Jlg 1230ES Parts Manual Instrukcja Użytkownika

Illustrated Parts ManualModel1230ESP/N3121223October 8, 2013

1-4 1230ES 3121223SECTION 1 FRAME110 4923602 1 Harness, Field Wire Connection (Not Shown - See Section 7 for Breakdown)2780266 Ref. HUB ASSEMBLY DRef.

7-32 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456 DRIVE MODULE) (CONTINUED)ITEM # PART

3121223 1230ES 8-1SECTION 8DECALS

8-2 1230ES 3121223SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION 610817102881713101191210210861031101071515143710724411121216104105OR10912 FREN

3121223 1230ES 8-3SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0274914 Ref. COMMON DECALS INSTALLATION J1 1

8-4 1230ES 3121223SECTION 8 DECALS101 (cont’d) 1704341 ANSI Export Spec (Portuguese/Spanish Language)1704339 ANSI Export Spec (Spanish/English Languag

3121223 1230ES 8-5SECTION 8 DECALS109 1 Decal - CSA Options:1705303 CSA Spec OnlyNot Required All Specs Except CE Spec110 1 Decal - Instruction/Warnin

8-6 1230ES 3121223SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 1230ESThe following list will service one machine (built to current production per dat

9-2 1230ES 3121223SECTION 9 RECOMMENDED SERVICE PARTS STOCKMODEL 1230ESThe following list will service one machine (built to current production per da

3121223 1230ES 10-1SECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may not be applicable

3121223 1230ES 1-5SECTION 1 FRAMEFIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

10-2 1230ES 3121223SECTION 10 SPECIAL OPTIONSRef. Tools for Service7002821 1 Crimper, Wire7002823 1 Extractor, Pin - Universal4460467 A/R Extractor, P

PagePart Number PagePart Number PagePart NumberPagePart Number3121223 1230ES 11-1SECTION 11 PART NUMBER INDEX0060084 ... 1-13010

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 1230ES 3121223SECTION 11 PART NUMBER INDEX1001155025 ... 2-13100115

PagePart Number PagePart Number PagePart NumberPagePart Number3121223 1230ES 11-3SECTION 11 PART NUMBER INDEX4341144 ... 1-15434

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 1230ES 3121223SECTION 11 PART NUMBER INDEX7011997 ... 4-11701

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

1-6 1230ES 3121223SECTION 1 FRAMEFIGURE 1-2.WHEEL DRIVE ASSEMBLY 26BOR26A26BOR26A672525523182021191129424812132259101499152816227314104171310310510911

3121223 1230ES 1-7SECTION 1 FRAME 127125128126STYLE “A”151153154152STYLE “B”108A108B202201203204205A205B205C205D206GENUINE PARTS207208209210A21

1-8 1230ES 3121223SECTION 1 FRAMEFIGURE 1-2. WHEEL DRIVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. WHEEL DRIVE ASSEMBLYRef. Note: Due to s

3121223 1230ES 1-9SECTION 1 FRAMERef. BRAKE & MOTOR COMPONENTS101 to 102 Not Used103 Use Item 208 1 Brush & Terminal Assembly104 70000790 2 Sp

1-10 1230ES 3121223SECTION 1 FRAME205C USA Built Machines Options:70001347 Wheel Drive Assembly 100109274370002308 Wheel Drive Assembly 1001118359206

3121223 1230ES 1-11SECTION 1 FRAMEFIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-12 1230ES 3121223SECTION 1 FRAMEFIGURE 1-3. POTHOLE PROTECTION INSTALLATION 1811639201417124A134134A191113212322227266A64A515191324588A101913

3121223 1230ES 1-13SECTION 1 FRAMEFIGURE 1-3. POTHOLE PROTECTION INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0274564 Ref. POTHOLE PROTECTION

1-14 1230ES 3121223SECTION 1 FRAMEFIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS OR2467821321210110110210320220120320520610430

3121223 1230ES 1-15SECTION 1 FRAMEFIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.0274558 Ref.

