JLG 1230ES Illustrated Parts Manual 3121223 – PDF DOWNLOAD

Illustrated Parts Manual

Model 1230ES P/N 3121223 October 8, 2013

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REVISION LOG NOTES:

NOTE: Country of Manufacture - The 1230ES Scissor Lifts are manufactured by JLG Industries in the following countries: USA, France and China. Refer to the Serial Number Tag to identify the country of manufacture. Machines manufactured in the USA will have a serial number prefix of 02 (i.e. 02XXXXXXXX), machines manufactured in France will have a prefix of A2 (i.e. A2XXXXXXXX) and machines manufactured in China will have a prefix of B2 (i.e. B2XXXXXXXX).

NOTE: Production in France starts August 2006 & ends February 2010 with S/N A200009897.

NOTE: Drive Module Identification - The module is located inside the frame. Open the left side battery door and identify the drive module by part number or visual identification before ordering parts. (See illustration below). Also, identify the country of manufactured by referring to the S/N nameplate before ordering parts (See note above).

USA built machines: Machines built prior to S/N 0200203195 use the 1600346 Drive Module. Machines with S/N 0200203195 to Present use the 1001092456 Drive Module.

French built machines: All machines use the 1600346 Drive Module.

China built machines: All machines use the 1001092456 Drive Module.

P/N 1600346 (Color: Blue)

P/N 1001092456 (Color: Black)

MANUAL REVISION LOG: April 12, 2013 - Revised Manual (Edited to B/M 0010670 Revision 19) July 31, 2006 - Original Issue of Manual (Edited to B/M 0010670 Revision 4) January 15, 2007 - Revised Manual (Edited to B/M 0010670 Revision 6) August 1, 2007 - Revised Manual (Edited to B/M 0010670 Revision 8) February 15, 2008 - Revised Manual (Edited to B/M 0010670 Revision 8) August 15, 2008 - Revised Manual (Edited to B/M 0010670 Revision 11) August 12, 2009 - Revised Manual (Edited to B/M 0010670 Revision 11) March 1, 2010 - Revised Manual (Edited to B/M 0010670 Revision 12) November 1, 2010 - Revised Manual (Edited to B/M 0010670 Revision 17) April 8, 2011 - Revised Manual (Edited to B/M 0010670 Revision 18) July 14, 2011 - Revised Manual (Edited to B/M 0010670 Revision 19) October 7, 2011 - Revised Manual (Edited to B/M 0010670 Revision 19) January 12, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19)

3121223

1230ES

A

REVISION LOG June 22, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19) August 21, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19) January 7, 2013 - Revised Manual (Edited to B/M 0010670 Revision 19) April 12, 2013 - Revised Manual (Edited to B/M 0010670 Revision 19) July 9, 2013 - Revised Manual (Edited to B/M 0010670 Revision B) October 8, 2013 - Revised Manual (Edited to B/M 0010670 Revision B)

B

1230ES

3121223

TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5

STEERING AND DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 WHEEL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS . . . . . . . . . . . . . . 1-14 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5

PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 2-2 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 BATTERIES AND COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1

MAST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4

PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 PLATFORM CONSOLE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 DRIVE/STEER P/Q CONTROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2

LIFT CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-1

HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-1 7-2 7-3 7-4

ELECTRICAL SCHEMATIC (MACHINES WITH 1600346 DRIVE MODULE). . . . . . . . . 7-2 ELECTRICAL SCHEMATIC (MACHINES WITH 1001092456 DRIVE MODULE) . . . . . 7-4 ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456 DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 8-1

DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3121223

1230ES

i

TABLE OF CONTENTS FIGURE NO.

ii

TITLE

1230ES

PAGE NO.

3121223

SECTION 1 FRAME

3121223

1230ES

1-1

SECTION 1 FRAME FIGURE 1-1.STEERING AND DRIVE INSTALLATION

208 207

206

206

206 205 204 202 201 102 203 11 1 3

11 4 9A 9 2

9A 13

16

10

2 15

105

14

101

10 7A

107

7

15

8 8A

7A

6 12

106 104

5 15 103

103 101 105

1-2

1230ES

3121223

SECTION 1 FRAME FIGURE 1-1. STEERING AND DRIVE INSTALLATION ITEM #

1 2 3 4 5 6 7 7A 8 8A 9 9A 10 11 12 13 14 15 16

PART NUMBER

QTY.

