JLG 1230ES Service Manual - Manual (Page 107)

SECTION 6 - MAST COMPONENTS
3121222 – JLG Lift – 6-7
Mast Removal
NOTE: To ease removal and installation of the mast assem-
bly it is recommended that the complete machine be
elevated on suitable stands to allow easy access to
the mounting bolts on the base of the mast assem-
bly.
1. Lower the mast assembly completely before begin-
ning the mast removal process to ensure no residual
pressure remains in the lift cylinder.
2. Attach an overhead crane by strap through the cross
supports on the top of mast sections.
3. Remove the four (4) bolts, nuts, washers, and shims
from the base mount of the mast. Access the bolts
and nuts through the access holes in the bottom
and front of the base frame.
NOTE: Before removing the mast off the machine, you must
decide which way you want to disconnect the har-
ness cables to the AC receptacle box and platform
control box running through the power-trak in the
mast.
You can either disconnect the cables from their
source at the rear of the machine in the charger
compartment and free the cables through to the front
of the machine so the cables come out with the
mast.
Or disconnect the power-trak from the top of the
mast and allow it slide out through the bottom of the
mast as it is lifted off of the machine. This method
also requires the AC receptacle box and the platform
control box cable to be disconnected and feed down
through the mast with the power-trak.
4. If removing the power-trak from the mast use the fol-
lowing steps; (See illustration above)
a. Remove the attach screws from the power-trak
guide bracket.
b. Push the power track and cables down into the
mast past the hanger bracket slot in the side of
the mast.
5. At the top of the mast, carefully open the bleeder
valve on the top of the main hydraulic cylinder #1
attached to the base frame.
NOTE: While lifting the mast assembly out of the frame,
hydraulic cylinder #1 will still be attached to the base
frame, lift slowly straight up ONLY, do not attempt to
lift on an angle or the hydraulic cylinder may be dam-
aged.
NOTE: Also when lifting the mast assembly, if you detached
the power-trak from the top of the mast it will need to
be lowered out the bottom of the mast as the mast is
lifted upwards.
6. Carefully lift the mast assembly up out of the frame
far enough to gain access to the wire harness con-
nector for the lift down selenoid, and the hydraulic
lines connected to hydraulic cylinder #1, still
attached to the base frame.
Figure 6-7. Mast Base Mounting Hardware
(Front of frame shown cutaway for illustrative purposes only)
1. Mast Assembly
2. Fastening Hardware 3. 20 Ga. (.0359 in.)-
Mounting Shim
Figure 6-8. Power-Trak - Removal
1. Attach Screws
2. Power-Trak Hanger
Bracket (a)
3. Power-Trak Guide (b)
4. Hyd. Cyl. #1 Bleeder Valve
Note: (a) Remove hanger bracket from slot in mast and push
down into the mast.
(b) If platform has already been removed this will be
hanging loose.
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