Document Outline

• A. GENERAL
• B. HYDRAULIC SYSTEM SAFETY
• C. MAINTENANCE
• SECTION 1. MACHINE SPECIFICATIONS
  • 1.1 OPERATING SPECIFICATIONS
    • Platform Capacities
    • Dimensional Data
    • Tires
    • Batteries
    • Critical Stability Weights
  • 1.2 LUBRICATION
    • Lubrication Capacities
    • Hydraulic Oil
    • Lubrication Specifications
    • Oil Check Procedure
  • 1.3 CYLINDER SPECIFICATIONS
  • 1.4 TORQUE REQUIREMENTS
  • 1.5 SERIAL NUMBER LOCATIONS
• SECTION 2. GENERAL SERVICE INFORMATION
  • 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
    • Maintenance and Inspection Table Codes:
    • Footnotes:
  • 2.3 SERVICING AND MAINTENANCE GUIDELINES
    • General
    • Safety and Workmanship
    • Cleanliness
    • Components Removal and Installation
    • Component Disassembly and Reassembly
    • Pressure-Fit Parts
    • Bearings
    • Gaskets
    • Bolt Usage and Torque Application
    • Hydraulic Lines and Electrical Wiring
    • Hydraulic System
    • Lubrication and Servicing
    • Batteries
  • 2.4 LUBRICATION INFORMATION
    • Hydraulic System
    • Lubrication Specifications
    • Hydraulic Oil
    • Changing Hydraulic Oil
• SECTION 3. THEORY OF OPERATION - 1230ES
  • 3.1 OVERVIEW
  • 3.2 MODES OF OPERATION
    • Ground Mode
    • Platform mode
  • 3.3 CAN COMMUNICATIONS
  • 3.4 CONTROLS & SENSORS
    • Elevation
    • Joystick
    • Tilt
  • 3.5 TRACTION
    • Personalities
    • Interlocks
  • 3.6 PUMP/LIFT/MAST
    • Personalities
    • Interlocks
  • 3.7 STEER
    • Personalities
    • Interlocks
• SECTION 4. BASE COMPONENTS
  • 4.1 BASE ASSEMBLY COMPONENTS
  • 4.2 BASE FRAME COVERS
    • Base Top Cover - Installation
    • Step Plate/Battery Charger Cover - Installation
    • Battery Tray/Side Door - Installation
  • 4.3 WHEELS AND TIRES - DRIVE AND REAR
    • Tire Wear and Damage
    • Wheel and Tire Replacement
    • Wheel Installation
  • 4.4 REAR WHEEL HUB - INSTALLATION
  • 4.5 STEERING LINKAGE ASSEMBLY - INSTALLATION
  • 4.6 STEER CYLINDER - SERVICING
    • Steer Cylinder Disassembly
    • Hydraulic Cylinder Component Inspection
    • Steer Cylinder - Assembly
  • 4.7 DRIVE MOTOR/SPINDLE ASSEMBLY - INSTALLATION
  • 4.8 WHEEL DRIVE ASSEMBLY - SERVICING
    • Drive Motor Electrical Evaluation
    • Roll And Leak Testing
    • Oil Type & Capacity
    • Drive Motor Power Harness Routing
    • Wheel Drive Brake - Manual Disengage Procedure
    • Wheel Drive Motor Assembly - Removal From Machine
    • Drive Motor Disassembly
    • Drive Motor Inspection and Servicing
    • Drive Motor - Reassembly
    • Main Gear Box Disassembly
    • Input Carrier Disassembly
    • Hub - Disassembly
    • Spindle Disassembly
    • Spindle Sub-Assembly
    • Hub Sub-Assembly
    • Input Carrier Sub-Assembly
    • Main Gear Box Sub-Assembly
    • Motor Assembly
  • 4.9 HYDRAULIC PUMP/MOTOR/VALVE ASSEMBLY - SERVICE PROCEDURE
    • Common Difficulties
    • Pump Components
    • Hydraulic System Pressure Check Port
    • Hydraulic System Pressure Settings
    • Pump/Motor/Valve Assembly - Removal/Installation
    • Motor Cover/Motor Installation
    • Preventative Maintenance - Brush Wear - Dust Removal Procedure
    • Motor Brush Installation
  • 4.10 POT HOLE PROTECTION SYSTEM
• SECTION 5. CONTROL COMPONENTS
  • 5.1 CONTROL COMPONENTS OVERVIEW
  • 5.2 CONTROL COMPONENTS - SERVICE
    • Main Power Contactor Relay
    • Elevation Limit Switch
    • Ground Alarm
    • Warning Beacon - Frame Mounted
    • Manual Brake Release Switch
    • AC Power - Breaker Box Installation (CE Specification Machines ONLY)
