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Illustrated Parts Manual
Model
1230ES
P/N
3121223
October 8, 2013
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 |
P/N |
1600346 |
1001092456 |
(Color: Blue) |
(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 STEERING AND DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 WHEEL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1-3 POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1-4 BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS . . . . . . . . . . . . . . 1-14 1-5 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-3 GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE
MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-4 GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE
MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-5 BATTERIES AND COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 MAST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-2 PLATFORM CONSOLE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4-3 DRIVE/STEER P/Q CONTROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4-4 DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 4-12
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-1 LIFT CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 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 ELECTRICAL SCHEMATIC (MACHINES WITH 1600346 DRIVE MODULE). . . . . . . . . 7-2 7-2 ELECTRICAL SCHEMATIC (MACHINES WITH 1001092456 DRIVE MODULE) . . . . . 7-4 7-3 ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346
DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7-4 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. |
TITLE |
PAGE NO. |
ii |
1230ES |
3121223 |
SECTION 1
FRAME
3121223 |
1230ES |
1-1 |
SECTION 1 FRAME
FIGURE 1-1.STEERING AND DRIVE INSTALLATION
106
104
1
3
208
207
206 206
206
205
204 202
201
|
102 |
|
|
|
203 |
11 |
|
|
11 |
|
|
4 |
|
|
9A |
|
|
9 |
|
|
9A |
2 |
|
|
|
|
13 10 |
16 |
|
2 |
14 |
105 |
15 |
|
101 |
10 |
|
|
7A |
7 |
|
107 |
|
|
15 |
8 |
|
7A |
8A |
|
|
6 |
|
|
|
|
|
|
12 |
|
5 |
|
15
103
103
101
105
1-2 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-1. STEERING AND DRIVE INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
|
REV. |
|
|
|
|
|
|
|
0274549 |
Ref. |
STEERING AND DRIVE INSTALLATION |
|
E |
1 |
0100019 |
A/R |
Compound, Locking |
|
|
2 |
0761016 |
4 |
Bolt M10 x 40mm |
|
|
3 |
0630606 |
2 |
Capscrew M12 x 25mm |
|
|
4 |
0903594 |
1 |
Bracket, Steering Knuckle (Right) |
|
|
5 |
0903595 |
1 |
Bracket, Steering Knuckle (Left) |
|
|
6 |
1684458 |
1 |
Steer Cylinder Assembly (See Section 5 for Breakdown) |
|
|
7 |
3010164 |
1 |
Link, Steering |
|
|
7A |
0440263 |
2 |
Bushing, Flange |
|
|
8 |
3010165 |
1 |
Arm, Steering (Left) |
|
|
8A |
0440263 |
2 |
Bushing, Flange |
|
|
9 |
3010166 |
1 |
