JLG 400CRT Service Manual

4.7 (3)

Service & Maintenance Manual

Model

330CRT

400CRT

3121111

August 18, 2004

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A.A GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

A.B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

A.C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

•NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

•REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

•DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

•OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.

•KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

•USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

•NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

•BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

•BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

•KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISON LOG

Original Issue - April 11, 2000

Revised - December 12, 2000

Revised - September 28, 2001

Revised - October 18, 2002

Revised - April 6, 2004

Revised - August 18, 2004

– JLG Lift –

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		TABLE OF CONTENTS
	TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH		PAGE NO.
SECTION	A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-a
A.B	Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-a
A.C	Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-a
SECTION	1 - SPECIFICATIONS
1.1	Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-1
1.2	Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-1
1.3	Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-1
1.4	Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-2
1.5	Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-2
1.6	Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-5
1.7	Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-5
1.8	Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-5
1.9	Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-6
1.10	Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-6
1.11	Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 1-6
SECTION	2 - PROCEDURES
2.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-1
2.2	Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-1
2.3	Lubrication Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-2
2.4	Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-3
2.5	Valves - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-3
2.6	Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-4
2.7	Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-4
2.8	Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-4
2.9	Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-5
2.10	Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-9
2.11	Steer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-14
2.12	Oscillation Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-16
2.13	Magnetic Speed Pickup Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-16
2.14	Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-17
2.15	Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-18
2.16	Automatic Choke - Field Adjustment (DF-750) . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-18
2.17	Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-19
2.18	Flash Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-21
2.19	Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 2-27
SECTION	3 - TROUBLESHOOTING
3.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 3-1
3.2	Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 3-1
3.3	Hydraulic Circuit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 3-1

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TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO.

TITLE

PAGE NO.

1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-1. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-2. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1. Arms and Platform Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-2. 330CRT Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-3. 400CRT LIft Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-5. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-6. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-7. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-8. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-9. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-10. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-11. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-12. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-13. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-14. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-15. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-16. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-17. Magnetic Speed Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-18. Magnetic Speed Pickup Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-19. Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-20. Automatic Choke Adjustment (DF-750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-21. Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-22. Analyzer Flow Chart - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

3-1. Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-2. Electrical Schematic - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-3. Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-4. Hydraulic Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

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TABLE OF CONTENTS

LIST OF TABLES

TABLE NO.

TITLE

PAGE NO.

1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-4 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-5 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2-1 Cylinder Component Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-3 Help Messages and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-4 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-5 Machine Configuration Programming Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-6 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

3-1 Elevation System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-4 Electrical System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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TABLE OF CONTENTS

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SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1CAPACITIES

Hydraulic Oil Tank

Approximately 16 U.S. gallons (60.6 liters) w/15% air space.

Hydraulic System (Including Tank)

Approximately 20 U.S. gallons (75.7 liters)

Fuel Tank

Approximately 13 U.S. gallons (48.8 liters)

Diesel Engine

Manufacturer - Kubota 1105

Low RPM - 1500

High RPM - 3000

Alternator - 40 Amp

Fuel Consumption

Low RPM - 0.93 gph (3.5 lph) High RPM - 1.7 gph (6.6 lph) Horsepower - 28 @ 3000 RPM

Engine Crankcase

Gasoline Engine

3.4 quarts (3.2 liters) w/filter

2.9 quarts (2.7 liters) w/o filter

Diesel Engine

5.4 quarts (5.1 liters) w/filter

4.9 quarts (4.6 liters) w/o filter

Coolant Capacity

3.5 U.S. gallons (13.2 liters)

Drive/Steer System

Toe-In - Adjust to 1/2 inch (12.7 mm) overall

Drive Motor Displacement400 cc

Drive Brake - Spring applied, hydraulic release, release pressure - 300 psi (20.7 bar) max.

