JLG 1230ES Service Manual - Manual (Page 110)

SECTION 6 - MAST COMPONENTS
6-10 – JLG Lift – 3121222
4. Slide the inner-mid and the mount/inner mast sec-
tions into the outer-mid mast section.
5. At the top of the mast assembly, install the power-
trak assembly into the power-trak compartment of
the mount/inner mast section. (See Figure 6-13.)
6. Attach the power-trak hanger bracket to the mount/
inner mast section. (See Figure 6-13.)
7. Slide the multi-stage hydraulic cylinder into the
hydraulic cylinder compartment of the mast assem-
bly. (See Figure 6-12.)
8. Attach the cylinder rod of cylinder #1 and 2 into their
anchor cross bars at the top of the mast assembly.
Secure using the proper bolt and nut assembly. (See
Figure 6-11.)
Mast Installation
1. Move the mast assembly near the machines base
frame. At the top of the mast assembly attach a lift-
ing strap and lift the mast assembly into a vertical
position.
2. Open the bleeder valve at the top of hydraulic cylin-
der #1, then pull the cylinder rod out the bottom of
the cylinder approximately 2 ft. (61cm).
3. Carefully lift the mast assembly over the machine
and center it into the opening where the mast is
mounted on the machine.
4. If the power-trak assembly harness was left attached
to the base frame when the mast was removed, lift it
off the base frame and hold it vertically. As the mast
assembly is lowered take the top end of the power-
trak assembly and feed it into the power-trak com-
partment on the front side of the mast assembly.
5. Lower mast assembly down or pull cylinder rod out
of cylinder #1 and align the holes in the bottom of
the rod assembly with the holes in the base frame.
Secure using the proper bolts, apply Loctite #242 to
the threads of the rod attach bolts on final assembly.
(See Figure 6-10.)
6. Re-connect the lift down valve harness connector to
the lift down valve mounted on the front of the cylin-
der rod assembly.
7. Re-connect the extend and return lines to the back
of the cylinder rod assembly. (See Figure 6-9.)
8. Carefully lower the mast assembly, while lowering
feed the power-trak assembly into the mast and lift
the power-trak assembly till it is completely over top
of the lift down valve assembly. (See Figure 6-2.)
9. Feed the control cables through the notch in the baf-
fle plate inside the mast. Install the P-clamp onto the
control cables for attachment to the right-rear mast
mounting bolt.
10. Continue to lower the mast until the holes in the
mount/inner mast section mounting plates are
aligned with the holes in the base frame mounting
plates. (See Figure 6-7.) Check the side to side play
between the mast mount and the frame mount, shim
equally to both sides until side to side play is
removed. Install the mast mounting bolts, nuts, and
washers, with the nuts inboard.
Hydraulic Cylinder - lnstallation
1. Tool (Simular/Fabricate)
2. Detent in Cylinder Rod 3. Rod Anchor Brackets