Arm, Steering Right) |
|
|
9A |
0440263 |
2 |
Bushing, Flange |
|
|
10 |
3291005 |
2 |
Locknut M10 |
|
|
11 |
3423303 |
4 |
Pin, Linkage |
|
|
12 |
3423230 |
1 |
Pin, Clevis |
|
|
13 |
3423235 |
1 |
Pin, Clevis |
|
|
14 |
3423236 |
1 |
Pin, Clevis |
|
|
15 |
3760348 |
5 |
Ring, Retaining |
|
|
16 |
3841143 |
1 |
Keeper |
|
|
|
|
Ref. |
DRIVE INSTALLATION |
|
|
|
|
Ref. |
Note: For Module Identification, see note on Revision Log |
|
|
|
|
|
Page A before ordering parts. |
|
|
|
0274550 |
Ref. |
Machines with 1600346 Drive Module |
|
I |
|
1001118433 |
Ref. |
Machines with 1001092456346 Drive Module |
|
A |
101 |
0630580 |
20 |
Bolt, Wheel |
|
|
102 |
2780266 |
2 |
Hub Assembly (See Items 201-208 for Breakdown) |
|
|
103 |
|
2 |
Wheel Drive Assembly Options (See Figure 1-2 for Breakdown): |
|
|
|
|
Ref. |
Note: Requires identification of drive module before |
|
|
|
|
|
ordering parts. Refer to Revision Log Page A of this |
|
|
|
|
|
manual. |
|
|
|
1001092743 |
|
USA Built Machines with 1600346 Drive Module |
|
|
|
1001118359 |
|
USA Built Machines with 1001092456 Drive Module |
|
|
|
Use 1001092743 |
|
French Built Machines Prior to S/N A200007624 |
with |
|
|
|
|
1600346 Drive Module (was p/n 3160329) |
|
|
|
1001092743 |
|
French Built Machines S/N A200007624 to S/N A200009897 |
|
|
|
|
|
with 1600346 Drive Module |
|
|
|
1001118359 |
|
China Built Machines |
|
|
104 |
3760463 |
2 |
Ring, Retaining |
|
|
105 |
Use 2915012 |
4 |
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. |
|
|
106 |
4740523 |
2 |
Washer |
|
|
107 |
4740524 |
2 |
Washer |
|
|
108 |
4240018 |
2 |
Tie-Strap (Not Shown) |
|
|
109 |
1321682 |
2 |
Clamp, Worm (Not Shown - Used on Drive Motor Cable) |
|
|
|
|
|
|
|
|
3121223 |
1230ES |
1-3 |
SECTION 1 FRAME
FIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
110 |
4923602 |
1 |
Harness, Field Wire Connection (Not Shown - See Section 7 |
|
|
|
|
for Breakdown) |
|
|
2780266 |
Ref. |
HUB ASSEMBLY |
D |
|
|
Ref. |
Note: Quantities shown are for 1 assembly. Two Assemblies |
|
|
|
|
are required per machine. |
|
201 |
Use 1001102354 |
1 |
Cap, Dust (was p/n 7012524) |
|
202 |
Use 3300423 |
1 |
Nut, Slotted (was p/n 7010641) |
|
203 |
Use 3450406 |
1 |
Pin, Cotter 2” x 3/16” (was p/n 7010642) |
|
204 |
Use 4740468 |
1 |
Washer (was p/n 7019697) |
|
205 |
Use 1001102351 |
1 |
Bearing, Cone - Outer (was p/n 7026185) |
|
206 |
Not Available |
1 |
Hub (Purchase Complete Hub p/n 2780266) |
|
207 |
Use 1001102353 |
1 |
Bearing, Cone - Inner (was p/n 7026183) |
|
208 |
Use 1001102349 |
1 |
Seal (was p/n 7026184) |
|
|
|
|
|
|
1-4 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
3121223 |
1230ES |
1-5 |
SECTION 1 FRAME
FIGURE 1-2.WHEEL DRIVE ASSEMBLY
17
13 103
|
|
105 |
|
|
109 |
12 |
|
110 |
|
|
|
|
104 |
111 |
|
|
112
|
1 |
|
|
|
|
|
|
106 |
107 |
|
9 |
|
|
|
|
