear of the machine for tieing down. Lifting Reference Figure 4-15. for proper locations when lifting machine.
SECTION 4 - MACHINE OPERATION Figure 4-15. Lifting Using Spreader Bar. 1. Lifting Strap or Chains 2.
SECTION 4 - MACHINE OPERATION 4.11 TOWING It is not recommended that this machine be towed, except in the event of an emergency such as a machine malfunction or a total machine power failure. 1 Electric Brake Release (See Figure 4-16.) NOTE: Electrical release of the brakes requires enough battery power to hold the brakes in released mode until destination is reached. 1. Chock wheels or secure machine with tow vehicle. 2. Power up machine in ground mode on the ground control station (1). 3.
SECTION 4 - MACHINE OPERATION Mechanical Brake Release (See Figure 4-17.) 1. Chock wheels or secure machine with tow vehicle. 2. At the ground control station power machine down by pressing the E-Stop switch in. 3. Remove the two cover bolts (1), cover (2), and cover o-ring seal (3) from the back of drive motor unit. 4. Insert the cover bolts into the two disengage holes in the brake housing (4), see Item 4 in Figure 4-17., Brake - Manual Disengage. 5.
SECTION 4 - MACHINE OPERATION NOTES: 4-20 – JLG Lift – 3121221
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL INFORMATION 5.3 This section explains the steps to be taken in case of an emergency situation during operation. 5.2 EMERGENCY OPERATION Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE: 1. Other personnel should operate the machine from ground controls only as required. 2. Only qualified personnel in the platform may use the platform controls.
SECTION 5 - EMERGENCY PROCEDURES 5.4 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details. USA: 877-JLG-SAFE (554-7233) EUROPE: (44) 1 698 811005 AUSTRALIA: (61) 2 65 811111 E-mail: productsafety@jlg.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 INTRODUCTION Other Publications Available Specific to this Machine: This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine. Service and Maintenance Manual ..........3121222 Illustrated Parts Manual..............................
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 Table 6-1. Operating Specification (Continued) OPERATING SPECIFICATIONS DESCRIPTION Table 6-1. Operating Specification DESCRIPTION MODEL 1230ES PLATFORM Maximum Platform Height 12 ft. (3.66 m) DRIVING Maximum Drive Speed Maximum Stowed Travel Grade (Gradeability) (Reference Figure 4-12. on page 4-14) Maximum Stowed Travel Grade (Sideslope) (Reference Figure 4-12. on page 4-14) 3 mph (4.8 kph) 0.5 mph (0.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Platform Capacities Dimensional Data Table 6-2. Capacities Table 6-3. Dimensions CE/AUST (INDOOR ONLY) ANSI/CSA DESCRIPTION MODEL 1230ES Max. Capacity Max. Persons Max. Capacity Max. Persons 500 lb. 2 230 kg 1 Platform Height - Elevated 12 ft. 3.66 m Platform Height - Stowed 22 in. 56 cm Working Height 18 ft. 5.48 m Overall Stowed Machine Height 65.25 in. 166 cm Rail Height (From platform floor) 43.8 in. 111.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 Tires CRITICAL STABILITY WEIGHTS Table 6-4. Tire Specifications DESCRIPTION MODEL 1230ES Size 12.72 in. x 3.937 in. ( 323mm x 100mm) Max Tire Load 2500 lbs (1134 kg) Wheel Bolt Torque 120 ft lb (163 Nm) Batteries Table 6-5. Battery Specifications DESCRIPTION 6-4 MODEL 1230ES DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 NOTE: The factory installed hydraulic oil (Nervofluid 15) has a BLUE TINT for identification purposes only, but is fully compatible and can be mixed with any of the JLG recommended hydraulic oils mentioned following. LUBRICATION Lubrication Capacities Table 6-7. Capacities COMPONENT MODEL 1230ES Hydraulic Tank 0.8 Gal. (3 L) Hydraulic System (Including Tank) 1.75 Gal (4.1 L) Hydraulic Oil Table 6-8.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Lubrication Specifications Table 6-10. Hydraulic Oil Specifications (OEM) Table 6-9. Lubrication Specifications SPECIFICATION KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.) EPGL HO 6-6 MOBIL DTE 11M NERVOFLUID 15 ISO Viscosity Grade #15 #15 Gravity API 31.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 OPERATOR MAINTENANCE Oil Check Procedure • • • • Lube Point(s) - Hydraulic Reservoir Reservoir Capacity: 0.80 Gal. (3 L) Lube - Hydraulic Oil Interval - Check Daily NOTE: Be certain the hydraulic oil has warmed to operating temperature before checking the oil level in the reservoir. 1. From either side of the machine, open the side access door on the base frame (1). Locate the hydraulic oil reservoir (2) on the pump unit (3).