Hydraulic Filter - Full flow paper (Cartridge type) 10 Microns Nominal

Tires

Standard 30.4 x 10 loader pneumatic or foam filled

NOTE: Inflate pneumatic tire to 55 psi (3.8 bar)

1.2COMPONENT DATA

Gasoline Engine

Manufacturer - Kubota 750 Dual Fuel

Displacement - 750 cc

Low RPM - 2200

High RPM - 3600

Alternator - 40 Amp external

Battery - 85 Amphour, 700 cold cranking amps @ 0° F

Fuel Consumption

Low RPM - 1.3 gph (4.9 lph)

High RPM - 2.4 gph (9 lph)

Horsepower - 24.5 @ 3600 RPM

1.3PERFORMANCE DATA

Travel Speed

High drive - 3.5 m.p.h.

Gradeability

35%

Turning Radius (Inside)

7 ft. (2 m)

Lift Speed

Table 1-1. Lift Speeds

Model	Lift Up (Sec)		Lift Down (Sec)

330CRT - DF	26.5	- 28.5	43 - 48

330CRT - Diesel	33 - 35		43 - 48

400CRT - DF	39	- 43	49 - 51

400CRT - Diesel	43	- 47	49 - 51

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1-1

SECTION 1 - SPECIFICATIONS

Platform Capacity - Fixed Platform

330CRT - 1,000 lb. (455 kg)

400 CRT - 800 lb. (365 kg)

Platform Extension Capacity

All Models - 250 lb (120 kg)

Machine Weight

330CRT - Approx. 9,320 lb. (4,228 kg) 440CRT - Approx. 10,070 lb. (4,568 kg)

Machine Height (Fully Extended)

330 CRT - 33 ft. (10 m)

1.5LUBRICATION

Table 1-2. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING	SAE VISCOSITY GRADE
TEMPERATURE RANGE

0 to +23 degrees F	10W
(-18 to -5 degrees C)

0 to +210 degrees F	10W-20,10W-30
(-18 to +100 degrees C)

+50 to +210 degrees F	20W-20
(+10 to +100 degrees C)

400 CRT - 40 ft. (12 m)

Machine Platform Height (Platform Lowered)

330 CRT - 66.5 in. (1.7 m)

400 CRT - 68.25 in. (1.7 m)

Machine Length

10 ft. 2 in. (3 m)

Machine Width

69 in. (1.8 m)

NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of152.

NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

Lubrication Specifications

1.4TORQUE REQUIREMENTS

All wheel lugs must be torqued at 105 ft lb (142 ft lb) every 50 hours.

Table 1-3. Lubrication Specifications

KEY	SPECIFICATIONS

MPG	Multipurpose Grease having a minimum dripping
	point of 350 degrees F. Excellent water resistance
	and adhesive qualities, and being of extreme pres-
	sure type. (Timken OK 40 pounds minimum.)

EPGL	Extreme Pressure Gear Lube (oil) meeting API ser-
	vice classification GL-5 or MIL-Spec MIL-L-2105.

EO	Engine (crankcase) Oil. Gas - API SF/SG class, MIL-
	L-2104. Diesel - API CC/CD class, MIL-L-2104B/
	MIL-L-2104C.

HO	Hydraulic Oil. API service classification GL-3, e.g.
	Mobil 424.

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	Note:
500 Hrs. = 3 months
1000 Hrs. =		6 months
2000	Hrs. =	1 year	4 Extends from
4000	Hrs. =	2 years	4 Extends from
			front of machine

				3
		1	2
		Figure 1-1. Lubrication Diagram
		Table 1-4. Lubrication Chart
INDEX	COMPONENT	NUMBER/TYPE LUBE POINTS	LUBE METHOD	INTERVAL
NO	COMPONENT	NUMBER/TYPE LUBE POINTS	LUBE METHOD	HOURS
NO				HOURS
1	Hydraulic Oil Reservoir	Fill Cap/Drain Plug	HO - Check HO Level	10/500
			HO - Change HO
2	Hydraulic Filter Element	N/A	Initial Change - 50 Hours	250
3	Rail Slides	N/A	MPG - Brush	100
4	Engine Crankcase	Fill Cap/Drain Plug	Check Engine Oil Level	10/100

KEY TO LUBRICANTS:

MPG - Multi-purpose Grease

EPGL - Extreme Pressure Gear Lube

HO - Hydraulic Oil (Mobil 424)

TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.