|
|
|
|
|
32 |
|
|
|
|
25 |
9 |
|
114 |
|
|
|
||
|
|
|
10 |
113 |
|
|
|
14 |
|
|
|
|
|
|
|
|
|
|
16 |
9 |
|
|
|
2 |
|
15 |
|
|
|
OR |
|
|
|
|
28 |
|
|
|
|
26A |
|
|
|
|
26B |
|
|
|
|
|
|
|
|
14 |
|
26B |
|
|
27 |
24 |
|
|
||
|
|
3 |
||
8 |
OR |
|
|
|
|
|
|
|
|
|
26A |
|
|
|
6 |
|
4 |
|
|
7 |
|
|
|
|
25 |
|
|
|
|
5 |
|
|
|
|
|
25 |
|
|
19 |
|
23 |
21 |
|
|
|
18 |
|
|
|
|
20 |
|
|
29 |
|
|
|
|
|
|
|
11 |
|
|
1-6 |
1230ES |
3121223 |
SECTION 1 FRAME
201 |
207 |
|
|
203 |
208 |
202 |
|
204 |
209 |
||
|
|||
205A |
210A |
|
|
205B |
210B |
|
|
205C |
211A |
|
|
205D |
211B |
|
|
206 |
|
|
|
|
GENUINE PARTS |
|
108A |
OR |
108B |
|
|
151
153
154
152
STYLE “A” |
STYLE “B” |
3121223 |
1230ES |
1-7 |
SECTION 1 FRAME
FIGURE 1-2. WHEEL DRIVE ASSEMBLY
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
Ref. |
WHEEL DRIVE ASSEMBLY |
|
|
|
Ref. |
Note: Due to service updates, drive motors may use any of |
|
|
|
|
the various parts listed below. Visual identification will be |
|
|
|
|
required. |
|
|
|
Ref. |
Note: Requires identification of drive module before |
|
|
|
|
ordering parts. Refer to Revision Log Page A of this |
|
|
|
|
manual. |
|
|
Use 1001092743 |
Ref. |
French Built Machines Prior to S/N A200007624 with |
D/F |
|
|
|
1600346 Drive Module (was p/n 3160329) |
|
|
1001092743 |
Ref. |
French Built Machines S/N A200007624 to S/N A200009897 |
D |
|
|
|
with 1600346 Drive Module |
|
|
1001092743 |
Ref. |
USA Built Machines with 1600346 Drive Module |
D |
|
1001118359 |
Ref. |
USA Built Machines with 1001092456 Drive Module |
A |
|
1001118359 |
Ref. |
China Built Machines with 1001092456 Drive Module |
A |
|
|
Ref. |
HUB ASSEMBLY |
|
1 |
Not Available |
1 |
Spindle |
|
2 |
Use Item 206 |
1 |
Hub |
|
3 |
Use Item 204 |
1 |
Ring, Input |
|
4 |
Use Item 203 |
1 |
Gear, Input Sun |
|
5 |
Use Item 203 |
3 |
Gear, Input Planet |
|
6 |
Use Item 203 |
3 |
Pin, Planet Gear |
|
7 |
Use Item 203 |
1 |
Carrier |
|
8 |
Use Item 203 |
1 |
Gear, Output Sun |
|
9 |
Use Item 207 |
3 |
Gear, Output Planet |
|
10 |
Use Item 207 |
3 |
Pin, Output Planet |
|
11 |
Use Item 201 |
1 |
Cover |
|
12 |
7024757 |
1 |
Bushing Kit, Kingpin (Includes 2 Bushings) |
|
13 |
See Note |
1 |
Motor, Electric (Note: Use item 205A, 205B or 205C) |
|
14 |
See Note |
2 |
Bearing, Main (Note: Use Item 202, 204, 206 or 207) |
|
15 |
Use Item 207 |
1 |
Bearing, Shaft |
|
16 |
70001739 |
1 |
Seal, Lip |
|
17 |
7024786 |
1 |
Seal, Lip |
|
18 |
Use Item 203 |
3 |
Ring, Retaining |
|
19 |
Use Item 201 |
1 |
Ring, Retaining |
|
20 |
70000191 |
1 |
O-Ring |
|
21 |
Use Item 201 |
1 |
Thrustwasher |
|
22 |
Not Used |
|
|
|
23 |
Use Item 203 |
1 |
Plate, Thrust |
|
24 |
Use Item 203 |
1 |
Ring, Retaining |
|
25 |
See Note |
9 |
Thrustwasher (Note: Use Item 203 or 207) |
|
26 |
See Note |
A/R |
Bearing/Bushing Options (Note: Use Item 203 or 207): |
