JLG 1230ES Vertical Mast Service Manual
206 pages · Publication 3121222
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- Models
- 1230ES
- Serial coverage
- Prior to M130008779, 0130000001 to Present, 0200000001 to Present, 1200000001 to, Present, A200006116 to Present
- Manual type
- Service Manual
- Pages
- 206
- Publication
- 3121222
- Condition
- Brand new
What's inside
From the manual's own table of contents: 250 sections, 318 entries. See sample pages (PDF, 632 KB)
General1 topic
- OPERATING SPECIFICATIONS
Platform Capacities
Dimensional Data
Tires
Batteries
Critical Stability Weights1 topic
- LUBRICATION
Lubrication Capacities
Hydraulic Oil
Lubrication Specifications
Hydraulic Oil Specifications
Oil Check Procedure4 topics
- CYLINDER SPECIFICATIONS
- TORQUE REQUIREMENTS
- SERIAL NUMBER LOCATIONS
- MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance2 topics
- PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
- SERVICING AND MAINTENANCE GUIDELINES
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Show all 251 sections
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication and Servicing1 topic
- LUBRICATION INFORMATION
Changing Hydraulic Oil2 topics
- OVERVIEW
- MODES OF OPERATION
Ground Mode
Platform mode2 topics
- TABLE OF CONTENTS CAN COMMUNICATIONS
- CONTROLS & SENSORS
Elevation
Joystick
Tilt1 topic
- TRACTION
Personalities
Interlocks4 topics
- PUMP/LIFT/MAST
- STEER
- BASE ASSEMBLY COMPONENTS
- BASE FRAME COVERS
Base Top Cover - Installation
Step Plate/Battery Charger Cover - Installation
Battery Tray/Side Door - Installation1 topic
- WHEELS AND TIRES - DRIVE AND REAR
Tire Wear and Damage
Wheel and Tire Replacement
Wheel Installation3 topics
- REAR WHEEL HUB - INSTALLATION
- STEERING LINKAGE ASSEMBLY - INSTALLATION
- STEER CYLINDER - SERVICING
Steer Cylinder Disassembly
Hydraulic Cylinder Component Inspection
Steer Cylinder - Assembly2 topics
- DRIVE MOTOR/SPINDLE ASSEMBLY - INSTALLATION
- 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 Assembly1 topic
- HYDRAULIC PUMP/MOTOR/VALVE ASSEMBLY - SERVICE PROCEDURE
Common Difficulties
Pump Components1 topic
- TABLE OF CONTENTS 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 Installation3 topics
- POT HOLE PROTECTION SYSTEM
- CONTROL COMPONENTS OVERVIEW
- 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)1 topic
- TRACTION SYSTEM
Common Traction System Difficulties
Removal
Installation
Power Module Electrical Evaluation
Power Module Diagnostics
ZAPI Power Module Electrical Evaluation1 topic
- GROUND CONTROL MODULE - SERVICE PROCEDURE
Ground Control Station
Printed Circuit Board (PCB) Replacement1 topic
- PLATFORM CONTROL STATION - SERVICE INFORMATION
Platform Control Station Assembly
Upper Control Box - Component Replacement
Lower Control Box - Component Replacement1 topic
- BATTERY/BATTERY CHARGER
Battery Maintenance and Safety Practices
Battery Installation1 topic
- BATTERY CHARGER - INSTALLATION
Battery Charger Troubleshooting7 topics
- BATTERY CHARGER/INVERTER (OPTION) - INSTALLATION
- MAST COMPONENTS OVERVIEW
- PLATFORM TOOL TRAY - INSTALLATION
- MAST COVER PLATE - INSTALLATION
- PLATFORM AC RECEPTACLE BOX - INSTALLATION
- MAST ASSEMBLY - COMPONENTS
- PLATFORM ASSEMBLY
Platform - Extending Mast Unpowered
Platform Removal
Platform Installation1 topic
- MAST ASSEMBLY
Mast Removal1 topic
- TABLE OF CONTENTS Mast Disassembly
Mast - Reassembly
Mast Installation
Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure
Mast Installation Completion1 topic
- MULTI-STAGE HYDRAULIC CYLINDER - SERVICING
Overview
Hydraulic Cylinder - Disassembly
Hydraulic Cylinder - Assembly
Hydraulic Cylinder Assembly Testing1 topic
- 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)3 topics
- MACHINE CONFIGURATION PROGRAMMING INFORMATION
- MACHINE PERSONALITY - ADJUSTMENT SETTINGS
- TILT SENSOR CALIBRATION
Ground Module Software Version 1.5
Ground Module Software Version 1.4
Calibration Failures2 topics
- TILT SENSOR ELECTRICAL EVALUATION
- ELEVATION ANGLE SENSOR ELECTRICAL EVALUATION
Tilt vs. Allowed Height Evaluation5 topics
- ELEVATION SENSOR CALIBRATION
- INTRODUCTION
- X-CONNECTOR REFERENCES
- DTC INDEX
- 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 Hardware2 topics
- GENERAL
- TABLE OF CONTENTS MULTIMETER BASICS
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements
Procedure1 topic
- ELECTRICAL SWITCH TESTING
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side1 topic
- APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading1 topic
- WORKING WITH DEUTSCH CONNECTORS
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly8 topics