NOTE: Be sure to lubricate like items on each side

NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank. Oil should be visible in ADD sight window on hydraulic tank. If oil is not visible, add oil until oil is visible in both ADD and FULL sight windows on tank. Do not overfill tank.

Any time the pump coupling is removed, coat splines of coupling with Texaco Code 1912 grease prior to assembly.

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Figure 1-1. Torque Chart

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Serial Number

(Stamped)

Serial Number Plate

Figure 1-2. Serial Number Location

1.6PRESSURE SETTINGS

Main Relief - 3300 psi ± 50 psi (228 bar ± 3.4 bar)

Steer Relief (Left) - max 2600 psi (179 bar)

Steer Relief (Right) - max 1600 psi (110 bar)

Lift Pressure - 330CRT - 2300 psi (159 bar)

400CRT - 2500 psi (172 bar)

Leveling Jacks Valve (If Equipped) - 1200 psi (83 bar)

1.7SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the machine. The plate is located on the left side of the machine between the fuel tank and the rear wheel. In addition, should the serial number plate be damaged or missing, the machine serial number is stamped on the top of frame between the front wheels.

1.8LIMIT SWITCHES

The machine is equipped with the following limit switches:

High Drive Speed Cut-Out - High drive speed is cut out when platform is raised above stowed (fully lowered) position.

Tilt Alarm - 3° - A horn is sounded and a warning light is illuminated when the machine is operated on a slope that exceeds 3° with the platform raised. If the machine is operated on a 3° slope with the platform completely lowered, only the warning light is illuminated.

Drive Cut-Out (400CRT only) - Drive function is cut-out when the machine reaches a preset height of 30 ft. (0.8 m).

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1.9CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), in parentheses.

Table 1-5. Cylinder Specifications

Description	Bore	Stroke	Rod Dia

Lift Cylinder	4.0	63.7	2.75
(330CRT)	(10.2)	(161.8)	(7.0)

Upper Lift Cylinder	3.0	58.1	2.75
(400CRT)	(7.62)	(147.6)	(7.0)

Lower Lift Cylinder	4.0	58.1	2.75
(400CRT)	(10.2)	(147.6)	(7.0)

Lockout Cylinder	3.0	3.75	1.25
(Oscillating Axle)	(7.6)	(9.5)	(3.2)

Leveling Jack	2.0	14.0	1.25
Cylinder	(5.1)	(35.6)	(3.2)

Steer Cylinder	2.5	7.1	1.25
	(6.4)	(18.1)	(3.2)

1.11 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: FILLED TIRES, ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Table 1-7. Critical Stability Weights

Component	Lb	Kg


Tires (Balasted Only)	246	111

Gas/DF Engine (Dry with flywheel and hous-	136	62
ing)

Diesel Engine (Dry with flywheel and hous-	256	116
ing)

1.10 MAJOR COMPONENT WEIGHTS

Table 1-6. Major Component Weights

Component	Lb	Kg

Fixed Platform	569	258

Platform Extension	230	104

Arm Assembly330CRT	3200	1452
(Includes Lift Cylinder)

Arm Assembly400CRT	3900	1769
(Includes Lift Cylinder)

Chassis with Foam Filled Tires	4980	2259

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SECTION 2. PROCEDURES

2.1GENERAL

This section provides information necessary to perform maintenance on the scissor lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES

CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND

TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

The maintenance procedures included consist of servicing and component removal and installation, disassembly and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

2.2SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

Cleanliness

1.The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

2.At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3.Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

4.Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

5.Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90°.