|
26A |
|
66 |
Bearing, Needle |
|
26B |
|
6 |
Bushing |
|
27 |
See Note |
1 |
Ring, Retaining (Note: Use Item 204, 206 or 207) |
|
28 |
Use Item 207 |
1 |
Ring, Retaining |
|
29 |
Use Item 201 |
2 |
Plug |
|
30 to 31 |
Not Used |
|
|
|
32 |
Use Item 207 |
3 |
Washer, Tanged |
|
|
|
|
|
|
1-8 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
Ref. |
BRAKE & MOTOR COMPONENTS |
|
101 to 102 |
Not Used |
|
|
|
103 |
Use Item 208 |
1 |
Brush & Terminal Assembly |
|
104 |
70000790 |
2 |
Spring, Brush |
|
105 |
70000791 |
1 |
Box, Brush |
|
106 |
Use Item 208 |
1 |
Ring, Retaining |
|
107 |
Use Item 208 |
1 |
Bearing |
|
108 |
|
1 |
Harness, Electrical Cable Options: |
|
|
|
Ref. |
Note: Requires identification of drive module before |
|
|
|
|
ordering parts when equipped with item 108B style cable. |
|
|
|
|
Refer to Revision Log Page A. |
|
108A |
Use 1001093652 |
|
Hub with Item 108A Style Cable (was p/n 7024770) |
|
108B |
1001093652 |
|
Hub with Item 108B Style Cable & 1600346 Drive Module |
|
108B |
1001118363 |
|
Hub with Item 108B Style Cable & 1001092456 Drive |
|
|
|
|
Module |
|
109 |
70000792 |
1 |
Commutator |
|
110 |
Use Item 209 |
1 |
Disc, Reaction |
|
111 |
7024785 |
1 |
Disc, Friction |
|
112 |
Use Item 209 |
1 |
Brake Assembly |
|
113 |
Use Item 210 |
2 |
Flatwasher |
|
114 |
Use Item 210 |
2 |
Bolt |
|
115 to 124 |
Not Used |
|
|
|
|
|
|
— — — — — — — — — — |
|
|
|
Ref. |
Style “A” Brake Cover |
|
125 |
Use Item 211A |
1 |
Plate, Cover |
|
126 |
See Note |
1 |
O-Ring (Note: Use Item 210 or 211A) |
|
127 |
70000383 |
1 |
Connector, Strain Relief |
|
128 |
Use Item 211A |
1 |
Cover |
|
129 to 150 |
Not Used |
|
|
|
|
|
|
— — — — — — — — — — |
|
|
|
Ref. |
Style “B” Brake Cover |
|
151 |
Use Item 211B |
1 |
Plate, Cover |
|
152 |
70001949 |
1 |
Gasket, Cover |
|
153 |
Use item 211B |
1 |
Cover, Top |
|
154 |
Use Item 211B |
1 |
Cover, End |
|
|
|
Ref. |
KIT OPTIONS |
|
201 |
7024747 |
1 |
Cover Kit (Includes Items 11,19, 20,21 & 29) |
|
202 |
7024748 |
1 |
Main Seal Kit (Includes Qty 1 of Items 14,16 & 20) |
|
203 |
7024749 |
1 |
Input Carrier Kit (Includes Items 4-8,18,20 & 23-26) |
|
204 |
7024758 |
1 |
Input Ring Kit (Includes Item 3,20,27 & Qty 1 of Item 14) |
|
205 |
|
1 |
Motor Kit Options (Includes Items 13,17,103-114 & 151-154): |
|
205A |
Use 1001100819 |
|
French Built Machines Prior to S/N A200007624 (was p/n |
|
|
|
|
3160329) |
|
205B |
|
|
French Built Machines Options S/N A200007624 to S/N |
|
|
|
|
A200009897: |
|
|
70001347 |
|
Wheel Drive Assembly 1001092743 |
|
|
70002308 |
|
Wheel Drive Assembly 1001118359 |
|
|
|
|
|
|
3121223 |
1230ES |
1-9 |
SECTION 1 FRAME
FIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
205C |
|
|
USA Built Machines Options: |
|
|
70001347 |
|
Wheel Drive Assembly 1001092743 |
|
|
70002308 |
|