1-16 1230ES 3121223SECTION 1 FRAMEFIGURE 1-5.FRAME COVERS INSTALLATION 2222121212125312111106123448911

3121223 1230ES 1-17SECTION 1 FRAMEFIGURE 1-5. FRAME COVERS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0274560 Ref. FRAME COVERS INSTALLATION

1-18 1230ES 3121223SECTION 1 FRAMEFIGURE 1-5. FRAME COVERS INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 2-1SECTION 2GROUND COMPONENTS

2-2 1230ES 3121223SECTION 2 GROUND COMPONENTSFIGURE 2-1.PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION 8111311121266B6A6C743A311A 22015B5C55A9101071

3121223 1230ES 2-3SECTION 2 GROUND COMPONENTSFIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. PUMP/M

2-4 1230ES 3121223SECTION 2 GROUND COMPONENTS12 2 Fitting Options:2144610 Straight Fitting1001101362 90° Fitting13 2221086 1 Fitting, Pressure Check02

3121223 1230ES 2-5SECTION 2 GROUND COMPONENTSFIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV

3121223 1230ES AREVISION LOGNOTES:NOTE: Country of Manufacture - The 1230ES Scissor Lifts are manufactured by JLG Industries in the following countrie

2-6 1230ES 3121223SECTION 2 GROUND COMPONENTSFIGURE 2-2.ELECTRICAL COMPONENTS INSTALLATION B DEACAB CDE884A4B4C4D175886102333 1211141313OR

3121223 1230ES 2-7SECTION 2 GROUND COMPONENTSFIGURE 2-2. ELECTRICAL COMPONENTS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. ELECTRICAL CO

2-8 1230ES 3121223SECTION 2 GROUND COMPONENTSFIGURE 2-3.GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE MODULE) 1234567810111213141415 16

3121223 1230ES 2-9SECTION 2 GROUND COMPONENTSFIGURE 2-3. GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE MODULE)ITEM # PART NUMBER QTY. DESCRIPT

2-10 1230ES 3121223SECTION 2 GROUND COMPONENTSFIGURE 2-4.GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE MODULE) 139218456217128192081

3121223 1230ES 2-11SECTION 2 GROUND COMPONENTSFIGURE 2-4. GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE MODULE)ITEM # PART NUMBER QTY. DESC

2-12 1230ES 3121223SECTION 2 GROUND COMPONENTSFIGURE 2-5.BATTERIES AND COVERS INSTALLATION 29NOTE: REPLACEMENT DECALS ON FRONT OF BATTERY BOXES

3121223 1230ES 2-13SECTION 2 GROUND COMPONENTSFIGURE 2-5. BATTERIES AND COVERS INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. BATTERIES AND

2-14 1230ES 3121223SECTION 2 GROUND COMPONENTS202 3380600 1 Tray (Right)203 to 204 Not Used205 0630587 1 Bolt, Carriage M6 x 25mm206 3290605 1 Locknut

3121223 1230ES 3-1SECTION 3MAST

B 1230ES 3121223REVISION LOGJune 22, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19)August 21, 2012 - Revised Manual (Edited to B/M 0010670

3-2 1230ES 3121223SECTION 3 MASTFIGURE 3-1.MAST INSTALLATION 104205104204104202111400401154081141154034064071064024034051022272241520920920920

3121223 1230ES 3-3SECTION 3 MASTFIGURE 3-1. MAST INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. MAST INSTALLATION1001098653 Ref. All Specs

3-4 1230ES 3121223SECTION 3 MASTRef. Note: Use p/n 1001092165 as replacement whenever possible. Combination of both types of pads may be used.110 Not

3121223 1230ES 3-5SECTION 3 MASTRef. Note: Use p/n 1001092165 as replacement whenever possible. Combination of both types of pads may be used.210 0100

3-6 1230ES 3121223SECTION 3 MASTFIGURE 3-1. MAST INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 4-1SECTION 4PLATFORM

4-2 1230ES 3121223SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATION172120207242625213212219302303304SEE PAGE 2 FORGATE DOOR OPTIONSNOTE: REPLACEMENT

3121223 1230ES 4-3SECTION 4 PLATFORM 1416789121218222343233102315152922791141816B128C8BALL SPECS EXCEPTAUSTRALIAN SPECSAUSTRALIAN SPECS ONLYGEN

4-4 1230ES 3121223SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. PLATFORM INSTALLATION1001098653 Ref

3121223 1230ES 4-5SECTION 4 PLATFORMRef. KIT OPTIONS100 1001101322 1 Gate Latch Kit (Australian Spec Only) (Includes 1-2, 7, 10, 13-15, 16B, 18, 22, 2

3121223 1230ES iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6 1230ES 3121223SECTION 4 PLATFORMFIGURE 4-2.PLATFORM CONSOLE BOX INSTALLATION 27201A201B201C201D6100A100B100C1011021210110221910216171717831

