JLG 1230ES Parts Manual

Illustrated Parts Manual

Model

1230ES

P/N

3121223

October 8, 2013

REVISION LOG

P/N

1600346

(Color: Blue)

P/N

1001092456

(Color: Black)

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.

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

208

207

206

205

204

203

202

201

102

105

101

107

106

104

103

105

161014

FIGURE 1-1.STEERING AND DRIVE INSTALLATION

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

26B

26A

26B

26A

202119

29424

104

103

105

109

110

111

112

106

107

114

113

FIGURE 1-2.WHEEL DRIVE ASSEMBLY

1-6 1230ES 3121223

SECTION 1 FRAME

127

125

128

126

STYLE “A”

151

153

154

152

STYLE “B”

108A

108B

202

201 203

204 205A 205B 205C 205D

206

GENUINE PARTS

207 208

209 210A 210B 211A 211B

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

1600346 Drive Module (was p/n 3160329)

1001092743 Ref. French Built Machines S/N A200007624 to S/N A200009897

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

D/F

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

134A1911132123

FIGURE 1-3. POTHOLE PROTECTION INSTALLATION

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

213

212

101

102

103

202

201 203

205

206

104

301

FIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS

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

1Not Used

2 2920161 1 Light, Beacon

7016319 1 Bulb, Replacement

7016372 1 Len, Replacement 3Not Used 4 4060865 1 Guard, Strobe 5Not 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-

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

111

106

FIGURE 1-5.FRAME COVERS INSTALLATION

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

1Not 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

Prior to S/N 0200196530 & All French Built Machines

0274552 Ref. All Specs Except Australian & CE Specs USA Built Machines

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

201

5C55A91

107

101

10510

FIGURE 2-1.PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION

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

Equipment)

1001101832 Ref. French Built Machines Prior to S/N A200009318 (Service

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

Equipment)

1001101832 Ref. USA Built Machines Prior to S/N 0200189255 (Service

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 ORDERING 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

4A4B4C

FIGURE 2-2.ELECTRICAL COMPONENTS INSTALLATION

2-6 1230ES 3121223

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