Wheel Drive Assembly 1001118359 |
|
206 |
7024756 |
1 |
Hub Kit (Includes Items 2,16,20,27 & Qty 1 of Item 14) |
|
207 |
7024750 |
1 |
Output Planet Kit (Includes Items 9,10,15,20,25-28,32 & Qty 1 |
|
|
|
|
of Item 14) |
|
208 |
7024771 |
1 |
Motor Brush & Bearing Kit (Includes Items 103, 106 & 107) |
|
209 |
7024772 |
1 |
Brake Kit (Includes Items 110, 111 & 112) |
|
210 |
7024773 |
1 |
Motor Hardware Kit (Includes 113, 114 & 126) |
|
211 |
|
1 |
Brake Cover Kit Options: |
|
211A |
7024787 |
|
Style “A” (Includes Items 125 - 128) |
|
211B |
70001265 |
|
Style “B” (Includes Items 151 - 154) |
|
|
|
|
|
|
1-10 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
3121223 |
1230ES |
1-11 |
SECTION 1 FRAME
FIGURE 1-3. POTHOLE PROTECTION INSTALLATION
|
|
1 |
|
16 |
|
|
|
18 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
3 |
|
|
|
|
|
9 |
20 |
|
|
14 |
|
|
|
|
|
|
27 |
|
|
|
|
|
|
2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
22 |
|
23 |
|
|
|
|
|
|
|
26 |
|
|
|
|
|
|
|
17 |
21 |
10 |
|
|
|
|
|
|
|
||
7 |
|
|
|
|
|
|
|
7A |
|
|
|
|
|
|
24 |
|
|
|
15 |
|
|
|
|
|
|
5 |
|
|
|
|
|
|
|
|
|
|
|
13 |
|
|
|
8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
8A |
|
|
|
|
|
|
|
|
|
19 |
|
|
|
|
|
|
13 |
6 |
|
|
4A |
|
|
|
|
|
|
|
13 |
|
|
10 |
|
6A |
|
|
11 |
|
|
25 |
|
|
|
|
19 |
|
|
5 |
|
|
|
|
|
|
13 |
19 |
|
4A |
|
||
|
|
|
|
|
|||
|
|
|
13 |
|
|
|
|
|
|
4A |
|
|
|
|
|
|
|
12 |
|
|
|
|
4 |
|
|
|
|
|
|
|
|
1-12 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-3. POTHOLE PROTECTION INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
0274564 |
Ref. |
POTHOLE PROTECTION INSTALLATION |
G |
1 |
0060084 |
1 |
Actuator |
|
2 |
0100035 |
A/R |
Compound, Locking |
|
3 |
0630587 |
2 |
Bolt, Carriage M6 x 25mm |
|
4 |
3010145 |
1 |
Bar, Pothole (Left) |
|
4A |
0440263 |
2 |
Bushing, Flange |
|
5 |
3010146 |
2 |
Link |
|
6 |
3010147 |
2 |
Link, Actuator (Left) |
|
6A |
0440263 |
1 |
Bushing, Flange |
|
7 |
3010152 |
1 |
Bar, Pothole (Right) |
|
7A |
0440263 |
2 |
Bushing, Flange |
|
8 |
3010153 |
2 |
Link, Actuator (Right) |
|
8A |
0440263 |
1 |
Bushing, Flange |
|
9 |
3290605 |
2 |
Locknut M6 |
|
10 |
3423189 |
2 |
Pin |
|
11 |
3423230 |
2 |
Pin |
|
12 |
3423231 |
2 |
Pin |
|
13 |
3760348 |
10 |
Ring, Retaining |
|
14 |
3841703 |
1 |
Rod, Actuator |
|
15 |
4010415 |
4 |
Screw M4 x 35mm |
|
16 |
4160160 |
1 |
Spring |
|
17 |
4220258 |
1 |
Pad, Actuator |
|
18 |
4569225 |
1 |
Tube, Actuator |
|
19 |
4569238 |
4 |
Spacer |
|
20 |
4811700 |
2 |
Flatwasher M6 |
|
21 |
3290405 |
4 |
Locknut M4 |
|
22 |
4031709 |
4 |
Capscrew M6 x 25mm |
|
23 |
4220308 |
2 |
Spacer |
|
24 |
4160222 |
1 |
Spring (Right) |
|
25 |
4160223 |
1 |
Spring (Left) |
|
26 |
4811400 |
2 |
Flatwasher M4 |
|
27 |
|
2 |
Switch, Limit Options: |
|
|
|
Ref. |
Note: Requires identification of drive module before |
|
|