- CONNECTOR LOADING DIAGRAMS
- X-CONNECTOR ID INDEX
- MACHINE LOCATION OF COMPONENT X-CONNECTORS
- ELECTRICAL LAYOUT AND SCHEMATICS
- ELECTRICAL SCHEMATICS
- PIN INPUT/OUTPUT TYPES
- AC POWER RECEPTACLES AND WIRING (PLATFORM) - CE SPEC MACHINES ONLY
- HYDRAULIC SCHEMATIC
Hydraulic Oil Check Procedure
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (METRIC Fasteners - Sheet 4 of 5)
Torque Chart (METRIC Fasteners - Sheet 5 of 5)
Platform Mast Support Tool
Basic Electronic Module Connections
Drive Motors Schematic - 1600346 (SEVCON) Power Module
Drive Motors Schematic - 1001092456 (ZAPI) Power Module
Lift System
Hydraulic Pump Electrical Schematic - 1600423 (SEVCON) Power Module
Steer System
Base Assembly Components
Wheel Lug Nut Tightening Sequence
Brake Manual Disengage Procedure
Drive Motor Side View
Drive Motor End View (Brake End)
Motor Terminal Assembly
Bearing Replacement Procedure
Main Electrical Power Connections - (1600346 - SEVCON Power Module)
Main Electrical Power Connections - (1001092456 - ZAPI Power Module)
Electrical Connections
Relief Pressure Setting Locations
Power Module - Installation
Sevcon Power Module Terminals
ZAPI Power Module Location
Ground Control Station Assembly
Tilt Sensor Location
Tilt Sensor Removal
Battery Fluid Level
Mast Components
(Mast shown cutaway for illustrative purposes only)
Mast Assembly - Orientation (Top View)
Extending Mast Unpowered
Platform to Mast - Installation
(Front of frame shown cutaway for illustrative purposes only)
Power-Trak - Removal
Hydraulic Cylinder Bottom End Bolts - Removal
Hydraulic Cylinder Connections - Removal
Hydraulic Cylinder Top End Bolts - Removal
Hydraulic Cylinder - Removal
Mast Sections - Disassembly
1230ES Lift Cylinder Internal Components - Top End
1230ES Lift Cylinder Internal Components - Lower End
Valve Block - Removal
Cylinder #2 and #3 Assembly - Removal
Cylinder Rod/Gland - Removal
Cylinder Rod Piston - Removal
Cyl. #2/3 to Cylinder Joint Assembly
(Machines Equipped with ZAPI - 1001092456 Power Module Only)
Voltage Measurement (DC)
Resistance Measurement
Continuity Measurement
Current Measurement (DC)
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
1230ES - Location of Component X-Connectors on Machine
1230ES - Location of Component X-Connectors on Ground Control Module
1230ES - Overview of Electrical System Components. (1600346 Drive Module)
1230ES - Overview of Electrical System Components. (1001092456 Drive Module)
Electrical Schematic - (Machines with 1600346 Drive Module)
Electrical Schematic - (Machines with 1001092546 Drive Module)
Electrical Schematic (Ground Control Module) - (Machines with 1001092546 Drive Module)
Battery Charger/Inverter Electrical Connection Schematic
Operating Specifications
Dimensions
Tire Specifications
Battery Specifications
Capacities
Nervofluid 15
Mobil DTE 10 Excel 15
Mobil EAL Environsyn H 32
Mobil SHC Hydraulic EAL 32
Cylinder Specifications
Maintenance and Inspection Requirements
Preventive Maintenance & Inspection Schedule
Wheel Torque Chart
Hydraulic Pressure Settings
ZAPI Power Module Specs
Module Terminal Functions
Tilt Sensor Harness for 1810140
Tilt Sensor Harness for 1001114936
Battery Algorithms
Machines Equipped with Sevcon (1600346) Power Module ONLY
Machine Personality Adjustment - Machines Equipped with Sevcon (1600346) Power Module
Machine Personality Adjustment - Machines Equipped with ZAPI (1001092456) Power Module
Tilt Cutout Settings
Connector Loading Diagrams
X-Connector ID Index
Ground Board J1 - Connector X001 (1600346 Power Module ONLY)
Ground Board J2 - Connector X002
Ground Board J3 - Connector X003
Platform Board J1 - Connector X050
Platform Board J3
Platform Board J4
Power Module - Connector X027 (1600346 Power Module)
Power Module - J1 (1001092456 Power Module ONLY)
Power Module - J2 (1001092456 Power Module ONLY)
Inside this manual
Real pages from this service manual (206 pages). Open the sample pages (PDF, 629 KB)
- Specifications, page 14: SECTION 1 - MACHINE SPECIFICATIONS
- Repair procedure, page 50: SECTION 4 - BASE COMPONENTS
- Diagram, page 182: SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 90: SECTION 5 - CONTROL COMPONENTS
- Color page, page 19: SECTION 1 - MACHINE SPECIFICATIONS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 1230ES are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3121222$69.85
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 206 pages
Quantity one is the manual described above.
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Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).