3121223 1230ES 4-7SECTION 4 PLATFORMFIGURE 4-2. PLATFORM CONSOLE BOX INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0274554 Ref. CONSOLE BOX INS

4-8 1230ES 3121223SECTION 4 PLATFORM16 1 Plate, Decal Options:See Note USA Built Machines (Was p/n 1001091283)(Note: Use Item 100C, 101 or 102)See Not

3121223 1230ES 4-9SECTION 4 PLATFORMRef. PLATFORM BOX COVER INSTALLATION0273841 Ref. USA Built Machines Prior to S/N 0200196453 & All French Built

4-10 1230ES 3121223SECTION 4 PLATFORMFIGURE 4-3.DRIVE/STEER P/Q CONTROLLER ASSEMBLY 11D1B1C1G1E1A2A2E2B22C2D1F33A

3121223 1230ES 4-11SECTION 4 PLATFORMFIGURE 4-3. DRIVE/STEER P/Q CONTROLLER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.See Note Ref. P/Q CONTROL

4-12 1230ES 3121223SECTION 4 PLATFORMFIGURE 4-4.DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY 3412

3121223 1230ES 4-13SECTION 4 PLATFORMFIGURE 4-4. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.See Note 1 J.R.

4-14 1230ES 3121223SECTION 4 PLATFORMFIGURE 4-4. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 5-1SECTION 5CYLINDER ‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘

ii 1230ES 3121223FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS

5-2 1230ES 3121223SECTION 5 CYLINDERFIGURE 5-1.LIFT CYLINDER ASSEMBLY #3#2#1888212121222222252555514141423131313444121616191718121211111132B2A2

3121223 1230ES 5-3SECTION 5 CYLINDERFIGURE 5-1. LIFT CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684469 Ref. LIFT CYLINDER ASSEMBLY H1N

5-4 1230ES 3121223SECTION 5 CYLINDERFIGURE 5-2. STEER CYLINDER ASSEMBLY 1841115121315614161710442100

3121223 1230ES 5-5SECTION 5 CYLINDERFIGURE 5-2. STEER CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684458 Ref. STEER CYLINDER ASSEMBLY

5-6 1230ES 3121223SECTION 5 CYLINDERFIGURE 5-2. STEER CYLINDER ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 6-1SECTION 6HYDRAULIC

6-2 1230ES 3121223SECTION 6 HYDRAULICFIGURE 6-1.HYDRAULIC DIAGRAM 23101101201201313312312311STEERCYLINDERLIFTCYLINDERPUMP/MOTOR/TANK

3121223 1230ES 6-3SECTION 6 HYDRAULICFIGURE 6-1. HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.Ref. HYDRAULIC COMPONENTS0274581 Ref. Hydra

6-4 1230ES 3121223SECTION 6 HYDRAULICFIGURE 6-1. HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 7-1SECTION 7ELECTRICAL

3121223 1230ES 1-1SECTION 1 FRAME

7-2 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-1. ELECTRICAL SCHEMATIC (MACHINES WITH 1600346 DRIVE MODULE) ATTACH TOBRAKERELEASESWITCH

3121223 1230ES 7-3SECTION 7 ELECTRICAL 1870188 D1870188 FATTACH TO #1 ON CHARGERNOTE: THIS SCHEMATIC USED WITH 1600346 DRIVE MODULE. SEE PAGE A

7-4 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-2. ELECTRICAL SCHEMATIC (MACHINES WITH 1001092456 DRIVE MODULE)

3121223 1230ES 7-5SECTION 7 ELECTRICAL 1001114879 BNOTE: THIS SCHEMATIC USED WITH 1001092456 DRIVE MODULE. SEE REVISION LOG PAGE A OF THIS MANUA

7-6 1230ES 3121223SECTION 7 ELECTRICAL

3121223 1230ES 7-7SECTION 7 ELECTRICAL1001114879 BNOTE: THIS SCHEMATIC USED WITH 1001092456 DRIVE MODULE. SEE PAGE A OF THIS MANUAL FOR DRIVE MODULE

7-8 1230ES 3121223SECTION 7 ELECTRICAL1001114879 BNOTE: THIS SCHEMATIC USED WITH 1001092456 DRIVE MODULE. SEE PAGE A OF THIS MANUAL FOR DRIVE MODULE

3121223 1230ES 7-9SECTION 7 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK

7-10 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE MODULE) 408407POTHOLEPROTECTIO

3121223 1230ES 7-11SECTION 7 ELECTRICAL 404409309309309H501602A602E602F602P602C602D602J602H602G602M602B602K602LDRIVECONTROLLER504C504G504H504E504

1-2 1230ES 3121223SECTION 1 FRAMEFIGURE 1-1.STEERING AND DRIVE INSTALLATION 2082072062062062052042032022011021051011011071061041031031053111499

7-12 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE MODULE)ITEM # PART NUMBER QTY. DES

3121223 1230ES 7-13SECTION 7 ELECTRICAL305 3740150 1 Contactor Relay Harness (Includes Relay)305A 4460891 1 Plug, Male - 2 Position4460465 2 Socket, F

7-14 1230ES 3121223SECTION 7 ELECTRICAL309M 4460931 1 Receptacle, Female -8 Position4460464 2 Pin, Male 4460943 3 Pin, Male (Gold)0840058 1 Boot 29024

3121223 1230ES 7-15SECTION 7 ELECTRICAL503 Not Available 2 Harness, Motor (Internal Connections - Purchase Complete Motor)Not Available 2 Receptacle,

7-16 1230ES 3121223SECTION 7 ELECTRICAL507 cont’d 220V-50/60HZ (0274802, 0275769, 0275770, 0275771, 0275773, 0275774, 0275775 Installations) Options:3

3121223 1230ES 7-17SECTION 7 ELECTRICAL507E A/R Cover Options:1671207 1 0274556 InstallationsNot Available 0 0274802 Installations (Purchase Component

7-18 1230ES 3121223SECTION 7 ELECTRICAL507H cont’d 4461205 1 0275770/0275775 Installations & 1001100344/ 1001141970 Service Kits 507J A/R Receptac

3121223 1230ES 7-19SECTION 7 ELECTRICAL508 4923602 1 Field Wire Connection Harness B508A 4461260 2 Receptacle, Female - 1 Position 4460508 2 Pin, Mal

7-20 1230ES 3121223SECTION 7 ELECTRICAL602M 1001091478 1 Plug, Male - 4 Position602N 4923391 1 Data Interface Harness (Internal Part of Inverter) D602

3121223 1230ES 7-21SECTION 7 ELECTRICALFIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE MODULE) (CONTINUED)ITEM # PART NUM

3121223 1230ES 1-3SECTION 1 FRAMEFIGURE 1-1. STEERING AND DRIVE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.0274549 Ref. STEERING AND DRIVE I

7-22 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456 DRIVE MODULE) POTHOLEPROTECTIONSW

3121223 1230ES 7-23SECTION 7 ELECTRICAL 404409309602A602E602F602P602C602D602J602H602G602BRELAY504C504G504H504E504D309H309H309D309A504B504ABATTERY

7-24 1230ES 3121223SECTION 7 ELECTRICALFIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456 DRIVE MODULE)ITEM # PART NUMBER QTY.

3121223 1230ES 7-25SECTION 7 ELECTRICALRef. GROUND CONTROL COMPONENTS301 0140043 1 Alarm and Harness (Separate Harness Not Available)301A 4460536 1 Re

7-26 1230ES 3121223SECTION 7 ELECTRICAL309S 1001118322 2 Connector - 6 Position91013191 4 Terminal4460464 8 Pin, Male 1001117837 Ref. BATTERY CABLE KI

3121223 1230ES 7-27SECTION 7 ELECTRICAL504 Ref. Battery Charger Components:504A Not Available DC Harness/Cord Set 504B 4460648 1 Plug, Anderson 504C N

7-28 1230ES 3121223SECTION 7 ELECTRICAL507C A/R AC Receptacle Box Kit Options:2902431 1 0274556 Installations Switch Box/Receptacle Kit (Includes Item

3121223 1230ES 7-29SECTION 7 ELECTRICAL507F cont’d 4461246 1 0275771 Installations (Includes Cover)4461244 1 0275769 Installations (Includes Cover)100

7-30 1230ES 3121223SECTION 7 ELECTRICAL507M 3380766 1 Shield, Circuit Breaker Mounting (Required Only on CE Spec Installations Except 0274802 Installa

3121223 1230ES 7-31SECTION 7 ELECTRICAL602E Not Available 1 Remote Control Harness (Internal Part of Inverter)602F Not Available 1 Plug, Male - 8 Posi