6.If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to lubricate the mating surface.

Bearings

1.When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2.Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

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3.If a bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4.Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

1.Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2.Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices.

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

1.Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system, drain and flush the entire system.

2.Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Batteries

Clean batteries, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry batteries and coat terminals with an anti-corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in Section 1.

2.3 LUBRICATION INFORMATION

Hydraulic System

1.The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

2.The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in Section 1 and the Preventive Maintenance and Inspection Chart in this section. Always examine filters for evidence of metal particles.

3.Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4.It is not advisable to mix oils of different brands or types, except as recommended, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components.

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Hydraulic Oil

1.Refer to Section1 for recommendations for viscosity ranges.

2.JLG recommends Mobilfluid 424, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures below -15° F (-26° C). is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -15° F (-26 ° C).

3.The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent. This will allow start up at temperatures down to -20 ° F (-29° C). However, use of this oil will give poor performance at temperatures above 120° F (49° C). Systems using DTE 11 oil should not be operated at temperatures above 200°F (94°C). under any condition.

Changing Hydraulic Oil

1.Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil every two years.

2.Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3.While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise regarding the use of greases in

maintenance stock, consult your local supplier for evaluation.

2.4CYLINDERS - THEORY OF OPERATION

The steer cylinder is of the double acting type. The steer system incorporates a double acting cylinder. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

The lift cylinder is a single acting type. It does not require oil when the cylinder is being retracted. The CRT is a gravity down machine.

A holding valve is used in the Lift circuit to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

2.5VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is springloaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Proportional Control Valves

The proportional control valves provide a power output matching that required by the load. A small line connected to a load sensing port feeds load pressure back to a sequence valve. The sequence valve senses the difference between the load and pump outlet pressure, and varies the pump displacement to keep the difference con-

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stant. This differential pressure is applied across the valve’s meter-in spool, with the effect that pump flow is determined by the degree of spool opening, independent of load pressure. Return lines are connected together, simplifying routing of return flow and to help reduce cavitation. Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence valve. Integral actuator port relief valves, anti-cavitation check valves, and load check valves are standard.

Relief Valves

Main relief valves are installed at various points within the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral reliefs are provided for each side of the circuit.

2.6COMPONENT FUNCTIONAL DESCRIPTION

Hydraulic Pump

The machine is equipped with two hydraulic pumps, a function pump and a drive pump. The function pump is a two-section gear pump that controls the lift and steer functions and provides a maximum output of 7.6 gpm (28.8 lpm). The drive pump is a single-section piston pump that controls the drive function and provides an output of 22 gpm (83.3 lpm).

Lift Cylinder Counterbalance/Manual

Descent Valve

The lift cylinder counterbalance/manual descent valve is located on top of the lift cylinder. The counterbalance valve is used to hold the platform in place when raised. A

cable is connected to the valve which, when pulled, manually opens the lift down port and allows the platform to be lowered in the event hydraulic power is lost.

2.7WEAR PADS

Sliding Pads

The original thickness of the sliding pads is 1 inches (25 mm). Replace sliding pads when worn to.875 inches (22 mm).

2.8CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper system operation is suspected.

Cylinder w/o Counterbalance Valves - Steer Cylinder

IMPORTANT

OPERATE FUNCTIONS FROM GROUND CONTROL STATION

ONLY.

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-

SURE.

1.Using all applicable safety precautions, activate motor and fully extend cylinder to be checked. Shut down motor.

2.Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the retract port.

3.Activate motor and activate cylinder extend function. Check retract port for leakage.

4.If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to retract port and retract cylinder.

5.With cylinder fully retracted, shut down motor and carefully disconnect hydraulic hose from cylinder extend port.

6.Activate motor and activate cylinder retract function. Check extend port for leakage.

7.If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If extend port leakage is less than 6-8 drops per

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