|
|
ordering parts. Refer to Revision Log Page A of this |
|
|
|
|
manual. |
|
|
Use 1001115448 |
|
Switch for Machines with 1600346 Drive Module (USA Built |
|
|
|
|
Machines Prior to S/N 0200195926) (was p/n 4360633) |
|
|
1001109088 |
|
Switch for Machines with 1600346 Drive Module (USA Built |
|
|
|
|
Machines S/N 0200195926 to Present) |
|
|
Use 1001115448 |
|
Switch for Machines with 1600346 Drive Module (French Built |
|
|
|
|
Machines) (was p/n 4360633) |
|
|
1001109088 |
|
Switch for Machines with 1001092456 Drive Module |
|
|
|
|
|
|
3121223 |
1230ES |
1-13 |
SECTION 1 FRAME
FIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS
2
4
8
6
7
101
104
212 213
301
202
101
OR
|
205 |
|
|
206 |
|
103 |
201 |
|
102 |
||
203 |
1-14 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
0274558 |
Ref. |
BEACON LIGHT INSTALLATION (OPTIONAL) |
D |
1 |
Not Used |
|
|
|
2 |
2920161 |
1 |
Light, Beacon |
|
|
7016319 |
1 |
Bulb, Replacement |
|
|
7016372 |
1 |
Len, Replacement |
|
3 |
Not Used |
|
|
|
4 |
4060865 |
1 |
Guard, Strobe |
|
5 |
Not Used |
|
|
|
6 |
4191406 |
2 |
Screw M4 x 12mm |
|
7 |
4191706 |
2 |
Screw M6 x 12mm |
|
8 |
4341144 |
1 |
Mount, Beacon |
|
|
0274562 |
Ref. |
BATTERY CHARGER INSTALLATION |
D |
101 |
|
1 |
Battery Charger Assembly |
|
|
|
Ref. |
Note: Cable ends are the only serviceable parts. See |
|
|
|
|
Section 7 for call-outs. |
|
|
Use 1001128737 |
|
USA Built Machines Prior to S/N 0200197381 (was p/n |
|
|
|
|
0400238 - Kit p/n 1001128737 includes Charger and Battery |
|
|
|
|
Temperature Sensor Kit) |
|
|
1001112111 |
|
USA Built Machines S/N 0200197381 to Present |
|
|
Use 1001128737 |
|
French Built Machines (was p/n 0400238 - Kit |
|
|
|
|
p/n 1001128737 includes Charger and Battery Temperature |
|
|
|
|
Sensor Kit) |
|
|
1001112111 |
|
China Built Machines |
|
102 |
4191706 |
2 |
Screw M6 x 12mm |
|
103 |
4811700 |
2 |
Flatwasher M6 |
|
|
0274563 |
Ref. |
BATTERY CHARGER/INVERTER COMBINATION INSTALLA- |
E |
|
|
|
TION (ANSI & CSA SPECS OPTION) |
|
201 |
0100011 |
A/R |
Compound, Locking |
|
202 |
1001093839 |
1 |
Battery Charger/Inverter Assembly (was p/n 0400237) |
|
203 |
0760812 |
4 |
Screw M8 x 25mm |
|
204 |
Not Used |
|
|
|
205 |
2820239 |
1 |
Pad, Insulator |
|
206 |
4740562 |
4 |
Flatwasher |
|
207 to 211 |
Not Used |
|
|
|
212 |
1706749 |
1 |
Decal - Inverter |
|
213 |
1706750 |
1 |
Decal - On/Off Inverter |
|
214 |
1706765 |
1 |
Decal - Hazardous Voltage (Not Shown - Located on Mast Cover |
|
|
|
|
Near AC Receptacle) |
|
301 |
Use 2915230 |
1 |
BATTERY CHARGER REPROGRAM CONTROLLER KIT FOR |
|
|
|
|
DELTA-Q CHARGER ONLY (WAS P/N 1600466) |
|
|
|
|
|
|
3121223 |
1230ES |
1-15 |
SECTION 1 FRAME
FIGURE 1-5.FRAME COVERS INSTALLATION
|
2 |
|
12 |
|
5 |
2 |
2 |
|
|
12 |
12 |
|
2
12 
106
111
3
12
4 |
9 |
|
3
12
11
4
8
1-16 |
1230ES |
3121223 |