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 BATTERY MAINTENANCE BATTERY FILLER CAP VENT TUBE Battery Maintenance and Safety Practices ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 TIRES AND WHEELS Tire Wear and Damage Inspect tires periodically for wear or damage. Tires with worn edges or distorted profiles require replacement. Tires with significant damage in the tread area or side wall, require immediate evaluation before replacing the machine into service. Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3. Tightening of the lug nuts should be done in stages. Following the recommended sequence, tighten lug nuts per wheel torque. Table 6-11. Wheel Torque Chart 2nd Stage 3rd Stage 20-30 ft lbs (28 - 42 Nm) 65-80 ft lbs (91 - 112 Nm) 105 -120 ft lbs (142 - 163 Nm) 4. Wheel lug nuts should be torqued after the first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 DIAGNOSTIC TROUBLE CODES (DTC) 6.1 The DTC tables following are sorted in groups by the first two digits, these digits represent the number of flashes the system distress indicator lamp will flash on the platform indicator panel when a fault occurs. For example: a “2-1 Power-Up” on page 6-14 would be indicated by 2 flashes, a pause, then 1 flash, a pause, then would keep repeating until the fault is cleared.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.2 DIAGNOSTIC TROUBLE CODES (DTC) CHECK TABLES 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 001 EVERYTHING OK The normal help message in platform mode. Displays on the analyzer only. 002 GROUND MODE OK The normal help message in ground mode. Displays on the analyzer only.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 005 DRIVE & LIFT UP PREVENTED - TILTED & Driving is not possible since the platform is ELEVATED elevated and the chassis is not level. • Check that the machine is tilted. If so, lower the platform and reposition the machine to a level surface. • Fully stow the platform. • The tilt sensor is part of the ground control box. Check that the ground control box is secured to the machine.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 009 DRIVE PREVENTED - ELEVATED ABOVE The platform is elevated above the caliDRIVE CUTOUT HEIGHT brated cutout height. • Check that the elevation angle sensor is securely mounted. Refer problem to a qualified JLG mechanic. 2-1 Power-Up DTC FAULT MESSAGE DESCRIPTION CHECK 211 POWER CYCLE This help message is issued at each power cycle. Displays on the analyzer only. Normal operation.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 2-2 Platform Controls DTC FAULT MESSAGE 223 FUNCTION PROBLEM - DRIVE & LIFT ACTIVE TOGETHER DESCRIPTION CHECK The drive and lift inputs are closed simulta- • Check drive/lift switch for visible damage. neously in platform mode. Refer problem to a qualified JLG mechanic. 224 FUNCTION PROBLEM - STEER LEFT PER- The steer left switch was closed during MANENTLY SELECTED power-up in platform mode.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 2-3 Ground Controls DTC FAULT MESSAGE DESCRIPTION CHECK 231 FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED The ground control box lift switch was closed up or down, during power-up in ground mode. • Check if the lift switch is obstructed or jammed. Refer problem to a qualified JLG mechanic. 232 GROUND LIFT UP / DOWN ACTIVE TOGETHER The lift up / down inputs are closed simulta- • Check if the lift switch is obstructed or jammed. neously.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 2-5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 254 DRIVE & LIFT UP PREVENTED - CHARGER CONNECTED Drive or lift is not possible while the vehicle • Check if the charger is connected to off board power source and disconis charging AND is configured to prevent all nect if desired. motion. Refer problem to a qualified JLG mechanic.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 2-5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 259 MODEL CHANGED - HYDRAULICS SUS- The model selection has been changed. PENDED - CYCLE EMS Refer problem to a qualified JLG mechanic. 2510 DRIVE PREVENTED - BRAKES NOT RELEASING There is a problem with the drive or brake system. • Ensure vehicle is not stuck on something preventing movement. Refer problem to a qualified JLG mechanic.