DESCRIPTION

REV.

0274549

Ref.

STEERING AND DRIVE INSTALLATION

E

0100019 0761016 0630606 0903594 0903595 1684458 3010164 0440263 3010165 0440263 3010166 0440263 3291005 3423303 3423230 3423235 3423236 3760348 3841143

A/R 4 2 1 1 1 1 2 1 2 1 2 2 4 1 1 1 5 1 Ref. Ref.

101 102 103

0274550 1001118433

Ref. Ref.

0630580 2780266

20 2 2 Ref.

1001092743 1001118359 Use 1001092743 1001092743

104 105

1001118359 3760463 Use 2915012

2 4

106 107 108 109

4740523 4740524 4240018 1321682

2 2 2 2

3121223

Compound, Locking Bolt M10 x 40mm Capscrew M12 x 25mm Bracket, Steering Knuckle (Right) Bracket, Steering Knuckle (Left) Steer Cylinder Assembly (See Section 5 for Breakdown) Link, Steering Bushing, Flange Arm, Steering (Left) Bushing, Flange Arm, Steering Right) Bushing, Flange Locknut M10 Pin, Linkage Pin, Clevis Pin, Clevis Pin, Clevis Ring, Retaining Keeper DRIVE INSTALLATION Note: For Module Identification, see note on Revision Log Page A before ordering parts.

Machines with 1600346 Drive Module Machines with 1001092456346 Drive Module

I A

Bolt, Wheel Hub Assembly (See Items 201-208 for Breakdown) Wheel Drive Assembly Options (See Figure 1-2 for Breakdown): Note: Requires identification of drive module before ordering parts. Refer to Revision Log Page A of this manual.

USA Built Machines with 1600346 Drive Module USA Built Machines with 1001092456 Drive Module French Built Machines Prior to S/N A200007624 with 1600346 Drive Module (was p/n 3160329) French Built Machines S/N A200007624 to S/N A200009897 with 1600346 Drive Module China Built Machines Ring, Retaining Tire & Wheel Assembly Kit (includes qty 5 of item 101) (Was p/ns 4520565, 1001100840 & 1001114467) Note: Must replace Tire & Wheel Assemblies in pairs per axle.

Washer Washer Tie-Strap (Not Shown) Clamp, Worm (Not Shown - Used on Drive Motor Cable)

1230ES

1-3

SECTION 1 FRAME FIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED) ITEM #

PART NUMBER

QTY.

DESCRIPTION

110

4923602

1

Harness, Field Wire Connection (Not Shown - See Section 7 for Breakdown)

2780266

Ref. Ref.

Use 1001102354 Use 3300423 Use 3450406 Use 4740468 Use 1001102351 Not Available Use 1001102353 Use 1001102349

1 1 1 1 1 1 1 1

HUB ASSEMBLY Note: Quantities shown are for 1 assembly. Two Assemblies are required per machine.

Cap, Dust (was p/n 7012524) Nut, Slotted (was p/n 7010641) Pin, Cotter 2” x 3/16” (was p/n 7010642) Washer (was p/n 7019697) Bearing, Cone - Outer (was p/n 7026185) Hub (Purchase Complete Hub p/n 2780266) Bearing, Cone - Inner (was p/n 7026183) Seal (was p/n 7026184)

201 202 203 204 205 206 207 208

1-4

1230ES

REV.

D

3121223

SECTION 1 FRAME FIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED) ITEM #

3121223

PART NUMBER

QTY.

DESCRIPTION

1230ES

REV.

1-5

SECTION 1 FRAME FIGURE 1-2.WHEEL DRIVE ASSEMBLY

17 13

103

105 109 12

110 111

104

112

1 106 9 32

107

25

114

9 10

113

14 16 9 OR

2

15 28

26A 26B 14 26B 27

24

3

OR

8

26A 6

4 7

25 5 25 23

19 21

18

29

20 11

1-6

1230ES

3121223

SECTION 1 FRAME

201 203 204 205A 205B 205C 205D 206

207 208 209 210A 210B 211A 211B

202

GENUINE PARTS

OR

108A

125

108B

127

151 153

128

154

152

126

STYLE “B”

STYLE “A”

3121223

1230ES

1-7

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