  • 5.3 TRACTION SYSTEM
    • Common Traction System Difficulties
  • 5.4 POWER MODULE - P/N-1600346
    • Removal
    • Installation
    • Power Module Electrical Evaluation
    • Power Module Diagnostics
  • 5.5 Power Module - P/N-1001092456
    • ZAPI Power Module Electrical Evaluation
  • 5.6 GROUND CONTROL MODULE - SERVICE PROCEDURE
    • Ground Control Station
    • Printed Circuit Board (PCB) Replacement
  • 5.7 PLATFORM CONTROL STATION - SERVICE INFORMATION
    • Platform Control Station Assembly
    • Upper Control Box - Component Replacement
    • Lower Control Box - Component Replacement
  • 5.8 Battery/Battery Charger
    • Battery Maintenance and Safety Practices
    • Battery Installation
  • 5.9 BATTERY CHARGER - INSTALLATION
    • Battery Charger Troubleshooting
  • 5.10 BATTERY CHARGER/INVERTER (OPTION) - INSTALLATION
• SECTION 6. MAST COMPONENTS
  • 6.1 MAST COMPONENTS OVERVIEW
  • 6.2 PLATFORM TOOL TRAY - INSTALLATION
  • 6.3 MAST COVER PLATE - INSTALLATION
  • 6.4 PLATFORM AC RECEPTACLE BOX - INSTALLATION
  • 6.5 MAST ASSEMBLY - COMPONENTS
  • 6.6 PLATFORM ASSEMBLY
    • Platform - Extending Mast Unpowered
    • Platform Removal
    • Platform Installation
  • 6.7 MAST ASSEMBLY
    • Mast Removal
    • Mast Disassembly
    • Mast - Reassembly
    • Mast Installation
    • Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure
    • Mast Installation Completion
  • 6.8 MULTI-STAGE HYDRAULIC CYLINDER - SERVICING
    • Overview
    • Hydraulic Cylinder - Disassembly
    • Hydraulic Cylinder Component Inspection
    • Hydraulic Cylinder - Assembly
    • Hydraulic Cylinder Assembly Testing
• SECTION 7. JLG CONTROL SYSTEM
  • 7.1 ELECTRONIC CONTROL SYSTEM
    • To Connect the Hand Held Analyzer:
    • Using the Analyzer:
    • Changing the Access Level of the Hand Held Analyzer:
    • Machine Setup
    • Diagnostic Trouble Codes (DTC)
  • 7.2 MACHINE CONFIGURATION PROGRAMMING INFORMATION
  • 7.3 MACHINE PERSONALITY - ADJUSTMENT SETTINGS
  • 7.4 TILT SENSOR CALIBRATION
    • Ground Module Software Version 1.5
    • Ground Module Software Version 1.4
    • Calibration Failures
  • 7.5 TILT SENSOR ELECTRICAL EVALUATION
  • 7.6 ELEVATION ANGLE SENSOR ELECTRICAL EVALUATION
    • Tilt vs. Allowed Height Evaluation
  • 7.7 ELEVATION SENSOR CALIBRATION
• SECTION 8. DIAGNOSTIC TROUBLE CODES
  • 8.1 Introduction
  • 8.2 X-CONNECTOR REFERENCES
  • 8.3 DTC Index
  • 8.4 DTC Check Tables
    • 0-0 Help Comments
    • 2-1 Power-Up
    • 2-2 Platform Controls
    • 2-3 Ground Controls
    • 2-5 Function Prevented
    • 3-1 Line Contactor Open Circuit
    • 3-2 Line Contactor Short Circuit
    • 3-3 Ground Output Driver
    • 4-2 Thermal Limit (SOA)
    • 4-4 Battery Supply
    • 6-6 Communication
    • 6-7 Accessory
    • 7-7 Electric Motor
    • 8-1 Tilt Sensor
    • 8-2 Platform Load Sense
    • 9-9 Hardware
• SECTION 9. GENERAL ELECTRICAL INFORMATION & SCHEMATICS
  • 9.1 GENERAL
  • 9.2 MULTIMETER BASICS
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 9.3 ELECTRICAL SWITCH TESTING
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 9.4 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 9.5 WORKING WITH DEUTSCH CONNECTORS
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly
  • 9.6 X-CONNECTOR REFERENCES
  • 9.7 CONNECTOR LOADING DIAGRAMS
  • 9.8 X-CONNECTOR ID INDEX
  • 9.9 MACHINE LOCATION OF COMPONENT X-CONNECTORS
  • 9.10 ELECTRICAL LAYOUT AND SCHEMATICS
  • 9.11 PIN INPUT/OUTPUT TYPES
  • 9.12 AC POWER RECEPTACLES AND WIRING (PLATFORM) - CE SPEC MACHINES ONLY
  • 9.12 HYDRAULIC SCHEMATIC