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3-2 Line Contactor Short Circuit DTC FAULT MESSAGE 321 LINE CONTACTOR MISWIRED ON OR WELDED DESCRIPTION CHECK There is a problem with the line contactor. Refer problem to a qualified JLG mechanic. 322 CONTACTOR DRIVER PERMANENTLY ON There is a problem with the power module Refer problem to a qualified JLG mechanic. line contactor control. 326 AUXILIARY RELAY - SHORT TO BATTERY There is a problem with the auxiliary relay contacts or wiring.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3-3 Ground Output Driver DTC FAULT MESSAGE DESCRIPTION CHECK 339 STEER RIGHT SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 3310 STEER RIGHT OPEN CIRCUIT A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 3311 GROUND ALARM SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 4-2 Thermal Limit (SOA) DTC FAULT MESSAGE DESCRIPTION CHECK 421 POWER MODULE TOO HOT - PLEASE WAIT The power module has reached thermal cut- • Power down and allow to cool. out. • Do not operate in ambients over 140° F (60° C). Refer problem to a qualified JLG mechanic. 422 DRIVING AT CUTBACK - POWER MODULE CURRENT LIMIT The drive portion of the power module has Refer problem to a qualified JLG mechanic. reached thermal limit.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 4-4 Battery Supply DTC FAULT MESSAGE 444 LSS BATTERY VOLTAGE TOO LOW DESCRIPTION CHECK A problem has been detected with the load • Recharge batteries or check for damaged batteries. sense system. Refer problem to a qualified JLG mechanic.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6-7 Accessory DTC FAULT MESSAGE 671 ACCESSORY FAULT DESCRIPTION CHECK An accessory module is reporting a fault. • See accessory module documentation for troubleshooting. Refer problem to a qualified JLG mechanic. 7-7 Electric Motor DTC FAULT MESSAGE 771 OPEN CIRCUIT DRIVE MOTOR WIRING DESCRIPTION CHECK The power module detected a problem in the drive motors' power circuit wiring. Refer problem to a qualified JLG mechanic.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7-7 Electric Motor DTC FAULT MESSAGE 777 OPEN CIRCUIT PUMP MOTOR WIRING DESCRIPTION CHECK The power module detected a problem in the drive motors' power circuit wiring. Refer problem to a qualified JLG mechanic. 778 TRACTION T HIGH - CHECK POWER CIR- The power module detected a problem in CUITS the drive motors' power circuit wiring. Refer problem to a qualified JLG mechanic.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 8-1 Tilt Sensor DTC FAULT MESSAGE DESCRIPTION CHECK 812 NO DATA FROM TILT SENSOR - NOT CON- No signal from tilt sensor. NECTED OR FAULTY Refer problem to a qualified JLG mechanic. 8-2 Platform Load Sense DTC FAULT MESSAGE DESCRIPTION CHECK 821 LSS CELL #1 ERROR A problem has been detected with the load Refer problem to a qualified JLG mechanic. sense system.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 991 LSS WATCHDOG RESET A problem has been detected with the load Refer problem to a qualified JLG mechanic. sense system. 992 LSS EEPROM ERROR A problem has been detected with the load Refer problem to a qualified JLG mechanic. sense system. 993 LSS INTERNAL ERROR - PIN EXCITATION A problem has been detected with the load Refer problem to a qualified JLG mechanic. sense system.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 9-9 Hardware DTC FAULT MESSAGE 9910 FUNCTION LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER DESCRIPTION CHECK The platform board software version is not Refer problem to a qualified JLG mechanic. compatible with the rest of the system. 9911 FUNCTION LOCKED OUT - LSS MODULE The load sensing system module software Refer problem to a qualified JLG mechanic. SOFTWARE VERSION IMPROPER version is not compatible with the rest of the system.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 9950 POWER MODULE FAILURE - INTERNAL A problem has been detected with the power module. 9951 ERROR 9952 9953 9954 9955 9956 9957 9958 9960 9962 9963 9964 9969 9971 9970 99143 99144 99145 99146 99147 99148 99149 6-28 Cycle machine power on /off a few times if this doesn’t clear the DTC, refer problem to a qualified JLG mechanic.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number ______________________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 3121221 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda. Rua Eng.