SECTION 1 FRAME
FIGURE 1-5. FRAME COVERS INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
0274560 |
Ref. |
FRAME COVERS INSTALLATION |
I |
1 |
Not Used |
|
|
|
2 |
4191708 |
4 |
Bolt M6 x 20mm |
|
3 |
0760614 |
4 |
Bolt M6 x 30mm |
|
4 |
3290605 |
4 |
Locknut M6 |
|
5 |
3380604 |
1 |
Panel, Top Cover |
|
6 to 7 |
Not Used |
|
|
|
8 |
3380619 |
1 |
Cover, Charger |
|
9 |
3575919 |
1 |
Plate, Step |
|
10 |
Not Used |
|
|
|
11 |
4420070 |
1 |
Tape, Anti-Skid |
|
12 |
4811700 |
A/R |
Flatwasher 6mm |
|
|
|
Ref. |
PLATFORM BUMPER INSTALLATION |
|
|
1001098653 |
Ref. |
All Specs Except Australian & CE Specs USA Built Machines |
G |
|
|
|
Prior to S/N 0200196530 & All French Built Machines |
|
|
0274552 |
Ref. |
All Specs Except Australian & CE Specs USA Built Machines |
Q |
|
|
|
S/N 0200196530 to Present & All China Built Machines |
|
|
1001100633 |
Ref. |
Australian Specs |
C |
|
0274552 |
Ref. |
CE Specs |
Q |
101 to 105 |
Not Used |
|
|
|
106 |
1001008575 |
2 |
Bumper (was p/n 0940088) |
|
|
|
Ref. |
Note: Recommend purchasing item 111 Nut when replacing |
|
|
|
|
Bumper. |
|
107 to 110 |
Not Used |
|
|
|
111 |
3290805 |
2 |
Nut M8 |
|
|
|
|
|
|
3121223 |
1230ES |
1-17 |
SECTION 1 FRAME
FIGURE 1-5. FRAME COVERS INSTALLATION (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
1-18 |
1230ES |
3121223 |
SECTION 2
GROUND COMPONENTS
3121223 |
1230ES |
2-1 |
SECTION 2 GROUND COMPONENTS
FIGURE 2-1.PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION
5
5A
5C
6A |
106 |
6B |
|
5B |
201 |
2 |
|
|
|
|
|
|
10 |
8 |
|
11 |
|
9 |
105 |
|
|
|
1A |
|
|
|
|
|
7 |
|
|
11 |
|
|
1 |
3A |
101 |
12 |
13 |
12 |
|
|
|
|
|
6 |
6C |
|
107 |
|
|
|
|
4 |
|
|
|
|
|
3 |
|
2-2 |
1230ES |
3121223 |
SECTION 2 GROUND COMPONENTS
FIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
Ref. |
PUMP/MOTOR/TANK ASSEMBLY |
|
|
3600432 |
Ref. |
French Built Machines Prior to S/N A200009318 (Original |
I |
|
|
|
Equipment) |
|
|
1001101832 |
Ref. |
French Built Machines Prior to S/N A200009318 (Service |
A |
|
|
|
Replacement) |
|
|
1001101831 |
Ref. |
French Built Machines S/N A200009318 to S/N A200009897 |
C |
|
3600432 |
Ref. |
USA Built Machines Prior to S/N 0200189255 (Original |
I |
|
|
|
Equipment) |
|
|
1001101832 |
Ref. |
USA Built Machines Prior to S/N 0200189255 (Service |
A |
|
|
|
Replacement) |
|
|
1001101831 |
Ref. |
USA Built Machines S/N 0200189255 to Present |
C |
|
1001101831 |
Ref. |
China Built Machines S/N B20000100 to Present |
C |
|
|
Ref. |
NOTE: ORIGINAL EQUIPMENT ASSEMBLY P/N 3600432 MAY |
|
|
|
|
HAVE BEEN REPLACED WITH SERVICE REPLACEMENT |
|
|
|
|
ASSEMBLY P/N 1001101832. IDENTIFY P/N BEFORE ORDER- |
|
|
|
|
ING REPLACEMENT COMPONENTS. |
|
|
|
Ref. |
NOTE: THE PARTS LIST BELOW (#1-13) IS FOR P/N 3600432 |
|
|
|
|
PUMP/MOTOR/TANK ASSEMBLY. NO SERVICE PARTS ARE |
|
|
|
|
