JLG Boom Lift 1230ES Service & Maintenance Manual 3121222 2025

[Hyundai]

Download this document, you need 2725 Gallons

JLG Boom Lift 1230ES Service & Maintenance Manual 3121222 2025
Size: 12.10 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 1230ES Boom Lift
Serial Number:
0130000001 to Present
0200000001 to Present
1200000001 to Present
A200006116 to Present
M130000001-M130008778
Part Number: 3121222
Publication Date: 2025
Number of Pages: 206 Pages

Contents:
Section A. Introduction - Maintenance Safety Precautions

General​

Hydraulic System Safety​

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​

Hydraulic Oil 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​

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​

1. Hydraulic Pump/Tank/Valve Assy.​

2. Steering Linkage Assembly​

3. Drive Motor/Spindle Assemblies​

4. Pot Hole Protection Assembly​

5. Static Strap​

6. Steer Cylinder Assembly​

7. Left Side (Battery Tray) Door​

8. Right Side (Battery Tray) Door​

9. Rear Wheel Assembly​

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​

1. Hub Cap​

2. Cotter Pin​

3. Spindle Nut​

4. Washer​

5. Outer Tapered Roller Bearing (a)​

6. Outer Bearing Race (a)​

7. Wheel Mounting Hub (a)​

8. Inner Bearing Race (a)​

9. Inner Tapered Roller Bearing (a)​

10. Hub Seal​

4.5 STEERING LINKAGE ASSEMBLY - INSTALLATION​

1. Left Steering Knuckle Lug​

2. Left Steering Arm Link​

3. Right Steering Arm Link​

4. Right Steering Knuckle Lug​

5. Steering Cross Link​

6. Hydraulic Steer Cylinder​

7. Steer Cylinder Anchor Pin​

8. Cross Link Anchor Pin​

9. Steer Cylinder - Steer Right Port​

10. Steer Cylinder - Steer Left Port​

11. King Pin​

12. Steering Knuckle Stop​

4.6 STEER CYLINDER - SERVICING​

1. Rod End Bushing​

2. Cylinder Head (Gland) (a)​

3. O’Ring Seal​

4. Backing Ring​

5. O’Ring Seal​

6. Cylinder Rod​

7. Piston (b)​

8. Piston Seal​

9. Bushing​

10. Piston Set Screw​

11. Main Gland Seal​

12. Wiper Seal​

13. O’Ring Seal​

Steer Cylinder Disassembly​

Hydraulic Cylinder Component Inspection​

Steer Cylinder - Assembly​

4.7 DRIVE MOTOR/SPINDLE ASSEMBLY - INSTALLATION​

1. DriveMotor/Spindle Assembly​

2. 60mm External Retaining Ring​

3. Spindle Retaining Washer​

4. Knuckle Lug Attach Screws (a)​

5. 60mm Thrush Washer​

6. King Pin (welded to frame) (b)​

7. Steering Knuckle Lug​

8. Drive Motor Power Harness (c)​

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​

1. PHP Actuator (Platform)​

2. Right/Left PHP Limit Switch​

3. Right Side Counterbalance Link​

4. Left Side Counterbalance Link​

5. PHP Link Plate​

6. Right PHP Bar​

7. Left PHP Bar​

8. Spacer Tube and Torsion Springs​

1. Actuator Attach Screws/Nuts​

2. PHP Actuator Assembly​

3. Limit Switch (a)​

4. Limit Switch Mounting Block (b)​

5. Limit Switch Attach Screws​

6. Torsion Spring (c)​

7. Tube Spacer​

8. Counterbalance Link Mounting Pin​

9. Pin Retaining Ring​

10. Left Side Countbalance Link​

1. Actuator Attach Screws/Nuts​

2. PHP Actuator Assembly​

3. Limit Switch (a)​

4. Limit Switch Mounting Bracket (b)​

5. Limit Switch Attach Screws​

6. Torsion Spring (c)​

7. Tube Spacer​

8. Counterbalance Link Mounting Pin​

9. Pin Retaining Ring​

10. Left Side Countbalance Link​

Section 5. CONTROL COMPONENTS

5.1 CONTROL COMPONENTS OVERVIEW​

1. Platform Control Station​

2. Ground Control Station​

3. Manual Brake Release Switch​

4. Battery Charger or Inverter/Charger​

5. Warning Beacon​

6. Right Side Batteries​

7. Ground Alarm​

8. Power Module​

9. Main Contactor Power Relay​

10. Elevation Cut-Back Sensor​

11. Left Side Batteries​

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​

1. Power Module​

2. Mounting Screws​

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​

1. Battery Charger Assembly​

2. Attach Screws/Washers​

3. AC Voltage - Input Cable​

4. LED/Power/Interlock Cables​

1. Charger Interlock Cable​

2. DC Power Cable to Batteries​

3. LED Indicator, Battery Temp. Sensor Cable​

1. Charger Interlock Cable​

2. DC Power Cable to Batteries​

3. LED Indicator, Battery Temp. Sensor Cable​

4. IEC End​

Battery Charger Troubleshooting​

5.10 BATTERY CHARGER/INVERTER (OPTION) - INSTALLATION​

1. Charger/Inverter Assembly​

2. Insulate Mounting Pad​

3. Attach Screws (a)​

4. Nylon Shoulder Washers​

1. AC Output Connector​

2. AC Input Connector​

3. Remote On/Off Switch Cable​

4. External DC Fuse Location​

5. DC (–) Connection​

6. DC (+) Connection​

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​

1. Platform/Outer Mast Section​

2. Outer Mid Mast Section​

3. Inner Mid Mast Section​

4. Mount/Inner Mast Section​

5. Hydraulic Cylinder #1​

6. Hydraulic Cylinder #2​

7. Hydraulic Cylinder #3​

8. Top (External) Slide Pads​

9. Power-Trak System​

10. Power-Trak Guide​

11. Power-Trak Shield Assy​

12. Bottom (Internal) Slide Pads​

1. Front of Machine​

2. Rear of Machine​

3. Platform/Outer Mast Section​

4. Outer Mid Mast Section​

5. Inner Mid Mast Section​

6. Mount/Inner Mast Section​

7. Hydraulic Cylinder Compartment​

8. Power-Trak Compartment​

9. Cylinder #1 Bleeder Valve​

10. Cylinder #2 Bleeder Valve​

11. Cylinder #3 Bleeder Valve​

12. Corner Slide Pads (a)​

6.6 PLATFORM ASSEMBLY​

Platform - Extending Mast Unpowered​

Platform Removal​

Platform Installation​

6.7 MAST ASSEMBLY​

1. Mast Assembly​

2. Fastening Hardware​

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 Electrical Schematics​

9.12 PIN INPUT/OUTPUT TYPES​

9.12 AC POWER RECEPTACLES AND WIRING (PLATFORM) - CE SPEC MACHINES ONLY​

9.13 HYDRAULIC SCHEMATIC​