AVAILABLE FOR THE 1001101831 AND 1001101832 PUMP/ |
|
|
|
|
MOTOR/TANK ASSEMBLIES. |
|
1 |
Not Available |
1 |
Adapter Assembly |
|
1A |
7011025 |
1 |
O-Ring |
|
2 |
70000661 |
1 |
Pump Assembly |
|
|
Not Available |
1 |
Seal Kit |
|
3 |
70000662 |
1 |
Motor Assembly |
|
|
70000663 |
1 |
Brush Kit |
|
|
70000664 |
2 |
Bearing, Ball |
|
3A |
70000665 |
1 |
Coupling |
|
4 |
70000666 |
1 |
Cartridge, Relief |
|
|
Not Available |
1 |
Seal Kit |
|
5 |
70000667 |
1 |
Tank Assembly |
|
5A |
70000668 |
1 |
Breather |
|
5B |
70000669 |
1 |
Filter |
|
5C |
70000670 |
1 |
Filter, Suction |
|
6 |
Not Available |
1 |
Valve Assembly |
|
6A |
70000671 |
1 |
Cartridge, Solenoid |
|
|
Not Available |
1 |
Seal Kit |
|
|
Not Available |
1 |
Coil |
|
6B |
70000672 |
1 |
Cartridge, Solenoid |
|
|
Not Available |
1 |
Seal Kit |
|
|
Not Available |
1 |
Coil |
|
6C |
70000666 |
2 |
Cartridge, Relief |
|
|
Not Available |
1 |
Seal Kit |
|
7 |
70000673 |
2 |
O-Ring |
|
8 |
70000674 |
3 |
Screw |
|
9 |
70000675 |
1 |
Bracket, Mounting |
|
10 |
70000676 |
2 |
Screw |
|
11 |
2144605 |
2 |
Fitting, Straight |
|
|
|
|
|
|
3121223 |
1230ES |
2-3 |
SECTION 2 GROUND COMPONENTS
FIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
12 |
|
2 |
Fitting Options: |
|
|
2144610 |
|
Straight Fitting |
|
|
1001101362 |
|
90° Fitting |
|
13 |
2221086 |
1 |
Fitting, Pressure Check |
|
|
0274581 |
Ref. |
PUMP/MOTOR/TANK INSTALLATION |
F |
101 |
0761016 |
2 |
Bolt M10 x 40mm |
|
102 to 104 |
Not Used |
|
|
|
105 |
3291005 |
2 |
Locknut M10 |
|
106 |
|
1 |
Pump/Motor/Tank Assembly Options (See Items 1-13 for |
|
|
|
|
Breakdown): |
|
|
Use 1001101832 |
|
French Built Machines Prior to S/N A200009318 (was p/n |
|
|
|
|
3600432) |
|
|
1001101831 |
|
French Built Machines S/N A200009318 to S/N A200009897 |
|
|
Use 1001101832 |
|
USA Built Machines Prior to S/N 0200189255 (was p/n |
|
|
|
|
3600432) |
|
|
1001101831 |
|
USA Built Machines S/N 02001892558 to Present |
|
|
1001101831 |
|
China Built Machines S/N 020000100 to Present |
|
107 |
4240147 |
1 |
Strap, Anti-Static |
|
|
|
Ref. |
KIT OPTIONS |
|
201 |
|
1 |
Maintenance Kit Options (Includes Item 5B & 1 Gallon of |
|
|
|
|
Hydraulic Oil): |
|
|
1001101328 |
|
3600432 Assembly |
|
|
Not Available |
|
1001101831 & 1001101832 Assemblies |
|
|
|
|
|
|
2-4 |
1230ES |
3121223 |
SECTION 2 GROUND COMPONENTS
FIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
3121223 |
1230ES |
2-5 |
SECTION 2 GROUND COMPONENTS
FIGURE 2-2.ELECTRICAL COMPONENTS INSTALLATION
|
14 |
C |
|
|
11 |
|
|
|
|
6 |
D |
B |
|
|
|
8 |
|
12 |
|
|
|
|
5 |
4D |
|
|
|
4C |
|
|
|
|
13 |
|
8 |
|
4A |
|
|
|
OR |
|
|
|
|
|
8 |
|
4B |
|
|
13 |
8 |
|
C |
|
B |
|
|
|
|
|
D
A 
E
10 |
|
|
A |
|
|
|
2 |
|
1 |
E |
|
|
3 |
|
|
|
3 |
|
|
3 |
7 |
|
|
2-6 |
1230ES |
3121223 |
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